Automated material transfer system

Abstract

An automated material conveying system is characterized in that the automated material conveying system comprises a roller conveying line (1) arranged to convey materials (6), a lifting device connected with one end of the roller conveying line (1) and arranged to receive the materials (6) conveyed by the roller conveying line (1), a belt conveying line (5) connected with the lifting device, the belt conveying line (5) having a multi-layer structure, each layer being used to accommodate the materials (6) having different heights conveyed by the lifting device, a height sensor (8) arranged to measure the height of the materials (6) and send the height measurement result to the lifting device, the lifting device determining the parking height of the materials (6) relative to the belt conveying line (5) based on the received height measurement result.

Description

Technical Field

[0001] This disclosure relates to automated material handling in smart factories, specifically to an automated material handling system for realizing the automatic transfer and sorting of materials (e.g., but not limited to material packaging boxes), improving warehousing and handling efficiency, reducing labor costs, and optimizing resource allocation. Background Technology

[0002] In traditional warehousing and material handling, forklifts are typically operated manually to move materials in pallet units. Forklifts have a simple structure, mainly consisting of the forklift body, forks, and pallets. Materials and bills of materials are moved from one location to another by manual operation. However, this method has many drawbacks, such as high labor costs, the need for skilled personnel to operate forklifts, and the risk of driver fatigue, leading to low handling efficiency and certain safety hazards.

[0003] A standard belt conveyor is a common material conveying device that uses a motor to drive a belt to transport materials from one end to the other. While its structure is relatively simple and its cost is low, its function is limited. It can only perform linear conveying and cannot automatically sort or store materials in multiple layers. Furthermore, its conveying speed is fixed, making it difficult to adjust flexibly according to actual production needs, and it has poor adaptability to materials of different sizes and weights.

[0004] Fixed roller conveyor lines use motors to drive rollers to rotate, thereby conveying materials. They offer a degree of flexibility, adapting to materials of different shapes, but also have functional limitations. They cannot automatically identify material information and perform sorting; moreover, the layout of the conveyor line is fixed, and once installed, it is difficult to adjust and expand according to production needs, making them insufficiently adaptable to the ever-changing production processes in smart factories.

[0005] Traditional material handling methods are characterized by high labor costs, low efficiency, and poor safety, making them unsuitable for the development needs of smart factories.

[0006] Existing conveyor line equipment has limited functionality and cannot achieve automatic material identification, sorting, and multi-level classification storage. It also cannot flexibly adjust its layout according to production needs and has poor adaptability to materials of different sizes and weights, making it difficult to meet the requirements of smart factories for efficient, accurate, and intelligent material conveying. Utility Model Content

[0007] To address one or more deficiencies in the prior art, an automated material handling system is proposed according to one aspect of this disclosure. The automated material handling system includes: a roller conveyor configured to convey material; a lifting device connected to one end of the roller conveyor and configured to receive the material conveyed by the roller conveyor; a belt conveyor connected to the lifting device, the belt conveyor having a multi-layer structure, each layer having a different height to accommodate materials of different heights conveyed by the lifting device; and a height sensor configured to measure the height of the material, the lifting device determining the stopping height of the material relative to the belt conveyor based on the height measurement result from the height sensor.

[0008] According to the foregoing aspects of this disclosure, the lifting device includes a first lifting device and a second lifting device.

[0009] The first lifting device is connected to one end of the roller conveyor line and is used to lift the material from the roller conveyor line to a position of the first lifting device that is higher than the output position of the roller conveyor line.

[0010] The automated material handling system also includes an overhead roller conveyor line, one end of which is connected to the first lifting device, for conveying the material from the first lifting device to the other end of the overhead roller conveyor line.

[0011] The second lifting device is connected to the other end of the overhead roller conveyor line and is used to lower the material from the overhead roller conveyor line to the stopping height.

[0012] The belt conveyor is connected to the second lifting device and is used to receive and transport the material.

[0013] The height sensor is installed at the other end of the overhead roller conveyor line to measure the height of the material and send the height measurement result to the second lifting device. The second lifting device determines the stopping height of the material relative to the belt conveyor line based on the received height measurement result.

