Tray Handler Sorting for Mixed-Thickness Tray Stacks

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Solution Overview

Problem

Existing tray handling systems for integrated circuits and other components are economically unfeasible and labor-intensive due to the need for multiple tray feeders and manual binning and sorting, especially when dealing with large volumes and varying part types, leading to inefficiencies and errors.

Innovation Solution

A tray handler system that can sort and stack trays of varying thicknesses without a magazine or cassette, allowing for efficient and automated handling, sorting, and storage, reducing the number of required stackers and feeders, and enabling on-demand delivery of desired tray subsets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple tray feeders are used to handle large volumes and varying part types, then the system can process diverse components, but the device complexity and cost increase significantly

Engineering Contradiction:

Improveability to handle varying part typesVSAvoidnumber of tray feeders

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The single tray handler is designed to perform multiple functions including feeding, stacking, and sorting trays of different types. The system can handle various part types by sorting trays into different stacks based on component type, test results, or other criteria, eliminating the need for multiple dedicated feeders

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the functions of multiple tray feeders and sorters into a single integrated tray handler unit. This unified device performs feeding, stacking, and sorting operations that previously required separate machines, thereby reducing overall system complexity

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If manual binning and sorting are performed, then labor costs are reduced, but productivity decreases and errors increase

Engineering Contradiction:

Improvesorting speedVSAvoidautomated sorting

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The tray handler automatically identifies and sorts trays based on their contents or test results without requiring manual intervention. The system self-manages the sorting process by directing trays to appropriate stacks, eliminating the need for human operators to perform binning and sorting tasks

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If trays of different thicknesses are handled, then versatility is improved, but the device complexity increases due to sorting requirements

Engineering Contradiction:

Improveability to handle varying tray thicknessesVSAvoidsorting mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The tray handler is designed to accommodate varying tray parameters including different thicknesses. The system adapts to these variations by adjusting its handling and sorting operations based on tray characteristics, allowing it to process diverse tray types without increasing mechanical complexity

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12378074B2Tray exchange and dispositioning systems, methods, and apparatuses

Publication Date: 2025.08.05 DWFRITZ AUTOMATION INC

AI summary

A tray handler for transporting a tray into or out from a selectable position within a tray stack stowed in the tray handler has an unload station to stow a tray during a sort procedure, a tray elevator configured to vertically transport the tray stack to the selectable position such that the tray is positioned to be horizontally received from or by the unload station, and a separator above the tray elevator and coupled to the unload station, the separator configured to vertically split the tray stack for opening the selectable position and horizontally transporting the tray into or out from the unload station.