Pallet Assembly with Continuous Block Feeding and Fixed Nailing
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Solution Overview
Problem
Existing pallet assembly machines require time-consuming adjustments of moulds/tools for different pallet sizes, suffer from significant weight-related inertia, and have inefficient block supply systems leading to production delays and quality issues.
Innovation Solution
A method and system utilizing continuous-pitch supply means and kinematic devices for precise block positioning, eliminating the need for mould adjustments and minimizing inertia, with framing mechanisms ensuring optimal alignment before nailing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If moulds/tools are adjusted to change pallet geometry, then different pallet sizes can be produced, but this takes a considerable amount of time
Solution Approach 1:
Instead of moving the nailing device to different positions to accommodate different pallet sizes, the invention inverts the approach by keeping the nailing device stationary and moving the pallet through it. The pallet is fed continuously in the direction of its longitudinal axis, allowing the nailing device to work at a fixed position while the workpiece moves past it.
Solution Approach 2:
The invention introduces continuous movement of the pallet through the nailing device, transforming the static adjustment process into a dynamic continuous production process. The pallet moves continuously in the direction of its longitudinal axis, enabling uninterrupted nailing operations without stopping for mould adjustments.
2Manufacturing precision
If moulds/tools are used to hold blocks, then blocks can be positioned accurately, but the weight of the moulds creates significant inertia that slows down movements
Solution Approach 1:
The invention reverses the traditional approach by keeping the nailing device stationary and moving the pallet instead. This eliminates the need for the heavy nailing device to move back and forth, thereby removing the inertia problem while maintaining precise block positioning through the stationary nailing device's fixed geometry.
Solution Approach 2:
The nailing device is divided into multiple stationary nailing stations arranged along the path of pallet movement. Each station handles specific blocks, allowing continuous processing without moving the entire heavy apparatus, thus maintaining precision while enabling faster throughput.
3Productivity
If back-and-forth block supply system is used, then blocks can be delivered to nailing position, but lost time due to return journeys and significant movement inertia occurs
Solution Approach 1:
Instead of moving blocks back and forth to a stationary nailing point, the invention inverts the motion by moving the pallet continuously forward while blocks are supplied to stationary nailing positions. This eliminates the return journey entirely, as the pallet and blocks move in the same continuous direction.
Solution Approach 2:
The block supply system is designed to deliver blocks continuously to the stationary nailing device as the pallet moves forward. This creates an uninterrupted flow where blocks are supplied, nailed, and the pallet advances simultaneously, eliminating idle return trips and maintaining continuous productive action.
4Manufacturing precision
If pressing means are used to frame blocks with deck, then proper alignment is achieved, but additional complexity and time are required
Solution Approach 1:
The framing function is merged with the continuous feeding mechanism. As the pallet moves continuously through the stationary nailing device, the blocks and deck are framed and aligned automatically by the fixed geometry of the nailing stations, combining alignment and nailing into a single integrated process without separate pressing means.
Data Source
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AI summary
Method and system for assembling a pallet with at least two rows of blocks nailed to a board element. Nailing said rows of blocks to said board element comprises: - supplying a first set of at least two blocks at respective supply points, such that the blocks are aligned with one another forming a row, and placing the board element in contact with the blocks; - nailing the board element to the blocks located at the respective supply points; - moving the assembly of board element and blocks previously nailed to a new nailing position, and supplying a second set of at least two blocks at said respective supply points; - nailing together the board element in the new nailing position and the second set of at least two blocks located at the respective supply points.