Robotic Board Sorting and Combining with Vertical Accumulation Rows
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Solution Overview
Problem
Existing systems for sorting and combining hardwood flooring pieces require manual labor, are prone to worker accidents, and can lead to inefficiencies and errors due to the need for visual sorting and limited space for conveying rows, which can result in bottlenecks and clogging.
Innovation Solution
A system comprising a conveyor, accumulation system, and robotic arms that automatically sort and combine board pieces by measuring and manipulating them to form rows of predetermined length, using sensors and controllers to optimize the process and minimize manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sorting is used, then workers can visually inspect and sort board pieces, but the risk of accidents increases and errors occur due to visual limitations
Solution Approach 1:
The patent replaces manual visual inspection and sorting with an automated optical sensing system. Sensors detect board piece characteristics and a robotic arm executes sorting actions, eliminating direct human contact with moving machinery while maintaining or improving sorting accuracy through consistent automated measurement and placement.
Solution Approach 2:
The system enables self-service sorting where the automated system performs inspection, decision-making, and physical sorting without human intervention. The robotic arm autonomously picks and places board pieces based on sensor data, making the sorting process independent of manual labor while ensuring consistent safety and accuracy.
2Productivity
If multiple conveying rows are added to avoid bottlenecks, then sorting efficiency improves, but space requirements increase
Solution Approach 1:
The patent utilizes vertical space by positioning the accumulation system above the conveying system. The robotic arm reaches upward to place board pieces on accumulation rows, transforming a two-dimensional horizontal layout into a three-dimensional configuration. This allows multiple accumulation rows to be stacked vertically over the conveyor, increasing sorting capacity without expanding the horizontal footprint.
Solution Approach 2:
The accumulation system is nested above the conveying system, with accumulation rows positioned vertically over the conveyor path. The robotic arm operates in the vertical space between the conveying system below and the accumulation system above, effectively nesting two functional systems in the same horizontal space to maximize productivity within limited area.
3Extent of automation
If automated systems are implemented, then worker safety improves and errors are reduced, but system complexity increases
Solution Approach 1:
The robotic arm serves multiple functions: it picks board pieces from the conveying system, determines their placement positions based on sensor data, and places them on appropriate accumulation rows. This multi-functional component consolidates what would otherwise require separate systems for detection, decision-making, and physical manipulation, reducing overall system complexity while maintaining high automation.
Data Source
AI summary
A sorting and combining system for board pieces is provided by the present invention. The system comprises a conveying system for the board pieces in association with at least one robotic arm and accumulating rows. The system may further comprise side rows for additional storing of board pieces. With the help of stopping systems, board pieces of the conveyor are assembled into stacks of predetermined length by the at least one robotic arm on the accumulating rows before being sent to an outfeed section. A method is further provided, the method analyzing the presence of board pieces on a conveyor, stopping gates and a reserve in order to complete stacks of rows of predetermined length on sorting boxes. The method makes the use of a robotic arm for the manipulation and displacement of board pieces.