[0014] Traditional warehousing and handling relies on manual operation of forklifts, resulting in high labor costs, low efficiency, and poor safety. Existing conveyor lines cannot achieve automated material transfer and sorting. Automated transfer and sorting can reduce manual intervention, improve warehousing and handling efficiency, and lower labor costs.

[0015] According to the above aspects of this disclosure, the roller conveyor line includes multiple roller conveyor line sections, each roller conveyor line section including a roller conveyor line base and at least one roller conveyor line turning part, the roller conveyor line turning part being rotatably connected to one end of the roller conveyor line base for turning 90 degrees when needed to leave a passage for people to pass through.

[0016] In existing technologies, fixed roller conveyor lines have a fixed layout, making it difficult to adapt to personnel passage requirements. The turning section of the roller conveyor line can leave passageways, improving the flexibility and adaptability of the equipment and facilitating personnel passage.

[0017] According to the above aspects of this disclosure, along the conveying direction of the roller conveyor line, anti-collision guardrails are respectively provided on both sides of each roller conveyor line base and / or along the conveying direction perpendicular to the roller conveyor line, anti-collision guardrails are provided on both sides of the corresponding roller conveyor line base.

[0018] Traditional conveyor lines are prone to displacement or other unpredictable factors due to collisions, affecting safety and stability. Installing crash barriers around the perimeter of the roller conveyor line protects the conveyor line and personnel, improving the safety and stability of the equipment.

[0019] According to the foregoing aspects of this disclosure, a safety light curtain is also provided on the roller conveyor base. The safety light curtain is located below the roller conveyor tilting section and is used to detect people or obstacles and pause the tilting operation of the roller conveyor tilting section when a person or obstacle is detected.

[0020] Obstacles may appear during the flipping process, posing a safety hazard. The installation of safety light curtains improves the safety of the equipment, avoids accidents during flipping operations, and protects personnel and equipment.

[0021] According to the various aspects of this disclosure described above, the automated material handling system further includes a barcode scanning device disposed on or near the roller conveyor base for reading label information on the material and transmitting the label information to a designated computer for material tracking.

[0022] Traditional fixed roller conveyor lines cannot automatically identify material information, making material tracking difficult. Barcode scanning devices enable automatic material identification and tracking, improving the accuracy and efficiency of material management.

[0023] According to the above aspects of this disclosure, the multi-layer structure of the belt conveyor includes at least three layers, namely a first layer, a second layer and a third layer, each layer being aligned on one side in the width direction of the belt conveyor, each layer being misaligned on the other side in the width direction of the belt conveyor, and the width of each layer decreasing sequentially from bottom to top in the height direction of the belt conveyor, thereby causing adjacent layers to be staggered in the width direction.

[0024] Conventional belt conveyor lines have limited functionality and cannot achieve automated sorting and multi-level classification storage. In contrast, this system features a multi-level structure, with each level accommodating materials of varying heights. The staggered arrangement of adjacent levels enables automated sorting and multi-level classification storage, improving warehouse space utilization and facilitating material retrieval by operators.

[0025] According to the foregoing aspects of this disclosure, the overhead roller conveyor line is provided with fireproof partitions and fireproof doors. The fireproof partitions have fireproof partition openings, and the fireproof doors close the fireproof partition openings in the event of a fire, thereby separating the areas above the overhead roller conveyor line on both sides of the fireproof partitions.

[0026] According to the foregoing aspects of this disclosure, the overhead roller conveyor line is equipped with an overhead roller turning mechanism.

[0027] The automated material handling system is configured such that when a fire alarm is received, the overhead roller turning mechanism flips to disconnect the overhead roller conveyor line, thereby allowing the fire door to roll down through the disconnected overhead roller conveyor line for isolation.

[0028] After the fire alarm is cleared, the fire door rises and opens, the overhead roller tilting mechanism resets, and the overhead roller conveyor line resumes operation.

[0029] Traditional conveyor lines lack fire safety design and struggle to meet fire zoning requirements. Fireproof partitions and doors are installed on overhead roller conveyors to separate areas during a fire, enhancing the equipment's fire resistance, meeting fire safety requirements, and protecting personnel and equipment. Traditional conveyor lines also lack fire emergency measures, resulting in insufficient safety. By installing an overhead roller tilting mechanism on the conveyor line to disconnect the line in case of fire, the equipment's fire resistance is enhanced, meeting fire safety requirements and thus protecting personnel and equipment safety.

