Prepositioned Gripper for Rapid Tray Feeder Extraction
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Solution Overview
Problem
Existing tray pulling mechanisms in manufacturing are inefficient, taking approximately 15 seconds to pull a tray from a tray feeder, which slows down the assembly process, especially when multiple trays are needed.
Innovation Solution
An improved tray pulling mechanism where the gripper is prepositioned in the gripping area, allowing for nearly instantaneous removal of the tray when it reaches the loading position, eliminating the need for intermediate motion and reducing the overall process cycle time by using handles with gaps and undercuts for secure engagement and rapid tray extraction and return.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a needle puller is used to pull trays from the tray feeder, then trays can be extracted from the vertical stack, but the process takes approximately 15 seconds which is relatively long and inefficient
Solution Approach 1:
The gripper is prepositioned in the gripping area within the tray array, ready to immediately engage with trays as they reach the loading position. This eliminates the time-consuming movement and positioning of the puller mechanism, reducing tray extraction time from 15 seconds to less than 8 seconds
Solution Approach 2:
The gripper mechanism is extracted from the traditional needle puller design and repositioned within the tray array structure itself. This allows the gripper to be already in place when trays arrive at the loading position, enabling immediate engagement and rapid extraction without intermediate motion
2Ease of operation
If a dedicated gripper is used to pull trays, then trays can be pulled to the assembly area, but the gripper must approach the tray after it reaches the loading position, adding to the cycle time
Solution Approach 1:
The gripper is prepositioned in the gripping area before trays arrive at the loading position. This preliminary positioning eliminates the need for the gripper to approach and position itself during the tray extraction cycle, reducing overall cycle time while maintaining easy operation
Solution Approach 2:
The gripper mechanism is merged with the tray array structure, positioning it within the array so that it is already in the optimal location to engage with trays as they reach the loading position. This integration eliminates separate approach movements and streamlines the extraction process
3Productivity
If the gripper is prepositioned in the gripping area, then tray removal can be nearly instantaneous, but the mechanism requires handles with gaps and undercuts for secure engagement
Solution Approach 1:
The gripper is prepositioned in the gripping area, ready to immediately engage with trays. This preliminary positioning enables nearly instantaneous tray removal, and the handle design with gaps and undercuts is specifically configured to work with this prepositioned gripper for secure engagement
Solution Approach 2:
The tray handles are designed with specific local features (gaps and undercuts) at the gripping area that correspond to the prepositioned gripper. These localized structural modifications enable secure engagement without requiring complex overall handle structures, balancing productivity gains with manageable complexity
Data Source
AI summary
A tray feeder mechanism comprising a plurality of trays within a tray feeder, each tray including a tray handle, and a gripper positioned within a gripping area defined by the tray handles, wherein the gripper is configured to remove a tray from the tray feeder when the tray feeder stops.