Object Rotation Controller for Palletizing Infeed Alignment
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Solution Overview
Problem
Palletizing infeed systems face challenges in achieving accurate and flexible customization of product orientation and positioning at high throughput rates, with existing solutions either inaccurately aligning objects or requiring them to be pre-aligned, which limits flexibility and increases the risk of misalignment and congestion.
Innovation Solution
A device equipped with a meter to measure object dimensions and a controller to rotate objects around an upright axis, ensuring accurate alignment of side surfaces with the transport direction, using sensors to detect misalignment and adjust spacing between objects, allowing for precise positioning and orientation on a carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If throughput rate is increased to improve productivity, then productivity is improved, but positioning and orientating accuracy of products deteriorates
Solution Approach 1:
A meter measures the actual dimension of the object and the carrier's movement, and this measurement is fed back to a controller. The controller uses this feedback information to calculate and determine the precise rotation angle needed to align the object, thereby maintaining high positioning accuracy even at increased throughput rates.
Solution Approach 2:
The patent replaces traditional mechanical alignment methods with an automated control system that uses electronic sensors (meter), computational algorithms (controller), and programmable logic to determine and execute the precise rotation angle, enabling accurate positioning at higher speeds without mechanical complexity.
2Productivity
If spacing between successive objects is reduced to improve productivity, then productivity is improved, but available space for individual manipulation deteriorates
Solution Approach 1:
The system automatically measures object dimensions and calculates the precise rotation angle without requiring manual intervention or large spacing for manual manipulation. The automated meter and controller enable the system to service itself, maintaining ease of operation through automation rather than physical space.
3Manufacturing precision
If objects are manipulated to achieve precise alignment, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical alignment devices with a simpler system consisting of a meter, controller, and rotation mechanism. The complexity is shifted from mechanical hardware to electronic control and software algorithms, reducing mechanical complexity while maintaining or improving alignment accuracy.
4Manufacturing precision
If traditional alignment methods are used to improve positioning accuracy, then positioning accuracy is improved, but adaptability to misaligned objects deteriorates
Solution Approach 1:
The meter measures the actual dimension and position of each object individually, providing feedback to the controller. This enables the system to adapt to each object's specific alignment status and calculate the precise rotation angle needed, making the system highly adaptable to misaligned objects while maintaining positioning accuracy.
Solution Approach 2:
The system dynamically adjusts the rotation angle for each object based on real-time measurements from the meter. Rather than using a fixed alignment mechanism, the system dynamically determines the optimal rotation angle for each object's current state, enhancing adaptability to misaligned objects.
Data Source
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AI summary
The present invention relates to a device, comprising: a carrier (2) to subsequently carry and transport substantially rectangular objects (3) in a transport direction (11); a meter (4) configured to measure a dimension (5) of the object relative to at least one direction and/or to measure a spacing between successive objects; and a controller (7) configured to rotate at least one object and/or to adjust said spacing; wherein the meter is configured to measure an outer dimension of a side surface of the object; and wherein the controller is configured to align the side surface of said object substantially in line with the transport direction The invention further relates to a method, comprising: providing at least one object; measuring a dimension of the object relative to at least one direction and/or measuring a spacing between successive objects; rotating at least one object around an upright axis line and/or adjusting a spacing between successive objects; wherein measuring the dimension of the object comprises measuring an outer dimension of a side surface of the object; and wherein rotating the at least one object around the upright axis line comprises aligning the side surface of said object substantially in line with a transport direction of said object.