Movable Roller Frame for Pallet Transfer to Stacker
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Solution Overview
Problem
Existing pallet stacker systems require manual lifting and alignment of finished pallets, which is labor-intensive and inefficient, especially when transitioning from assembly tables to stackers, as they lack a mechanism to facilitate smooth and automatic movement of pallets into the stacker opening.
Innovation Solution
A pallet stacker apparatus with a movable roller frame and rotatable pallet roller allows for horizontal movement and alignment of pallets from an angled assembly table to the stacker opening, reducing operator effort by enabling rolling of pallets into the stacker, and includes a bias mechanism to return the roller frame to a receiving position for the next pallet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual lifting and alignment methods are used to transfer pallets from assembly tables to stackers, then operator flexibility and simplicity of equipment are maintained, but operator workload and time consumption increase significantly
Solution Approach 1:
A roller frame acts as an intermediary device between the assembly table and pallet stacker. The roller frame receives pallets from the assembly table and rolls them into the stacker opening, eliminating the need for manual lifting and alignment while keeping the overall system relatively simple.
Solution Approach 2:
The roller frame is designed to be movable rather than fixed, allowing it to dynamically position itself to receive pallets from the assembly table and then roll them into the stacker. This dynamic capability enables automated pallet transfer without requiring complex fixed machinery.
2Productivity
If automated lift mechanisms are used to move pallets vertically, then stacking speed and productivity improve, but the complexity of the stacking system increases
Solution Approach 1:
The pallet transfer system is segmented into two distinct functions: horizontal rolling (performed by the roller frame) and vertical stacking (performed by the existing lift mechanism). This segmentation allows each component to specialize in one task, improving overall productivity while maintaining manageable complexity through functional decomposition.
3Productivity
If the roller frame is positioned close to the assembly table for easy pallet reception, then pallet transfer efficiency improves, but the roller frame interferes with operator movement and pallet assembly operations
Solution Approach 1:
The roller frame is designed to be movable along the front of the pallet stacker, allowing it to dynamically adjust its position. It can move close to the assembly table when a pallet needs to be transferred to improve transfer efficiency, and move away when the operator needs space to work on pallet assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution streamlines the process of moving pallets from assembly tables to stackers, reducing operator effort and improving efficiency by allowing pallets to be rolled into the stacker opening, and automatically returning the roller frame to receive the next pallet, enhancing the overall workflow in pallet assembly and stacking.
Implementation Method 1
a pallet roller rotatably attached to a top of the roller frame about a substantially horizontal axis oriented substantially perpendicular to the loading direction, the pallet roller adapted to support a pallet in a substantially horizontal position such that the supported pallet can be rolled into the pallet opening
Data Source
AI summary
An apparatus to facilitate movement of a pallet from an assembly table to a pallet stacker comprises a roller frame adapted for movable attachment to the pallet stacker in front of the entrance to the pallet opening such that the roller frame can be moved, in a direction substantially horizontal and perpendicular to the loading direction, from a receiving position nearest to the assembly table, to a remote position farthest from the assembly table. A pallet roller is rotatably attached on top of the roller frame about a substantially horizontal axis oriented substantially perpendicular to the loading direction. The pallet roller supports a pallet in a substantially horizontal position such that the supported pallet can be rolled into the pallet opening of the pallet stacker. Conveniently a bias force is provided to return the roller frame to the receiving position when the pallet has been rolled off.