[0030] According to the above aspects of this disclosure, an alignment block and a pushing device are also provided on the roller conveyor base adjacent to the first lifting device.

[0031] The alignment block is fixedly disposed on at least one side of the roller conveyor base and configured such that the material is aligned with the inlet of the first lifting device, thereby facilitating the smooth and accurate entry of the material into the first lifting device.

[0032] The pusher device is located on the other side of the roller conveyor base and is configured to push the material toward the alignment block, thereby causing the material to abut against the alignment block.

[0033] In existing technologies, the material's position is inaccurate when entering the lifting device, affecting the stability of the transmission. In this technical solution, alignment blocks and push-block devices are installed on the roller conveyor base adjacent to the first lifting device to align the material. This ensures that the material enters the lifting device smoothly and accurately, improving the stability and accuracy of material transmission.

[0034] According to the foregoing aspects of this disclosure, pairs of sensors are respectively provided at the belt inlet and belt tail of each layer of the belt conveyor line.

[0035] Once the pair of sensors located at the belt inlet detect the material, the corresponding layer of the belt conveyor starts operating to receive the material.

[0036] When the pair of sensors located at the belt inlet fail to detect material, the corresponding layer of the belt conveyor stops.

[0037] Once the pair of sensors located at the tail of the belt detect the material, the corresponding layer of the belt conveyor stops and no longer receives material.

[0038] Conventional belt conveyors cannot achieve automatic material transport and orderly arrangement. Pairs of sensors installed at the entrance and end of each layer of the belt conveyor detect materials and control the belt's operation, thereby achieving automatic material transport and spaced arrangement, improving transmission efficiency and orderliness.

[0039] According to the various aspects of this disclosure described above, the roller conveyor line is provided with a pair of sensors for detecting the presence of the material and for triggering the automatic start of the roller conveyor line.

[0040] Traditional conveyor lines require manual operation and have a low level of automation. Pairs of sensors are installed on the roller conveyor line to detect materials and trigger automatic start-up. This reduces manual operation, enables the roller conveyor line to operate automatically, and improves the level of automation.

[0041] According to the above aspects of this disclosure, the roller conveyor line is equipped with a pause button and an emergency stop button. The pause button is used to pause the conveying operation of the current roller conveyor line section without affecting the downstream roller conveyor line section, and the emergency stop button is used to stop the operation of the entire roller conveyor line.

[0042] Traditional conveyor lines lack flexible control methods and have insufficient safety. Pause and emergency stop buttons are installed on roller conveyors to pause or stop the conveying operation, improving equipment safety and controllability, facilitating operation and management, and protecting personnel and equipment.

[0043] According to the above aspects of this disclosure, the roller conveyor is equipped with a rotary button and a rotary motor. Pressing the rotary button drives the roller conveyor's flipping section to flip to create a passageway. The roller conveyor is also equipped with a rotation warning device that emits an audible and visual alarm during the flipping process.

[0044] Fixed conveyor layouts restrict personnel movement and have poor adaptability. Rotary buttons and motors are used to drive the tilting section of the roller conveyor to create passageways, which enhances the flexibility and adaptability of the equipment, improves safety, and facilitates personnel movement.

[0045] According to the foregoing aspects of this disclosure, the first lifting device includes a lifting platform capable of lifting materials from a descending position to an output position.

[0046] The lifting platform is configured to return to the lowered position when no items are detected, and wait to be reloaded with materials.

[0047] Traditional material handling methods cannot achieve vertical material transport, resulting in low efficiency. The first lifting device of the lifting platform is used to lift materials, enabling vertical material transport and improving efficiency and flexibility.

[0048] According to the foregoing aspects of this disclosure, the material is, for example, but not limited to, a material packaging box.

[0049] The automated material handling system of this utility model has the following technical advantages: It improves warehousing and handling efficiency by realizing automatic material transfer and sorting, reducing manual intervention and increasing handling efficiency. It reduces labor costs by decreasing reliance on manual labor. Through precise control of material flow and consumption, it reduces waste and energy consumption. The design of tilting tracks and partitioned racks meets fire zoning requirements and improves equipment safety. Furthermore, the roller conveyor lines and elevators are equipped with safety protection devices such as safety light curtains and emergency stop buttons, further enhancing equipment safety. The speeds of both roller conveyor lines and belt conveyor lines are adjustable, allowing for flexible adjustments based on actual production needs. The equipment layout can be adjusted and expanded according to production requirements, improving the adaptability and flexibility of the equipment.

