Overhead and Pinch Conveyor Auto-Return for Two-Sided Sanding
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Solution Overview
Problem
Furniture manufacturing processes, particularly sanding operations, are labor-intensive and time-consuming due to the need for manual flipping and inspection of items, leading to increased costs and reduced throughput.
Innovation Solution
An apparatus with a support structure, loading and pinch conveyors, and a control system that automates the conveyance and flipping of items, allowing a single operator to process both sides of a planar item without manual handling, and can be retrofitted to existing processing machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual flipping and inspection is used, then labor flexibility is maintained, but productivity decreases and labor costs increase
Solution Approach 1:
The pinch conveyor is designed with movable jaws that can dynamically open and close to grip and release items. The conveyor system incorporates motorized controls that allow dynamic adjustment of gripping force and positioning, enabling automatic item handling and flipping operations without manual intervention
Solution Approach 2:
The system enables self-service automation where the pinch conveyor automatically grips items, transports them through the processing machine, flips them using the overhead conveyor, and returns them for second processing without requiring operator intervention. The motorized controls and sensor systems allow the equipment to service itself in the item handling process
2Productivity
If a two-person team is used, then inspection quality is maintained, but labor costs increase
Solution Approach 1:
The pinch conveyor system performs multiple functions: it grips items for transport, positions them before processing, flips them using the overhead conveyor mechanism, and returns them for second processing. This multi-functional design eliminates the need for separate manual operations by different personnel
Solution Approach 2:
The overhead conveyor is positioned vertically above the processing machine, utilizing the vertical dimension to enable item flipping and return operations. This spatial arrangement allows automatic handling in three-dimensional space, replacing the need for two operators working on opposite sides of the machine
3Extent of automation
If overhead conveyor is added, then automation is improved, but manufacturing space requirements increase
Solution Approach 1:
The overhead conveyor is positioned vertically above the processing machine rather than extending horizontally, utilizing the vertical dimension to perform flipping and return operations. This minimizes the horizontal footprint while enabling complete automation of item handling
Data Source
AI summary
An apparatus for use in manufacturing includes a support structure, a loading conveyor, an overhead conveyor, and a pinch conveyor. The apparatus provides for an auto-return of an item being processed in a manufacturing process by conveying the item upward with the loading conveyor, conveying the item across the support structure with the overhead conveyor, lowering and flipping the item with the pinch conveyor in order to feed the item into the processing machine. The process may then be repeated to process an opposite face of the item. One use is in furniture manufacturing where both sides of a board or panel require sanding.