Tote Stacker Machine Merging Orientation and Stacking
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Solution Overview
Problem
Existing tote stacker machines are inefficient due to their large size, slow operation, and requirement for significant space, leading to increased downtime and maintenance costs, as they often need multiple stations for orientation and stacking, and lack the ability to adjust the number of totes in a stack.
Innovation Solution
A high-speed tote stacker machine with a dual servo t-bot, self-centering pneumatic end effector, and vertical indexing elevator that allows for adjustable stack sizes, enabling efficient stacking and reduced space usage by using a combination of conveyor belts, tracks, and pneumatic guides to manage tote orientation and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing tote stacker machines use multiple stations for orientation and stacking, then stacking function is achieved, but machine size and space requirement increase
Solution Approach 1:
The patent combines multiple stations (orientation station and stacking station) into a single integrated station. The tote processor simultaneously performs orientation adjustment and stacking operations at one location rather than requiring separate stations, thereby reducing the overall machine footprint while maintaining full stacking functionality.
Solution Approach 2:
The single station is designed to perform multiple functions: it can orient totes in different directions (first and second directions), stack totes in vertical stacks, and adjust orientation angles. This multi-functional design eliminates the need for multiple specialized stations, reducing space requirements while preserving adaptability.
2Productivity
If existing tote stacker machines operate at high speed, then productivity increases, but operation time and complexity increase
Solution Approach 1:
The tote processor continuously receives totes from the conveyor and immediately processes them through orientation adjustment and stacking in an uninterrupted flow. The single-station design eliminates transfer times between multiple stations, enabling continuous high-speed operation without idle periods, thus increasing productivity while reducing total operation time.
Solution Approach 2:
The system pre-positions and pre-orients totes as they approach the processing station, so that when totes arrive at the stacking point, they are already ready for immediate stacking. This preliminary preparation enables faster processing speeds without increasing overall operation time.
3Adaptability or versatility
If existing tote stacker machines use fixed stacking capacity, then structure is simple, but adaptability to different stack sizes decreases
Solution Approach 1:
The stacking system is designed with adjustable parameters that allow the stack height and configuration to be dynamically changed based on requirements. The tote processor can adapt its stacking pattern and capacity within the single station, providing versatility without requiring multiple fixed-capacity machines or complex reconfiguration mechanisms.
4Productivity
If existing tote stacker machines require significant physical space, then stacking capacity is maintained, but time and cost efficiency decrease
Solution Approach 1:
By merging orientation and stacking functions into one station, the machine achieves full stacking capacity in a compact configuration. This reduces the physical space required while maintaining productivity, and the simplified structure with fewer components (single station versus multiple stations) reduces maintenance requirements and downtime, improving cost efficiency.
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
The machine efficiently stacks totes in a shorter time using less space, reduces errors, and minimizes downtime and maintenance costs by automating the orientation and stacking process with adjustable stack sizes and improved tote handling mechanisms.
Implementation Method 1
self-centering pneumatic end effector
Implementation Method 2
vertical indexing elevator
Implementation Method 3
combination of conveyor belts
Data Source
AI summary
Devices, systems, and methods are provided for a tote stacker machine. A tote stacker system may include a first conveyor belt, a sensor to determine an orientation of a first tote on the first conveyor belt, an end effector that moves in a lateral direction between a first position aligned with the first conveyor belt and a second position, and an elevator that is aligned with the second position and that includes a first track and a second track. The elevator may receive the first tote from the end effector and may down stack the first tote with a second tote. The tote stacker system may include a second conveyor belt at least partially positioned between the first track and the second track of the elevator, and the second conveyor may move the first tote and second tote away from the elevator.