Reusable Tray Management Device for Automated Food Container Processing
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Solution Overview
Problem
Current industrial systems for managing and processing reusable food containers face inefficiencies in inventory management, fault detection, and remediation, particularly in assembly lines where human labor is still necessary for complex tasks, leading to production constraints and safety risks.
Innovation Solution
The development of a system comprising a reusable tray management and processor device with a control system, tray-receiving end, conveyor, scanning devices, denester/dispenser, separator, and offloading end, equipped with rotary release actuators and vacuum pick-and-place actuators, for efficient handling, cleaning, and packaging of reusable food containers, integrating modular processing devices for washing, drying, sterilization, and packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If human labor is used for complex tasks in assembly lines, then adaptability and judgment are improved, but productivity and safety are worsened
Solution Approach 1:
The patent replaces human labor with automated robotic systems that perform assembly line tasks. The robotic systems are equipped with sensors and control mechanisms that enable them to handle complex tasks independently, thereby maintaining adaptability while significantly improving productivity and safety.
Solution Approach 2:
The system implements self-service through automated fault detection and remediation mechanisms. The robotic systems can independently detect errors, diagnose problems, and perform corrective actions without human intervention, maintaining the adaptability needed for complex tasks while eliminating safety risks associated with human labor.
2Adaptability or versatility
If human labor is used in hazardous tasks, then flexibility is improved, but safety is worsened
Solution Approach 1:
The patent substitutes human workers with robotic systems in hazardous environments. These robotic systems are designed with protective enclosures, sensors, and controlled movement capabilities that allow them to perform tasks in dangerous conditions without exposing workers to harmful factors, while maintaining the flexibility needed for varied tasks.
Solution Approach 2:
The system introduces an intermediary control layer between the robotic systems and the hazardous environment. This control system monitors conditions in real-time, adjusts robotic behavior dynamically, and intervenes when safety thresholds are approached, thereby enabling flexible task performance while eliminating direct human exposure to hazards.
3Productivity
If automated processing is implemented, then productivity is improved, but device complexity is worsened
Solution Approach 1:
The patent divides the automated processing system into modular segments, with each robotic unit performing specific functions. This segmentation allows the system to achieve high productivity through automation while keeping individual components relatively simple and easier to manage, maintain, and replace.
Solution Approach 2:
The system employs universal robotic platforms that can perform multiple functions through reconfigurable tooling and software programming. This multi-functionality reduces the need for specialized equipment for each task, thereby improving productivity through automation while minimizing the overall complexity by using a single versatile platform for diverse operations.
4Productivity
If standardized parts are used in assembly lines, then manufacturing efficiency is improved, but adaptability to product variations is worsened
Solution Approach 1:
The patent implements dynamic reconfigurability in the assembly line system. The robotic systems are equipped with adjustable end-effectors and reconfigurable work cells that can be quickly modified to accommodate different product specifications. This dynamic adaptability allows the system to maintain high manufacturing efficiency through standardized processes while responding flexibly to product variations.
Solution Approach 2:
The system utilizes programmable control mechanisms that allow parameters such as positioning, speed, and tooling to be dynamically adjusted based on product requirements. This enables the standardized assembly infrastructure to efficiently produce varied products by changing operational parameters rather than requiring physical reconfiguration, thereby maintaining both efficiency and adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system enhances the efficiency and safety of reusable food container management by automating the processing and inventory management, reducing human intervention in hazardous tasks, and ensuring consistent quality through precise fault detection and remediation, thereby improving production efficiency and reducing labor-related risks.
Implementation Method 1
vacuum pick-and-place actuators
Data Source
AI summary
New systems, methods and devices for the management of reusable food containers, such as dishes and/or trays, are provided. Systems and devices for managing a large inventory of dishes or trays to be re-used, are provided. A re-usable tray management and processor device is provided. The re-usable tray management and processor device includes a control system, a first, tray-receiving end, a tray conveyor, at least one scanning device(s), a denester/dispenser, a separator and an offloading end, configured to offload soiled reusable food containers to a washing, drying and packing section. Rotary release actuator(s) are included within the denester/dispenser. And a new form of rotary actuator and brush and excavator tool is provided, coupled with each of the rotary release actuators. In some embodiments, the control system plans actions downstream of a pre-cleaning station, based on data received from the scanning device(s).