Automated Tray Mounting on Pallets for Precise Component Handling
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Solution Overview
Problem
Existing tray handling systems require manual mounting of trays on pallets, lacking automation.
Innovation Solution
A tray handling device and method that includes a pallet collecting unit, tray unloading unit, tray mounting unit, and information writing unit to automate the process of unloading and mounting trays on pallets, using components like magnet bars and wireless tags for precise positioning and identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual mounting of trays on pallets is used, then flexibility in handling various tray sizes and shapes is maintained, but automation level and processing efficiency deteriorate
Solution Approach 1:
The patent replaces manual mechanical operations with an automated tray mounting device that uses a suction cup mechanism to grasp and mount trays onto pallets. The control unit automatically controls the movement and positioning of the tray mounting unit, substituting human labor with an automated mechanical system that maintains flexibility while improving efficiency.
2Manufacturing precision
If manual tray mounting is performed, then device complexity is reduced, but manufacturing precision and handling accuracy deteriorate
Solution Approach 1:
The patent introduces an automated tray mounting device with a control unit that precisely controls the positioning and mounting of trays. The suction cup mechanism provides consistent and accurate grasping, while the automated control system ensures precise placement on pallets, improving handling accuracy despite increased device complexity.
3Productivity
If automated tray mounting device is introduced, then productivity and automation level improve, but device complexity increases
Solution Approach 1:
The tray mounting device is designed with universal functionality to handle various tray sizes and shapes using the same suction cup mechanism and control system. This multi-functionality allows the device to maintain high productivity across different tray types without requiring multiple specialized devices, thereby managing complexity while improving efficiency.
4Loss of time
If manual operations are used, then ease of operation is maintained, but loss of time and operational efficiency deteriorate
Solution Approach 1:
The automated tray mounting device operates autonomously under control unit guidance, performing tray grasping, positioning, and mounting without continuous human intervention. The system serves itself by automatically controlling the tray mounting unit's movements, significantly reducing time consumption while the initial setup and programming provide ease of operation.
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
Enables automatic and efficient handling of trays, improving manufacturing efficiency by reducing manual labor and enhancing tray management in component mounting processes.
Implementation Method 1
a tray mounting unit configured to mount the tray on the pallet. The tray mounting unit includes a suction cup that grasps the tray
Data Source
AI summary
A tray is automatically mounted on a pallet. A tray handling device, which handles a tray collected from a component mounting device configured to mount a component held in a tray on a substrate, includes: a pallet collecting unit configured to take out a pallet on which the tray is mounted from a magazine collected from the component mounting device; and a tray unloading unit configured to unload the tray from the collected pallet.