Multidirectional Stepped Collator With Reset-Free Bidirectional Transfer

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Retail stores face inefficiencies and high costs in updating shelf edge markers due to the need for manual collation and collation systems that require significant time and labor, often resulting in errors and mismatches with store planograms.

Innovation Solution

A multidirectionally stepped auto-collation system using a dynamically oriented baffle with sliding stepped bins and a bidirectional pusher to automatically collate and transfer media sheets, eliminating the need for reset motions and reducing collation time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual collation methods are used with multiple employees, then collation can be performed, but labor costs and time consumption increase significantly

Engineering Contradiction:

Improvecollation speedVSAvoidcollation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system uses an automated reciprocating pusher that self-operates to transfer media sheets between stepped bins without requiring manual intervention. The pusher automatically reciprocates between first and second directions, enabling the system to collate and transfer sheets autonomously, eliminating the need for multiple employees to manually catch and collate each sheet.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system employs dynamically reconfigurable stepped bins that can change their vertical positions and configurations. The stepped bins are arranged to create first and second stair configurations that can be dynamically adjusted, allowing the system to adapt its collation process and maintain high productivity while reducing cycle time through optimized sheet transfer paths.

Inventive Principle:

Principle #15Dynamics

2Productivity

If traditional collation systems are used, then media sheets can be collated, but reset motions are required increasing cycle time

Engineering Contradiction:

Improvecollation efficiencyVSAvoidpusher cycle duration

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The automated reciprocating pusher operates continuously without reset motions by transferring media sheets in a continuous reciprocating motion between first and second directions. The pusher maintains continuous useful action by seamlessly transitioning between pushing sheets in the first direction to the first compiled collated stack and pushing sheets in the second direction to the second compiled collated stack, eliminating idle reset time and improving collation efficiency.

Inventive Principle:

Principle #20Continuity of useful action

3Loss of time

If single-direction pusher operation is used, then collation can be performed, but bidirectional operation would reduce the number of reset motions

Engineering Contradiction:

Improvereset timeVSAvoidpusher mechanism complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The pusher mechanism is designed with dynamic bidirectional capability, allowing it to automatically reciprocate between first and second directions. This dynamic design enables the pusher to serve multiple functions by transferring sheets to different compiled collated stacks depending on the operational phase, reducing reset motions without requiring multiple separate pusher mechanisms, thus managing complexity efficiently.

Inventive Principle:

Principle #15Dynamics

4Adaptability or versatility

If static stepped bins are used, then media sheets can be received, but dynamic reconfiguration would enable multi-directional collation

Engineering Contradiction:

Improvecollation configuration flexibilityVSAvoidbaffle mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The stepped bins are designed as dynamically reconfigurable components that can change their vertical positions and relative configurations. This dynamic capability allows the baffle to create different stair configurations (first and second configurations) to accommodate bidirectional sheet transfer, enabling the system to adapt to different collation requirements while managing complexity through a unified movable structure rather than multiple static structures.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12398014B2Multidirectionally stepped auto-collator system and method

Publication Date: 2025.08.26 XEROX CORP

AI summary

An automated media sheet processing system for automated collating, stacking and transferring media sheets exiting a media source includes a dynamically oriented baffle having a plurality of stepped bins. Each stepped bin is slidingly arranged adjacent another stepped bin, with the stepped bins configured to receive media sheets and allow them to fall onto and accumulate on the stepped bins. The stepped bins may move and change orientation into a stair configuration descending in different directions. An automated reciprocating pusher may move in the different directions orthogonally to the stepped bins to move and collate the media sheets into collated stacks downstream the stepped bins on different or opposite sides of the dynamically oriented baffle, with no reset or extraneous movement needed between reciprocating pushes. No reset is needed because the reciprocating pusher ends a first push in position to start a next push to the opposite side.