Repositionable Pop-Up Stops for Case Palletizer Configuration

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Custom-built case palletizers require lengthy reconfiguration downtimes and high labor costs when adapting to different article sizes or shapes, reducing throughput in high-volume factories.

Innovation Solution

The implementation of positionable pop-up stops in a row former of a case palletizer, allowing for rapid re-positioning and re-configuration to accommodate various article sizes and spacings, using modular and easily repositionable stop subassemblies with flexible hydraulic lines and sufficient wiring for actuator movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If custom-built case palletizer is designed for one article, then manufacturing precision is improved, but adaptability deteriorates

Engineering Contradiction:

Improvepalletizer configuration precisionVSAvoidarticle size adaptation

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The palletizer is divided into modular components (stops, actuators, support members) that can be independently repositioned and reconfigured. Each stop assembly functions as an independent module that can be quickly relocated along the conveyor to accommodate different article dimensions without reprogramming the entire system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from static, fixed-position stops to dynamic, repositionable stops that can be physically moved to new locations. The stops can be rapidly repositioned along the conveyor to match different article sizes and spacing requirements, enabling the palletizer to adapt to various product configurations.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If physical elements are re-configured, then adaptability is improved, but loss of time increases

Engineering Contradiction:

Improvearticle configuration adaptationVSAvoidreconfiguration downtime

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Multiple stop positions are pre-established along the conveyor at standard intervals. When reconfiguration is needed, stops are simply moved to pre-determined positions rather than creating new positions, significantly reducing reconfiguration time. The support members and mounting structures are pre-positioned to facilitate rapid stop relocation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces complex mechanical reconfiguration mechanisms with simple, manual stop relocation. Instead of using motors, sensors, and control systems to automatically reposition components, operators can quickly move stops by hand to predetermined locations, eliminating complex mechanics while maintaining adaptability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If physical re-building is performed, then adaptability is improved, but productivity deteriorates

Engineering Contradiction:

Improveproduct flow control adaptationVSAvoidpalletizer throughput

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The stop assemblies serve multiple functions: they can be positioned at different locations along the conveyor, they can accommodate various article sizes and shapes, and they can be quickly reconfigured without specialized tools or procedures. This multi-functionality allows a single palletizer to handle diverse product configurations, maintaining high productivity across different article types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9004259B1Repositionable extendable stop

Publication Date: 2015.04.14 INTELLIGRATED HEADQUARTERS LLC

AI summary

Repositionable extendable stops for material handling applications include top loading/unloading stops which engage with actuator through quick disconnects. Actuators are easily repositioned to a new stop location, and the stop reconnected to the actuator by loading the stop through the top of the conveyor.