Automated Tray Mounting on Pallets for Component Feed 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 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, utilizing components like magnet bars and wireless tags for precise positioning and identification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual mounting of trays on pallets is performed, then flexibility in handling various tray sizes and shapes is maintained, but automation is not realized and productivity is reduced

Engineering Contradiction:

Improveautomation of tray mountingVSAvoidmounting efficiency

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

The system enables self-service automation where the tray mounting device automatically performs the mounting operation without human intervention. The control unit coordinates the robotic arm or transfer mechanism to pick up trays from the magazine and automatically mount them onto pallets, transforming a manual process into an autonomous automated system that improves both productivity and automation extent

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical operation with an automated mechanical system. A robotic arm or automated transfer mechanism controlled by a control unit substitutes the human operator's hands and movements, enabling precise and repeatable tray mounting operations while significantly improving productivity and achieving full automation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If automated tray mounting is implemented, then productivity is improved, but device complexity increases

Engineering Contradiction:

Improvemounting efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The automated tray mounting device is designed with multi-functionality to handle various tray sizes and shapes using a single system. The magazine can accommodate different tray types, and the mounting mechanism is configured to adapt to multiple pallet configurations, reducing the need for multiple specialized devices and thereby managing complexity while maintaining high productivity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system incorporates dynamic elements such as adjustable positioning mechanisms, movable components, and flexible mounting structures that can adapt to different tray and pallet configurations. This dynamic design allows the same device to handle varied scenarios without requiring complex reconfiguration, thus improving productivity while keeping device complexity manageable

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20260040516A1Tray handling device and tray handling method

Publication Date: 2026.02.05 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

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.