Tray Stacking and Unstacking With Suction Cup Separation
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Solution Overview
Problem
Existing tray disinfection systems require manual handling, posing a risk of contamination and necessitating a dedicated operator for stacking and unstacking disinfected trays, which is inefficient and unsafe.
Innovation Solution
An automatic system for unstacking and restacking trays using a tray unstacker and stacker with vertical movement mechanisms, suction cups, and detecting means to ensure safe and automated handling without human contact, including a carriage for tray transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If manual handling is used to collect and stack disinfected trays at the tunnel outlet, then the system can operate with simple equipment, but operator contamination risk increases and dedicated full-time operators are required
Solution Approach 1:
The system performs tray collection and stacking automatically without human intervention. The conveyor belt continuously transports trays from the disinfection tunnel outlet to the stacking area, where they are automatically stacked by mechanical means. This self-service approach eliminates operator contact with potentially contaminated trays while maintaining continuous operation capability
Solution Approach 2:
Manual mechanical handling by operators is replaced with an automated mechanical system consisting of a conveyor belt and automatic stacking mechanism. The conveyor belt mechanically transports trays through the disinfection tunnel and positions them for stacking, while the automatic stacking mechanism performs the stacking operation without human intervention, thereby eliminating contamination risk
2Productivity
If manual stacking and unstacking is performed, then the device complexity is low, but productivity decreases due to the need for dedicated full-time operators
Solution Approach 1:
The conveyor belt enables continuous operation by constantly transporting trays from the disinfection tunnel outlet to the stacking area without interruption. This continuous flow eliminates the stop-and-start nature of manual handling, allowing the system to process trays at maximum throughput capacity throughout operational hours without requiring operator breaks or shifts
Solution Approach 2:
The automatic stacking mechanism performs the stacking operation autonomously as trays arrive on the conveyor belt, converting the manual labor-intensive process into an automated function that increases throughput while reducing the need for dedicated operators
3Reliability
If automated conveyor belt system is implemented, then contamination risk is eliminated, but the system requires complex automation equipment
Solution Approach 1:
The conveyor belt acts as an intermediary mechanism that transfers trays from the disinfection tunnel outlet to the stacking area without requiring direct operator contact. This intermediary system maintains operator safety by creating a physical barrier between operators and potentially contaminated trays while enabling efficient tray transport and stacking operations
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
Automates the process of unstacking and restacking disinfected trays, preventing contamination and reducing the need for manual handling, thus ensuring efficient and safe operation.
Implementation Method 1
the unstacker includes a movable assembly equipped with suction cups so that when the stack moves upwards, these suction cups can pick up the upper tray of the stack by means of a vacuum
Implementation Method 2
as well as a vibrator which generates vibrations to detach the trays that may be stuck to the one collected by the suction cups
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The invention describes an automatic system for stacking and unstacking trays received in a continuous flow, which comprises a stacking assembly and an unstacking assembly. The stacking assembly comprises a conveyor belt that receives trays, a tray stacker that comprises a tray receiver, two detecting means, and a tray storage carriage for receiving trays stacked in the tray receiver. The unstacking assembly comprises a tray store, a roller transport section onto which the trays are unloaded, a movable system of suction cups that collects the trays, seven detecting means, and a vibrator to detach overlapping trays.