[0050] Thus, in order to provide a better understanding of the detailed description herein and to better recognize the contribution of this disclosure to the prior art, the contents of this disclosure have been summarized quite broadly. Embodiments of this disclosure will, of course, be described below and will form the subject matter of the appended claims.

[0051] Similarly, those skilled in the art will recognize that the concepts upon which this disclosure is based can be readily used as the basis for designing other structures, methods, and systems for carrying out several purposes of this disclosure. Therefore, it is important that the appended claims be considered to include such equivalent structures, provided they do not exceed the spirit and scope of this disclosure. Attached Figure Description

[0052] The advantages of this disclosure will be more clearly demonstrated by the accompanying drawings, which will provide a better understanding of the present disclosure. The drawings described herein are for illustrative purposes only, representing selected embodiments and not all possible implementations, and are not intended to limit the scope of this disclosure.

[0053] Figure 1 A perspective view of an automated material handling system according to the present disclosure is shown.

[0054] Figure 2 A side view of a roller conveyor line according to this disclosure is shown;

[0055] Figure 3 An end view of the roller conveyor base of a roller conveyor line according to the present disclosure is shown;

[0056] Figure 4 The present disclosure shows anti-collision guardrails installed on both sides of each roller conveyor base along the conveying direction of the roller conveyor.

[0057] Figure 5The present disclosure shows a pause button, an emergency stop button, a rotary button, a rotary warning device, a rotary motor, a safety light curtain, and a pair of sensors installed on the base of a roller conveyor line.

[0058] Figure 6 The manual loading position of a roller conveyor line according to this disclosure is shown;

[0059] Figure 7 This illustration shows an exemplary arrangement of materials placed on a roller conveyor line in accordance with the present disclosure;

[0060] Figure 8 A schematic diagram showing two adjacent drive roller conveyor sections that are rotated upwards by 90 degrees, according to the present disclosure;

[0061] Figure 9 A schematic diagram showing material, a pushing device, and an alignment block located on a roller conveyor base according to the present disclosure;

[0062] Figure 10 A perspective view of a first lifting device according to the present disclosure is shown;

[0063] Figures 11 to 17 (a)-(c) in the figures show perspective views of the various components of an overhead roller conveyor line according to the present disclosure;

[0064] Figures 18 to 19 A schematic diagram of a belt conveyor line according to this disclosure is shown;

[0065] Figure 20 The alignment block and pusher device according to this disclosure are shown. Detailed Implementation

[0066] Figure 1 An automated material handling system according to an embodiment of the present disclosure is shown. Figure 1 The automated material handling system includes a roller conveyor line 1, a first lifting device 2, an overhead roller conveyor line 3, a second lifting device 4, and a belt conveyor line 5. The first lifting device 2 is connected to one end of the roller conveyor line 1, one end of the overhead roller conveyor line 3 is connected to the first lifting device 2, the other end of the overhead roller conveyor line 3 is connected to the second lifting device 4, and one end of the belt conveyor line 5 is connected to the second lifting device 4.

[0067] After the operator places material 6 (e.g., a material packaging box) onto roller conveyor 1, pairs of sensors set on roller conveyor 1 ( Figure 1 (Not shown in the image) Upon sensing the presence of material 6, the roller conveyor 1 automatically starts, and then the roller conveyor 1 transports material 6 to the first lifting device 2.

[0068] A barcode scanner 7 installed on or near the roller conveyor line 1 extracts label information (not shown) from the material 6, including but not limited to the part number and quantity, i.e., the part number and quantity of the material contained in the material 6. The extracted label information is processed according to a standard format and then transmitted to a designated computer (not shown) for classification and statistics.

[0069] After the barcode scanner 7 extracts the label information from the material 6, the first lifting device 2 lifts the material 6 to one end of the overhead roller conveyor 3 connected to the first lifting device 2. Subsequently, the overhead roller conveyor 3 transports the material 6 to the other end of the overhead roller conveyor 3.

