Transverse Log Stacking for Automated Wood Bundling and Bagging
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Solution Overview
Problem
Existing automated systems for bundling firewood logs are complex and inefficient, requiring complicated one-by-one capturing and aligning of each log before stacking and bagging.
Innovation Solution
A system that includes a bin-adjacent conveyor platform orienting logs transversely, sensors to count and control log stacking, and actuators to automate the opening and closing of hatches for efficient stacking and bagging, with a control module managing the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated one-by-one capturing and aligning of each log is implemented, then automation level increases, but system complexity increases
Solution Approach 1:
The system segments the log handling process into distinct functional zones: the conveyor platform for transverse transport, the bin portion for vertical stacking, and the bagging portion for final packaging. This segmentation allows each zone to perform its function independently, reducing overall system complexity while maintaining automation.
Solution Approach 2:
The conveyor platform acts as an intermediary device that bridges the log source and the bin portion. By orienting logs transversely on the conveyor platform before dropping them into the bin, the system eliminates the need for complex one-by-one capturing and aligning mechanisms, thus reducing complexity while preserving automation.
2Manufacturing precision
If complicated one-by-one capturing and aligning mechanisms are used, then log alignment precision improves, but device complexity increases
Solution Approach 1:
Instead of aligning logs one-by-one through complex mechanisms, the system inverts the approach by orienting all logs transversely on the conveyor platform simultaneously. This allows logs to be dropped into the bin in an already-oriented state, achieving alignment precision without complicated mechanisms.
Solution Approach 2:
The system changes the dimension of alignment by orienting logs in the transverse direction on the conveyor platform rather than attempting to align them longitudinally through complex mechanisms. This dimensional shift simplifies the alignment process while maintaining precision.
3Productivity
If automated hatch opening and closing is implemented, then operational efficiency improves, but device complexity increases
Solution Approach 1:
The actuator system is configured to automatically open and close hatches based on sensor detection of log presence and stack height. This self-service automation eliminates manual intervention while using relatively simple actuator mechanisms, improving operational efficiency without excessive complexity.
Solution Approach 2:
Sensors provide feedback to the control system about log presence and stack height, which automatically triggers the actuator to open or close hatches at appropriate moments. This feedback-based automation improves operational efficiency while keeping the actuator system relatively simple through intelligent control logic.
Data Source
AI summary
A system and method for bundling wood includes a bin portion collecting logs that drop off a conveyor platform in a transverse orientation relative to a direction of travel. A first sensor detects each log as it drops, forming a stack, and a control module maintains a running count of the logs in the stack. A hatch automatically opens and simultaneously drops a stack of logs therethrough based on the running count, e.g., based on the running count equaling a preselected number. A second sensor above the bin portion measures a distance from the second sensor to the stack. The hatch automatically opens to drop the stack therethrough to a lower bin in response to the running count reaching the preselected number of logs and/or the distance reaching a predetermined distance. A third sensor positioned adjacent a lower hatch in the lower bin automatically closes the hatch when blocked by the stack.