Automated Receptacle Stacker with Orientation Detection
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Solution Overview
Problem
In materials handling facilities, the manual collection and stacking of empty receptacles is labor-intensive and inefficient, particularly in environments where various sizes and orientations of receptacles need to be correctly positioned for stacking, leading to potential misfeeds and jams in automated systems.
Innovation Solution
An automated receptacle stacker system that integrates a rotator mechanism to detect and correctly orient receptacles before stacking, allowing for the automated collection and stacking of empty receptacles of varying sizes and types, reducing labor costs and increasing operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual collection and stacking of empty receptacles is performed, then labor flexibility is maintained, but labor intensity and inefficiency increase
Solution Approach 1:
The automated receptacle stacker performs the stacking operation autonomously without requiring manual intervention. The system self-regulates the collection, orientation detection, and stacking processes through integrated sensors and control mechanisms, eliminating the need for human workers to manually handle and stack receptacles while maintaining continuous operation capability.
Solution Approach 2:
The patent replaces manual mechanical stacking operations with an automated mechanical system. The automated stacker uses mechanical conveyance mechanisms, rotators, and stacking devices controlled by sensors and processors to perform functions previously done manually, thereby increasing productivity while reducing labor intensity.
2Reliability
If receptacles of various sizes and orientations are processed manually, then adaptability is maintained, but misstacking and positioning errors increase
Solution Approach 1:
The system performs preliminary orientation detection and correction before the stacking operation. Sensors detect the orientation of incoming receptacles, and rotators pre-adjust them to the correct position, ensuring that all receptacles are properly oriented before being stacked. This preliminary action prevents misstacking errors and maintains high stacking accuracy across different receptacle types.
Solution Approach 2:
The automated stacker incorporates dynamic adjustment capabilities to handle various receptacle sizes and orientations. The system can adapt its operation parameters, such as rotator angle and stacking position, based on real-time sensor feedback about the incoming receptacle characteristics, thereby maintaining both reliability and adaptability.
3Reliability
If automated stacking is implemented without orientation detection, then productivity increases, but misfeeds and jams increase
Solution Approach 1:
The automated stacker incorporates sensors that detect the orientation of incoming receptacles and provide feedback to the control system. Based on this feedback, the system automatically adjusts the rotator mechanism to correct any orientation errors before stacking. This feedback loop ensures high reliability by preventing misfeeds and jams while maintaining manageable system complexity through automated control.
Solution Approach 2:
The orientation detection sensors and rotator mechanism serve as intermediaries between the incoming receptacles and the stacking operation. These intermediaries detect and correct orientation issues before the receptacles reach the stacking point, thereby preventing misfeeds and jams without requiring overly complex automated handling mechanisms.
Data Source
AI summary
Methods and apparatus for stacking receptacles in materials handling facilities. An automated receptacle stacker may be integrated into a materials handling system to receive empty receptacles from upstream stations via an input conveyance mechanism, add the receptacles to a stack in a stack hopper, detect when the stack is complete, and output the stack onto an output conveyance mechanism. The output conveyance mechanism may convey the stack to a palletization station, and the stacker may begin another stack. This process may continue to build and output stacks of empty receptacles. In some implementations the receptacles may be stackable only when oriented correctly; in these implementations, orientation of the receptacles may be detected prior to stacking and incorrectly oriented receptacles may be either rotated to the correct orientation or diverted to a second receptacle stacker.