[0070] After the material 6 is conveyed to the other end of the overhead roller conveyor 3, the height sensor 8 set on or near the other end of the overhead roller conveyor 3 measures the height of the material 6 and transmits the measured height information to the second lifting device 4. The second lifting device 4 determines the stopping height of the material 6 relative to the belt conveyor 5 based on the received height information.

[0071] Material 6 is detected by height sensor 8. Next, the height sensor function program (not shown) determines the category of each material 6 and counts it. The automated material handling system counts the quantity of material 6 in each category. The automated material handling system performs post-processing on the category and counting results, including removing duplicate counts and detecting outliers. Then, the automated material handling system makes corresponding decisions based on this data.

[0072] The belt conveyor line 5 includes a multi-layer structure arranged from top to bottom (e.g., but not limited to...). Figure 1 The system has a three-layer structure, where each layer can hold materials 6 at different heights. The second lifting device 4 stops at the corresponding layer based on the received height information and feeds the material 6 into the corresponding layer of the belt conveyor 5. Finally, the movement of the belt conveyor 5 can transport the material 6 to various positions within the corresponding layer.

[0073] Although Figure 1The embodiment shows a first lifting device 2, an overhead roller conveyor line 3, and a second lifting device 4. However, those skilled in the art will understand that the overhead roller conveyor line 3 can be omitted (e.g., in some cases, an overhead roller conveyor line is not required) and only one lifting device is needed, such as a single first lifting device 2 or a single second lifting device 4. This single lifting device is connected to one end of the roller conveyor line (1) and is configured to receive the material (6) conveyed by the roller conveyor line (1). A belt conveyor line (5) is connected to the lifting device and has a multi-layer structure, each layer having a different height to accommodate materials (6) of different heights conveyed by the lifting device. A height sensor (8) is configured to measure the height of the material (6), and the lifting device determines the stopping height of the material (6) relative to the belt conveyor line (5) based on the height measurement results from the height sensor (8).

[0074] The material 6 is, for example, but not limited to, a material packaging box 6.

[0075] The following description, in conjunction with the accompanying drawings, is as follows: Figure 1 The components of the automated material handling system are shown.

[0076] like Figure 1 and Figure 2 As shown, the roller conveyor line 1 includes multiple continuously arranged roller conveyor line sections 1-1. Each roller conveyor line section 1-1 includes a roller conveyor line base 1-1-1 and at least one roller conveyor line turning section 1-1-2. Multiple conveying rollers are arranged on both the roller conveyor line base 1-1-1 and the at least one roller conveyor line turning section 1-1-2. Figure 6 As shown, both the roller conveyor base 1-1-1 and the roller conveyor turning section 1-1-2 can be used as manual feeding positions.

[0077] like Figure 2 As shown, the roller conveyor line 1 includes four roller conveyor line sections 1-1. Each roller conveyor line section 1-1 located at both ends of the roller conveyor line 1 includes a roller conveyor line base 1-1-1 and a roller conveyor line flipping part 1-1-2, wherein the roller conveyor line flipping part 1-1-2 is rotatably connected to one end of the roller conveyor line base 1-1-1. Each roller conveyor line section 1-1 located between the two ends of the roller conveyor line 1 includes a roller conveyor line base 1-1-1 and two roller conveyor line flipping parts 1-1-2, wherein the two roller conveyor line flipping parts 1-1-2 are respectively rotatably connected to both ends of the roller conveyor line base 1-1-1. Figure 2 In the process, the roller conveyor turning parts 1-1-2 of the two adjacent roller conveyor sections 1-1 are also arranged adjacent to each other and are coplanar.

[0078] like Figure 3 and Figure 4 As shown, along the conveying direction of the roller conveyor line 1, anti-collision guardrails 1-2 are respectively installed on both sides of each roller conveyor base 1-1-1. The anti-collision guardrails 1-2 are made of a metal-containing material, such as, but not limited to, carbon steel pipes with a diameter of ø50mm and a height of, for example, 350mm. Alternatively, anti-collision guardrails 1-2 can also be installed on both sides of the corresponding roller conveyor base 1-1-1 along a direction perpendicular to the conveying direction of the roller conveyor line 1.

[0079] Considering the material flow or other working conditions in the factory area, in order to avoid collisions and displacement of the conveyor line 1 and other uncertainties, anti-collision guardrails 1-2 are installed at the manual loading position to protect the safety distance of the conveyor line and personnel.

