Plate Stack Transfer Assembly With Safe Operator Access

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Solution Overview

Problem

The manual placement of heavy lead plates in lead-acid battery production is physically demanding and poses safety risks, with no existing devices capable of mechanically performing this task, and the presence of operators is required for monitoring and access, limiting automation and increasing labor demands.

Innovation Solution

A stack manipulation system that includes a non-static moving assembly and a static guide structure, allowing safe operator access while moving plates from an arrival location to a target location, with a conveyor and plate loosening device to handle stuck plates, enabling continuous operation without shutting down the system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual placement of lead plates is used, then operator can monitor and access the machine, but operator experiences physical stress and safety risks

Engineering Contradiction:

ImprovesafetyVSAvoidphysical demand

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system divides the workspace into two distinct zones: a first zone for the moving assembly that is inaccessible to operators during operation, and a second zone for machine access that is protected from the moving assembly. This spatial segmentation allows automated plate moving in one area while maintaining safe operator access to the machine in another area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A conveyor system acts as an intermediary between the moving assembly and the machine. The conveyor receives plates from the moving assembly and transports them to the machine, serving as a buffer that decouples the automated moving operation from the machine loading operation, thereby protecting operators while maintaining workflow.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If a moving assembly is used to move plates, then manual labor is reduced, but operator access to the machine is restricted

Engineering Contradiction:

Improveautomation levelVSAvoidoperator access

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The potentially dangerous moving assembly is extracted from the operator's workspace by placing it in a separate first zone with its own access restrictions. This extraction removes the hazard from the operator environment while preserving the ability to perform maintenance and monitoring tasks on the machine in the protected second zone.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If plates are moved in stacks, then handling efficiency is improved, but stuck plates cause processing problems

Engineering Contradiction:

Improvehandling efficiencyVSAvoidprocessing reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A plate loosening device is positioned at the entrance to the machine to perform preliminary action on stacked plates before they enter the processing area. This device separates plates that may be stuck together, ensuring that individual plates can be properly handled by the machine's processing mechanisms and preventing jams or processing errors.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If plates are reoriented from vertical to horizontal, then machine requirements are met, but additional complexity is introduced

Engineering Contradiction:

Improveorientation flexibilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The moving assembly is designed with multi-functionality, capable of both moving stacked plates and reorienting them from vertical to horizontal orientation. By integrating the reorientation capability into the existing moving assembly rather than adding a separate device, the system achieves orientation flexibility while minimizing additional complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12110196B2Stack manipulating system and corresponding method

Publication Date: 2024.10.08 G J HOLLESTELLE BEHEER BV

AI summary

The present invention relates to a stack manipulating system configured to move a stack of plates, in particular lead battery plates, from at least one arrival location to at least one target location at a machine where the plates are to be processed, and wherein the stack manipulating system comprises: -a first zone comprising the at least one arrival location and a non-static moving assembly having a range of motion, wherein the complete range of motion is located within the first zone, -a second zone comprising the at least one target location and the machine, wherein the second zone is configured to accommodate an operator, a separation, separating the second zone from the first zone, the separation being configured for preventing the operator to move into the first zone, -at least one conveyor traversing the separation, the at least one conveyor comprising an entrance in at least one intermediate location located in the first zone and an exit located in the second zone, wherein the conveyor defines a trajectory between the entrance and the exit and comprises a guide structure which extends between the entrance and the exit along said trajectory and which guides the stack of plates along said trajectory, and wherein, at least in the second zone, the guide structure is a static structure, wherein the moving assembly comprises moving parts, and wherein the moving parts are configured to stay outside the second zone.