Sequential Item Arrangement Apparatus for Random Discharge Sorting
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Solution Overview
Problem
Automated and semi-automated manufacturing facilities face disruptions due to the random order of component discharge, requiring complex sorting processes that occupy significant space and interrupt the assembly process, necessitating a method to rearrange and sequence components efficiently.
Innovation Solution
A method and apparatus that initially classify and temporarily store items discharged in random order, recognizing their discharge order, grouping them into predetermined units, and allocating specific loading positions for sequential arrangement and discharge when predetermined conditions are met, allowing for efficient and space-minimal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are discharged from storage location or supply unit on a conveyor, then components can be transported to assembly area, but components cannot be immediately introduced into assembly process because discharge order is not consistent
Solution Approach 1:
The system performs preliminary classification of components into groups based on their discharge orders before they reach the assembly point. By pre-organizing components into sequential groups during transport, the system ensures that components are ready for immediate assembly in the correct order, eliminating the need for interruption at the assembly area.
Solution Approach 2:
The component stream is divided into multiple groups based on discharge order ranges. Each group is assigned to a specific loading position where components are arranged in sequential order. This segmentation allows parallel processing of different component groups, maintaining continuous assembly flow while ensuring proper sequencing.
2Productivity
If a sorting process is required to arrange multiple components in sequence, then components can be supplied in required order for assembly, but the flow of assembly process is interrupted and considerable amount of space is needed
Solution Approach 1:
The system transitions from a single-line sequential sorting approach to a multi-dimensional parallel processing structure. Multiple loading positions are arranged spatially to handle different component groups simultaneously, reducing the linear space required for sorting while maintaining sequencing accuracy.
Solution Approach 2:
Components are classified and grouped into sequential ranges before reaching the sorting area. This preliminary organization reduces the complexity and space required for the actual sorting process, as components arrive pre-categorized and only need final positioning at their designated loading positions.
3Quantity of substance
If the number of components increases, then more components can be supplied for assembly, but the configuration or algorithm for sorting becomes complex
Solution Approach 1:
The system divides the component stream into multiple groups based on discharge order ranges, with each group assigned to a specific loading position. This segmentation transforms a single complex sorting task into multiple simpler parallel tasks, reducing overall system complexity while handling increased component volumes.
Solution Approach 2:
Components are pre-classified into groups during the discharge and transport phase, before reaching the sorting mechanism. This preliminary action simplifies the sorting configuration needed, as the system only needs to position pre-grouped components rather than sort individual items from a random mix.
Data Source
AI summary
A method and an apparatus for sequentially arranging items or objects discharged in a random order and discharging same again are disclosed. A method for sequentially arranging items discharged in a random order and discharging same again according to an embodiment comprises the steps of: receiving items discharged in a random order and recognizing a discharge order attached to or printed on the items; grouping the items into a predetermined number unit according to the discharge order, allocating and preparing in advance a different loading position of each group, and sequentially loading the items of the recognized discharge order at a loading position allocated to a group corresponding to the recognized discharge order of the items provided sequentially; and when a predetermined condition is satisfied in at least one loading position, arranging items in the discharge order of the items loaded at the corresponding loading position and then discharging the items one by one from the corresponding loading position.