Selective Panel Sorting System with Lifting Conveyors
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Solution Overview
Problem
Current production systems for painting panels face inefficiencies due to long lead times, high material waste, and costly paint changes, especially when producing customized panels with varying dimensions and finishes, which are not well-suited for modern market demands for quick delivery and product customization.
Innovation Solution
A system utilizing integrated roller or band conveyors with lifting devices to selectively sort and prepare customer orders by temporarily holding non-ordered panels in buffers, allowing for automated composition of orders within or outside a vertical oven/storage system, optimizing paint changes and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If panels are grouped by painting batch to reduce paint changes, then material waste is reduced, but lead time increases and customization capability is lost
Solution Approach 1:
The system segments the painting batch into individual panels that can be independently tracked and sorted. Each panel is identified and separated after painting, allowing customization without requiring complete repainting batches. This enables panels to be grouped by paint type during production, then divided and reassembled according to customer orders.
Solution Approach 2:
The system performs preliminary sorting and storage of panels by paint batch before final order assembly. Panels are pre-grouped by painting characteristics, stored in an organized manner, and then quickly retrieved and assembled according to customer requirements. This preliminary organization reduces both material waste from paint changes and lead time for order fulfillment.
2Adaptability or versatility
If manual withdrawing of panels is used to prepare orders, then customization is possible, but productivity decreases and lead time increases
Solution Approach 1:
The system uses automated identification and sorting mechanisms that enable panels to be self-sorted according to order requirements. Sensors and detection systems automatically identify panel characteristics, and the system autonomously directs panels to appropriate sorting locations without manual intervention. This maintains full customization capability while dramatically increasing productivity.
Solution Approach 2:
The patent replaces manual mechanical withdrawing of panels with an automated detection and sorting system. Optical sensors, RFID readers, or other detection devices automatically identify panels, and automated conveying mechanisms direct them to appropriate destinations. This substitution eliminates manual labor while maintaining the ability to handle customized orders with varying dimensions and finishes.
3Productivity
If batch production is used to produce panels in advance, then productivity increases, but lead time and inventory requirements increase
Solution Approach 1:
The system dynamically adjusts production batches based on actual customer orders rather than using fixed batch schedules. The sorting system can handle variable batch sizes and compositions, allowing production to be optimized for each specific order. This dynamic approach maintains high productivity while reducing lead time by producing only what is needed when it is needed.
Solution Approach 2:
The system enables partial discarding of completed batches that do not match current order requirements, with the understanding that these panels can be recovered and used for future orders. Panels are not committed to single batches but can be held in intermediate storage and reassigned based on emerging order requirements, reducing the need to produce excessive inventory in advance.
Data Source
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AI summary
Method for picking up painted panels (3) provided with different dimensions and finishing, which panels are inserted in a selective sorting system (100), the said selective sorting system (100) comprising at least a group (2, 52) of two mobile conveyor sectors which are superimposed one over the other, the said at least one group comprises an upper mobile conveyor sector (2', 52') having a predefined length and a lower mobile conveyor sector (2", 52") having a predefined length the said mobile sectors being provided of a driving motor for the advancement alternatively according to one of two directions and which mobile sectors of each of the said at least a group of two mobile conveyor sectors, further move together in a synchronized manner thanks to a motor (7) and are able to carry out a vertical displacement of lifting and lowering of the said group of mobile conveyor sectors (2, 52); at least a fixed conveyor sector (6, 56); said at least one group of mobile conveyor sectors (2, 52) and the at least one fixed conveyor sector (6) being arranged alternately and placed in series; the said method comprising the following steps: a. Uploading said painted panels (3, 3', 3", 3''') in said selective sorting system (100); b. Keeping said panels inside said selective sorting system (100) for a time sufficient for their drying or the completion of their drying; c. Withdrawing said panels (3, 3', 3", 3"') through an upload and/or download system for preparing a customer order; wherein the said upload and/or download system is provided of a software suitable for memorizing the position of the uploaded panels (3, 3', 3", 3"'); actuating the lifting and/or lowering motors (7) of the mobile conveyor sectors (52) and the motors for the advancement of the said mobile conveyor sectors (52) and of the at least one fixed conveyor sector (56) so as to move the panel/s (3) desired to prepare a customer's order, temporarily storing the undesired panels (3) in a buffer formed by the said mobile conveyor sectors (52'), wherein every single motor (7) and each group of mobile conveyor sectors (52) and every motor of the fixed conveyor sectors (56) is actuated independently. The invention relates also to a system for carrying out the method.