Traversing Part Sorter for Continuous Sheet Metal Scrap Handling
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Solution Overview
Problem
Existing sheet metal processing systems face inefficiencies in handling and sorting defective or scrap material, requiring manual labor and disrupting production flow when changing materials or alloys, and lack automated sorting and measurement capabilities for different sheet sizes.
Innovation Solution
A sheet metal processing cell equipped with a traversing part sorter and part capture table that automates the sorting and measurement of sheet metal, allowing continuous operation and efficient handling of scrap and defective materials by directing them to appropriate bins or measuring tables without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and sorting of scrap material is used, then labor flexibility is maintained, but productivity decreases and labor intensity increases
Solution Approach 1:
The system enables self-service automation where the traversing part sorter automatically receives, transports, and sorts scrap material without human intervention. The sorter traverses between the stacker and multiple scrap bins, autonomously depositing scrap into appropriate bins based on material type or alloy type, thereby eliminating manual handling while maintaining continuous processing operations.
Solution Approach 2:
The patent replaces manual mechanical handling with an automated mechanical system. The traversing part sorter uses a mechanical traversal mechanism to move between the stacker and scrap bins, and employs automated deposition mechanisms to place scrap material into the correct bins, substituting human labor with a programmed mechanical system that operates continuously.
2Adaptability or versatility
If scrap skids are shuffled around the facility using fork trucks, then material type sorting is achieved, but time consumption increases and operational complexity increases
Solution Approach 1:
The system prepares multiple scrap bins in advance at fixed positions near the stacker, each designated for specific material types or alloy types. This preliminary arrangement eliminates the need for time-consuming material changeover operations, as the traversing part sorter can immediately deposit scrap into the appropriate pre-positioned bins without requiring external equipment or operational delays.
Solution Approach 2:
The patent transitions from linear material handling (single scrap bin requiring external transport) to a multi-dimensional sorting system. The traversing part sorter moves horizontally between the stacker and multiple scrap bins arranged in a row, creating a spatial dimension for sorting that allows simultaneous access to multiple material categories without requiring vertical lifting or complex external transport operations.
3Measurement precision
If the processing line stops for measurement and inspection, then measurement accuracy is achieved, but production continuity is disrupted
Solution Approach 1:
The part capture table serves as an intermediary device between the stacker and the measurement/inspection area. It temporarily holds parts that require measurement, allowing the main processing line to continue operating without interruption. The intermediary table enables measurement operations to occur in parallel with continuous stacking operations, maintaining production continuity while ensuring measurement precision for critical parts.
Data Source
AI summary
A sheet metal processing cell has a stacker for forming a stack of sheet metal. The stacker has a stack forming portion and a diverter. The diverter is movable relative to the inlet of the stacker to receive a diverter length of sheet metal and convey it away from the inlet. A traversing part sorter of the cell has a first conveyer and a second conveyor. The traversing part sorter first conveyor receives the diverted length of sheet metal from the diverter conveyor and conveys it away from the diverter. The second conveyor conveys the diverted length of sheet metal from the stacker inlet conveyor in a direction transverse the direction of advancement into a respective scrap bin or onto a measuring table.