Movable Feeder Unit for Flat Object Stacking
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Solution Overview
Problem
Existing collection systems for flat objects are inefficient, prone to faults, and limited in flexibility, as they often require complex mechanical synchronization and can only stack objects in ascending order, leading to reduced throughput and potential damage to sheets with holes or folds.
Innovation Solution
A collection system with vertically disposed collection trays and a movable feeder unit that allows objects to be stacked in both ascending and descending orders, using a conveyor unit and retaining elements to manage high kinetic energy and prevent rebounding, enabling efficient and flexible stacking of flat objects, including folded sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex mechanical coupling is used to synchronize feeder stations, then objects can be deposited at predefined collecting points, but the system becomes time-consuming and lacks flexibility
Solution Approach 1:
The patent employs a movable feeder unit that can dynamically position itself at different collecting points along the transport line, replacing the need for complex mechanical coupling between multiple feeder stations. This dynamic positioning system allows the single feeder unit to service multiple collecting points sequentially, achieving the same deposition precision without the synchronization complexity of multiple synchronized feeders.
Solution Approach 2:
The single movable feeder unit is designed to perform the function of multiple stationary feeder stations by traveling along the transport line and depositing objects at various collecting points. This multi-functional approach consolidates what would otherwise require multiple specialized components into one universal unit, improving productivity while maintaining deposition accuracy.
2Adaptability or versatility
If objects are pushed under an already deposited sub-stack, then descending order stacking is achieved, but sheets with holes or notches may become kinked or jammed
Solution Approach 1:
Instead of pushing objects under the sub-stack from above, the patent inverts the approach by having the movable feeder unit deposit objects directly onto the collection trays at the appropriate positions. This eliminates the pushing action that causes kinking and jamming, while still achieving both ascending and descending order stacking through strategic deposition locations and timing.
Solution Approach 2:
The patent introduces collection trays as intermediary elements between the feeder unit and the final stack. Objects are deposited onto these trays which then form the stack, eliminating direct contact and pushing forces between objects that cause damage. The trays act as mediators that protect objects with holes or notches from mechanical stress.
3Adaptability or versatility
If folded sheets with different folding lengths are stacked in descending order, then collection versatility is improved, but sheets may become entangled causing jams or damage
Solution Approach 1:
The patent inverts the traditional stacking approach by using collection trays to receive objects directly from the feeder unit, then removing complete stacks later. This eliminates the problematic action of sliding folded sheets under existing stacks, which causes entanglement. The inversion of the process flow protects folded sheets with different lengths from mechanical damage while maintaining collection versatility.
4Quantity of substance
If a dual collection system with multiple trays is used, then stacking capacity is improved, but the system design becomes complex and maintenance-intensive
Solution Approach 1:
The patent merges the functions of multiple feeder stations and multiple collection trays into a simplified system with one movable feeder unit and a set of collection trays. The movable feeder unit combines the deposition function of multiple feeders, while the collection trays are designed to be independently removable. This merging reduces system complexity and maintenance requirements while preserving the stacking capacity through the multi-tray configuration.
5Productivity
If high-speed object deposition is performed, then productivity is improved, but objects bounce back and block the entrance or fall out of the tray
Solution Approach 1:
The patent applies preliminary anti-action by positioning limit stops at the bottom of the collection trays before objects are deposited. These limit stops are strategically placed to intercept objects that bounce back after high-speed deposition, preventing them from blocking the entrance or falling out of the trays. This preemptive measure counteracts the harmful rebound effect while maintaining high deposition speeds.
Data Source
AI summary
A collection system for collecting flat objects, including a plurality of collection trays disposed one on top of the other, each of the collection trays having an entrance and an exit; a feeder unit for feeding individual objects or assembled groups of objects to the entrance of the collection trays and for depositing the supplied objects in the respective collection tray, the feeder unit and collection trays being movable or swivelable relative to one another; a conveyor unit for removing the objects deposited in a collection tray through the exit of the respective collection tray; and a movable retaining element, which closes the entrance of one of the collection trays after an individual object or an assembled group of objects has been deposited in the respective collection tray. All of the objects collected in the collection trays are simultaneously removed from the collection trays by a conveyor unit and stacked.