Vertical Stacked Receiver Carriages for High-Speed Product Aggregation
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Solution Overview
Problem
In high-speed automated product packaging environments, the product aggregating apparatus faces bottlenecks due to the need to move over considerable distances to accommodate high incoming product rates, leading to inefficiencies and slowed processes.
Innovation Solution
The apparatus features an in-feed conveyor assembly with articulated conveyors that deliver product items to vertically stacked receiver carriages, allowing for alternating filling and emptying, and a pusher assembly for horizontal transfer of products to an aggregated receiver carriage, optimizing product flow and reducing movement distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the array of deposited product items is expanded to accommodate high incoming product rates, then the product aggregation capacity is improved, but the product picking and placing apparatus must move over considerable distance resulting in process slowdown
Solution Approach 1:
The patent transitions from a horizontal linear array of receptacles to a vertical three-dimensional stacked configuration. Multiple receptacles are arranged vertically one above another, allowing the picking apparatus to access multiple product items by moving vertically rather than traversing long horizontal distances. This dimensional change maintains high aggregation capacity while reducing the time penalty associated with item retrieval.
Solution Approach 2:
The patent employs dynamically adjustable receptacle positions within the vertical stack. The receptacles can be moved or reconfigured based on the incoming product rate and aggregation needs, allowing the system to optimize between storage capacity and retrieval speed. This dynamic adaptability enables the system to handle variable throughput requirements without being constrained by fixed geometric arrangements.
2Productivity
If the array of deposited product items is expanded to accommodate high incoming product rates, then the product aggregation capacity is improved, but the apparatus complexity increases
Solution Approach 1:
The patent divides the product storage function into multiple discrete, independently controllable receptacles arranged in a modular vertical stack. Each receptacle can be individually filled, emptied, and positioned, allowing the system to scale capacity by simply adding more modular units to the stack rather than redesigning the entire storage architecture. This segmentation reduces complexity by breaking down a large complex array into manageable standardized units.
Solution Approach 2:
The vertical receptacle stack is designed as a universal platform that can accommodate different product types, sizes, and aggregation requirements. The same basic receptacle structure and positioning mechanism serve multiple functions: storing individual items, grouping aggregated products, and interfacing with both conveyance and picking systems. This multi-functionality reduces overall system complexity by eliminating the need for specialized storage structures for different operational modes.
Data Source
AI summary
A product aggregating apparatus receives product with an in-feed conveyor assembly and provides the product in an aggregated, registered and/or organized form, such as to a product picking apparatus. The in-feed conveyor assembly includes at least one in-feed conveyor, each in-feed conveyor configured to deliver product to first and second locations. A product receiver assembly includes at least first and second product receiver carriages to receive product at the first and second locations, respectively. An aggregated product receiver assembly comprises a carriage configured for vertical movement to positions adjacent to each product receiver carriage. A pusher assembly, comprising a pusher carriage configured for vertical movement to positions adjacent to each product receiver carriage, contains pushers horizontally moveable to push product from the adjacent product receiver carriage and onto the carriage of the aggregated product receiver assembly for picking by an appropriate apparatus.