Automatic Stack Feeder Unloading Mechanism
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Solution Overview
Problem
Existing automatic feeding and sorting systems face challenges in maintaining proper stack pressure during the unloading of bulk articles from containers, leading to inefficiencies and errors in singulation or shingulation processes, especially when articles slump or fall due to inadequate support.
Innovation Solution
An automatic stack feeder system comprising a frame with belts, a lower support, and an upper support, along with a controller to coordinate their movements, ensures consistent stack pressure by using a lower paddle to extend through openings between the belts and an upper paddle to provide vertical support and open container doors, maintaining the stack's integrity as it moves towards the singulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are unloaded from bulk containers onto sorting apparatus, then unloading efficiency is improved, but articles slump or fall into non-ideal positions causing singulation errors
Solution Approach 1:
A stack support device acts as an intermediary between the container and the sorting apparatus. The support device includes a support surface that receives articles from the container and maintains them in a proper position for singulation, preventing slumping and ensuring accurate processing.
Solution Approach 2:
The stack support device is positioned and configured in advance to receive and hold articles in the correct orientation before they enter the singulation process. The support surface is pre-positioned to maintain ideal article positioning, preventing slumping before it occurs.
2Ease of operation
If stack pressure is not maintained during unloading, then articles can be moved freely, but singulation process is slowed down or hampered with errors
Solution Approach 1:
The support device applies localized pressure at specific points on the stack of articles through the support surface. This localized support maintains stack integrity and pressure where needed while allowing controlled movement of individual articles during singulation, balancing freedom of movement with processing speed.
3Object-affected harmful factors
If containers are fully enclosed to protect articles, then article protection is improved, but unloading process becomes more complex
Solution Approach 1:
The unloading system is segmented into distinct functional components: the container for protection, the stack support device for positioning, and the singulation mechanism for processing. The support device itself is segmented with a support surface and positioning elements that work independently but coordinate together, simplifying the overall unloading process while maintaining article protection.
Data Source
AI summary
Embodiments of a system and method for unloading articles from a container of items for use in an automatic stack feeder are disclosed. The automatic stack feeder may comprise a belt, a moveable lower paddle, and a moveable upper paddle, wherein the lower paddle is configured to partially extend through a belt of the automatic stack feeder. The movement of the belt, the lower paddle, and the upper paddle are coordinated such that there is no need to interrupt the operation of the automatic stack feeder to unload the container.