What it does
During my engineering internship at a major logistics facility, I identified significant workflow disruptions when waste compactors failed. My cage system redirects boxes from overhead conveyors directly into containers, maintaining operational efficiency.
Your inspiration
Working alongside maintenance technicians, I witnessed their frustration every time a compactor failed. The sight of workers manually cutting boxes and hauling containers across the facility struck me as inefficient and potentially hazardous. What caught my attention was the unused vertical space between the overhead conveyors and ground level – an opportunity hiding in plain sight. The idea came during a brainstorming session with senior technicians. While they focused on fixing the compactors faster, I realized we could create a system that would keep operations running smoothly even during failures, rather than just reducing repair time
How it works
The design centers around a metal cage structure positioned beneath overhead conveyors. When a compactor fails, an RME technician activates the system using a safety button near the cage. This opens a hinged panel at the top of the cage, creating an angled surface that guides boxes from the conveyor into the enclosure. Inside, the cage's dimensions match standard waste containers perfectly, eliminating gaps where boxes could fall outside. The lower section features a lockable door for easy container access. When a container needs changing, pressing the safety button stops the conveyor flow, allowing workers to safely swap full containers for empty ones. The system's height of three meters accommodates the existing conveyor layout, while the angled guide panel ensures boxes descend smoothly without jamming. All moving parts are accessible for maintenance, and the simple pin-locking mechanism for the upper door allows quick activation when needed.
Design process
The process began with extensive spatial analysis of the compactor area. Using a laser meter, I took precise measurements of the conveyor heights, clearances, and available floor space. These measurements formed the basis of my initial 3D model in SolidWorks, which helped visualize how the cage would fit within existing infrastructure. My first design was a simple cage matching container dimensions, but consultations with maintenance technicians quickly revealed its limitations. The cage was too small to handle the volume of boxes, and lacked a mechanism to guide them from the conveyor. This led to the second iteration, which featured increased height and a larger collection area. The breakthrough came when developing the box guidance system. I conceived a hinged panel that, when opened, creates an angled slide from the conveyor to the cage. The final refinement focused on safety features - I added a control button that stops the conveyor during container changes, and designed a pin-locking mechanism for the upper door to prevent unauthorized access.
How it is different
What sets this design apart is its simplicity and seamless integration with existing infrastructure. Unlike complex automated solutions that require extensive facility modifications, this system works with current conveyor layouts and standard waste containers. The only modifications needed are the cage installation and a simple electrical connection for the safety button. The design's cost-effectiveness comes from its straightforward construction - primarily steel framing and mesh panels - and minimal moving parts. There's no need for sophisticated control systems or specialized maintenance training. Most competing solutions either require major conveyor modifications or rely on expensive automated systems. In contrast, this design maintains continuous waste flow during compactor failures without complex machinery. It's a practical solution that can be implemented quickly, requires minimal maintenance.
Future plans
The next phase focuses on making the design adaptable to different facilities. The modular nature of the lower cage section means its height can be easily adjusted to accommodate various conveyor elevations, making it suitable for a wide range of industrial settings. The goal is to create a standardized yet customizable solution that maintenance teams can easily implement. Initial interest from other facilities in my workplace has been encouraging, suggesting there's real potential for wider adoption of this simple but effective system.
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