[0080] like Figure 5 As shown, a pause button 1-3 and an emergency stop button 1-4 are installed on the roller conveyor base 1-1-1. When the pause button 1-3 is pressed, the current section of the roller conveyor pauses, but it does not affect the downstream section. When the emergency stop button 1-4 is pressed, the entire roller conveyor line is brought to an emergency stop.

[0081] like Figure 8 As shown, along the conveying direction of the roller conveyor line 1, a rotary button 1-5, a rotary warning device 1-6, and a rotary motor 1-7 are also provided on both sides of the roller conveyor line base 1-1-1.

[0082] When personnel need to pass through roller conveyor 1, pressing the rotary button 1-5 drives the roller conveyor tilting section 1-1-2 to tilt 90 degrees via the rotary motor 1-7. This means that two adjacent roller conveyor tilting sections 1-1-2 are arranged as follows: Figure 8 The rotating section 1-1-2 rotates upwards by 90 degrees to create a passage for pedestrians. During the rotation process, including the upward rotation and downward retraction, the rotating warning device 1-6 provides alerts through flashing and sound. After personnel pass through roller conveyor 1, pressing the rotating button 1-5 resets the roller conveyor rotation section 1-1-2. This causes the two adjacent roller conveyor rotation sections 1-1-2 to rotate downwards by 90 degrees, closing the passage for pedestrians, and restoring the two roller conveyor rotation sections 1-1-2 to a coplanar configuration. When the rotating button 1-5 is pressed, if there is a material packaging box 6 on the roller conveyor rotation section 1-1-2, the material packaging box 6 must pass through the current roller conveyor section 1-1 before the roller conveyor rotation section 1-1-2 can rotate. Simultaneously, the section before the current roller conveyor section 1-1 pauses, while the downstream section after the current roller conveyor section 1-1 operates normally.

[0083] like Figure 5 As shown, a safety light curtain 1-8 is also installed on the roller conveyor base 1-1-1. The safety light curtain 1-8 is located below the roller conveyor tilting section 1-1-2 to avoid safety hazards caused by obstacles during the tilting process. For example, when the safety light curtain 1-8 detects that a person or object is attempting to cross the roller conveyor 1 during the tilting process of the roller conveyor tilting section 1-1-2, the detection signal emitted by the safety light curtain 1-8 can be used to pause the tilting operation of the roller conveyor tilting section 1-1-2 by the rotary motor 1-7.

[0084] Along the conveying direction of roller conveyor line 1, multiple sets of paired sensors 1-9 are also installed on roller conveyor line 1, spaced apart from each other. For example... Figure 5 and Figure 7 As shown, for example but not limited to, two pairs of sensors 1-9 are provided on each roller conveyor base 1-1-1, and one pair of sensors 1-9 is provided on the corresponding roller conveyor turning section 1-1-2. When a manual loading station places a material packaging box 6 onto the roller conveyor, the beam of light from the pair of sensors 1-9 is blocked by the material packaging box 6, and the detection signal from the pair of sensors 1-9 is used to control multiple conveyor rollers to start rolling to transport the material packaging box 6.

[0085] For example, but not limited to, multiple conveying rollers drive four driven rollers via a single driving roller, arranged sequentially to move the material packaging box 6. Depending on the size of the material packaging box 6, for example, rollers with a diameter of φ50mm and a center-to-center distance of 90mm can meet the conveying requirements. To reduce energy consumption and waste, if the corresponding roller conveyor section 1-1 does not detect a material packaging box 6 within a specified time period (e.g., 1 minute), the conveying operation of that roller conveyor section 1-1 will be suspended.

[0086] like Figure 9 and Figure 20 As shown, an alignment block 1-10 and a pusher device 1-11 are also provided on the roller conveyor base 1-1-1, which is adjacent to the first lifting device 2. The alignment block 1-10 is fixedly disposed on at least one side of the roller conveyor base 1-1-1. The pusher device (1-11) is disposed on the other side of the roller conveyor base 1-1-1, opposite to the alignment block 1-10.

