Multi-Ramp System for Passive Board Lowering
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Solution Overview
Problem
In the pallet industry, existing methods for handling and conveying boards at high speeds face challenges in maintaining board singulation and orientation while lowering them, leading to issues like surging and skewing due to uneven slopes and lack of control during stacking, which affects efficiency and accuracy.
Innovation Solution
A multi-ramp system that uses a combination of entrance, middle, and bottom ramps with containment and tipping radii, along with linear slides and shields to passively lower singulated and oriented boards, maintaining their spacing and orientation, and directing them to a suitable elevation for stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If boards are conveyed at high speeds on multiple strands of belt or chain conveyors, then productivity increases, but the change in elevation required increases to maintain board separation and orientation
Solution Approach 1:
The elevation change is divided into multiple segments through a multi-ramp system. Instead of one long slope, the patent uses several shorter ramps (first ramp, second ramp, third ramp) with different angles and lengths, each segment contributing to the total elevation change while maintaining board separation and orientation throughout the descent.
Solution Approach 2:
Different sections of the conveyor system have different ramp configurations tailored to local requirements. The first ramp handles initial elevation change, the second ramp provides intermediate adjustment, and the third ramp completes the descent. Each ramp's angle, length, and positioning are optimized for the specific board separation and orientation needs at that location.
2Manufacturing precision
If the conveyor runs up a steeper slope to maintain board separation, then board singulation improves, but the horizontal distance required increases
Solution Approach 1:
The steep slope is segmented into multiple shorter ramps with varying angles. The first ramp uses a moderate angle to begin separation, the second ramp provides intermediate orientation adjustment, and the third ramp completes the singulation process. This segmentation achieves precise board separation without requiring a single extremely steep slope that would demand excessive horizontal space.
Solution Approach 2:
The patent transitions from a single-dimensional steep slope to a multi-dimensional ramp system. By using multiple ramps at different angles and positions, the system achieves the necessary elevation change and board separation in a more compact horizontal footprint, effectively utilizing three-dimensional space rather than relying solely on horizontal distance.
3Device complexity
If boards are lowered using a single long slope, then the structure is simpler, but board surging and skewing occur due to lack of control
Solution Approach 1:
The single long slope is divided into multiple controlled segments (first ramp, second ramp, third ramp). Each ramp segment provides a controlled transition zone that allows the system to manage board speed, separation, and orientation incrementally. This segmentation prevents sudden changes in board motion that cause surging and skewing, while maintaining relatively simple ramp structures at each stage.
Solution Approach 2:
The multi-ramp system performs preliminary actions to control board motion before the final discharge. The first ramp initiates gentle lowering and separation, the second ramp pre-adjusts orientation and spacing, and the third ramp finalizes the board alignment. These preliminary controlled transitions prevent uncontrolled surging and skewing that would occur with a single uncontrolled long slope.
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
The system effectively lowers the pass line of boards by 44 inches while maintaining their perpendicular alignment and spacing, reducing the horizontal distance required for travel and enhancing the efficiency of board handling and stacking processes.
Implementation Method 1
A multi-ramp system that uses a combination of entrance, middle, and bottom ramps with containment and tipping radii, along with linear slides and shields to passively lower singulated and oriented boards
Data Source
AI summary
The invention provides an apparatus and method to passively lower a stream of individual boards inline with conveyors or other apparatus between a board feeding mechanism, such as an unscrambler machine, and a board handling mechanism such as a stacking machine in the pallet industry. The apparatus includes multiple ramps for lowering the boards.