Tray Stacking Buffer System for Mail Sorting
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Solution Overview
Problem
In mail sorting facilities, the manual stacking and storage of trays lead to logjams on conveyors, inefficient use of space, and increased costs due to the need for additional flooring and operator time, as the number of trays exceeds available bin locations.
Innovation Solution
A tray stacking and buffer system that includes a moveable platform and driven belts with lugs to capture and store trays in a vertical, nested configuration, allowing for automated stacking and retrieval, thereby reducing manual intervention and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If manual stacking and storage of trays is performed, then trays can be stored, but operator time and flooring space increase
Solution Approach 1:
The system enables automatic tray stacking and storage without manual operator intervention. The conveyance system automatically transports trays to buffer locations, and the stacking mechanism automatically stacks trays vertically, eliminating the need for operators to manually handle and stack trays.
Solution Approach 2:
The patent replaces manual mechanical stacking operations with an automated mechanical stacking system. The stacking mechanism uses mechanical components to automatically stack trays in a vertical configuration, substituting the manual mechanical process with an automated one.
2Quantity of substance
If manual stacking and storage of trays is performed, then trays can be stored, but flooring space increases
Solution Approach 1:
The system transitions from horizontal stacking to vertical stacking of trays. By stacking trays vertically in a compact configuration within the buffer system, the patent utilizes the vertical dimension rather than expanding horizontal flooring space to accommodate tray storage.
Solution Approach 2:
The patent implements a nested storage configuration where trays are stacked vertically in a compact arrangement. The stacking mechanism allows trays to be nested or stacked in a space-efficient manner, maximizing storage capacity within a limited footprint.
3Quantity of substance
If more trays are available than bin locations, then tray storage capacity increases, but logjams occur on conveyors
Solution Approach 1:
The patent introduces buffer locations as intermediary storage points between the conveyor and the final bin destinations. These buffer locations temporarily hold trays during processing, allowing the conveyor to continue operating without logjams while trays are being sorted and stacked at the buffer locations.
Solution Approach 2:
The system performs preliminary stacking and storage of trays at buffer locations before final delivery to bin destinations. By pre-processing and storing trays at intermediate buffer points, the system prevents congestion on the main conveyor and ensures continuous operation.
4Reliability
If trays are manually removed from conveyor and stacked on pallet, then conveyor logjams are avoided, but operator time and space increase
Solution Approach 1:
The patent merges the functions of tray removal, stacking, and storage into a single integrated automated system. The stacking mechanism combines multiple operations (removal from conveyor, vertical stacking, and storage) into one unified system, eliminating the need for separate manual operations and reducing overall system complexity.
Data Source
AI summary
A system and method for stacking and storing a plurality of trays includes a stacker system and a buffer system. The stacker system includes a component, e.g., a platform, which moves a tray between a raised position and a lowered position. The buffer system includes a plurality of opposing projections for capturing the tray when the component is in the raised position.