Rotating Block Carousel for Pallet Repair Automation
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Solution Overview
Problem
Existing pallet repair systems are inefficient and labor-intensive, lacking the ability to effectively and precisely insert blocks into partly assembled pallets, leading to increased labor costs and reduced repair speed.
Innovation Solution
A device comprising support surfaces and rotatable block carousels with arcuate paths for precise block insertion, allowing robots to perform the task with high precision, reducing human intervention and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated equipment is employed to streamline pallet repair, then productivity and repair speed increase, but device complexity increases
Solution Approach 1:
The automated pallet repair system is divided into distinct functional modules: a support surface for positioning the pallet, a rotatable block carousel for block delivery, and a positioning mechanism. Each module operates independently but coordinates through the automated control system, enabling high-speed repair while managing complexity through functional segmentation.
2Ease of manufacture
If blocks are inserted using forcing methods with boards pushed apart, then blocks can be installed into tight spaces, but manufacturing precision and insertion accuracy deteriorate
Solution Approach 1:
The block carousel pre-positions blocks at precise locations before insertion. The support surface pre-positions the pallet with accurate orientation. These preliminary positioning actions ensure that when the block is inserted, it aligns precisely with the required position, eliminating the need for forcing methods while maintaining high positioning accuracy.
Solution Approach 2:
The invention replaces manual forcing methods with an automated positioning and insertion system. The rotatable carousel delivers blocks with precise control, and the support surface ensures accurate pallet orientation, substituting imprecise manual operations with automated mechanical precision.
3Productivity
If laborers manually insert blocks into pallets, then device complexity remains low, but productivity and repair speed decrease
Solution Approach 1:
The block carousel is designed to automatically deliver blocks to the insertion position through rotation, without requiring complex robotic manipulators or multiple actuators. The system serves itself by using the carousel's rotational movement to both transport and position blocks, reducing overall device complexity while maintaining high insertion speed.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present disclosure relates to a device (1) for inserting a block (102) into a partly assembled pallet (100). The device comprising one or more support surfaces configured to support the pallet and position the pallet within a working area (200), and a first block carousel (10a) which is rotatable about a first axis (A1) orthogonal to the support plane. The first block carousel comprises a first block holding portion (20a) being configured to move from a block loading position to a block delivering position by a rotation of the first block carousel about the first axis. The first block holding portion is positioned at a first distance (L1) from the first axis such that the first block holding portion is movable along an arcuate path. The present disclosure further relates to a method for inserting a block into a partly assembled pallet.