[0087] like Figure 7As shown, the material packaging box 6 is basically rectangular in shape. When placed on the roller conveyor line 1, its short side (width) is basically along the conveying direction of the roller conveyor line, and its long side is basically perpendicular to the conveying direction of the roller conveyor line. The label can be affixed to the lower left side of the right side of the material packaging box 6 (i.e., the side directly facing the barcode scanner 7). The label can also be affixed to the lower left side of the front side of the material packaging box 6 (i.e., the side facing the conveying direction).

[0088] When the material packaging box 6 is conveyed to the barcode scanning station, a lifting and rotating mechanism (not shown) can be lifted from the roller conveyor base 1-1-1 and set to straighten the misaligned material packaging box 6.

[0089] The following situations may occur when scanning tags:

[0090] When the label is affixed to the lower left side of the right side of the material packaging box 6 (i.e., the side directly facing the barcode scanner 7), the lifting and rotating mechanism does not need to be raised, and the barcode scanner 7 directly scans the label and extracts the part number and quantity information.

[0091] When the label is affixed to the lower left side of the front of the material packaging box 6 (i.e., the side facing the conveying direction), since the barcode scanner 7 cannot scan the label information, the lifting and rotating mechanism rises from the roller conveyor base 1-1-1 and is set to lift the material packaging box 6 and rotate it 90°, so that the label faces the barcode scanner 7. After the barcode scanner 7 scans the label and extracts the part number and quantity information, the lifting mechanism resets.

[0092] Those skilled in the art will understand that when the label is affixed to the back or left side of the material packaging box 6, the lifting and rotating mechanism can be raised from the roller conveyor base 1-1-1 and configured to lift the material packaging box 6 and rotate it by a corresponding angle, so that the label faces the scanning device 7.

[0093] If both scans fail, the conveyor line will alarm and pause. An operator will then intervene, using a handheld scanner to scan the code. Upon successful scanning, the operator will press pause buttons 1-3, and the conveyor line will resume normal operation. The information extracted by the handheld scanner will also be statistically analyzed.

[0094] If the barcode scanning system fails and cannot collect information from the material packaging box 6, then manual operation of the barcode scanning device 7 will be temporarily used to scan the label.

[0095] The barcode scanner 7 reads the label on the material packaging box 6 and processes the read label information into the format expected by the customer and sends it to the designated processing system (not shown), such as, but not limited to, a computer processing system.

[0096] Subsequently, the pushing device 1-11 pushes out towards the alignment block 1-10 to push the material packaging box 6, thereby causing the material packaging box 6 to abut against the alignment block 1-10. The alignment block 1-10 aligns the material packaging box 6 with the inlet 2-1 of the first lifting device 2 (see...). Figure 10 This facilitates the smooth and accurate entry of the material packaging box 6 into the first lifting device 2.

[0097] like Figure 10 As shown, the first lifting device 2 includes a first outer frame 2-2 and a lifting platform 2-3 housed inside the first outer frame and capable of moving between a descending position 2-4 and an output position 2-5. A safety light curtain (not shown) can be installed at the inlet 2-1 of the first lifting device 2 to prevent clothing or body parts from getting caught in it.

[0098] The lifting platform 2-3 receives the material packaging box 6 conveyed by the roller conveyor 1 at the lowering position. Material sensors (not shown) can be installed at the lowering position 2-4 and the output position 2-5 to detect whether the material is in place. When the material packaging box 6 is detected to be in place, the lifting platform 2-3 will raise the material packaging box 6 from the lowering position 2-4 to the output position 2-5. When the lifting platform 2-3 detects that there is no item, it returns to the lowering position 2-4 to wait for reloading of the material packaging box 6.

[0099] For example, but not limited to, the lifting speed of the first lifting device 2 is 30 meters per minute, the lifting height is 3.8 meters, and the pause time is conservatively calculated to be more than 140 cycles per hour. For example, but not limited to, the first lifting device 2 is required to bear ≥30 kg per unit area, the lifting motor power is 0.75KW, and the maximum weight of the goods that can be lifted is 50 kg.

[0100] The lower part of the first external frame 2-2 is fixed to the ground by fastening devices (e.g., expansion bolts, not shown).

[0101] like Figure 11 and Figure 12 As shown, one end of the overhead roller conveyor line 3 is connected to the first lifting device 2, and the other end of the overhead roller conveyor line 3 is connected to the second lifting device 4.

[0102] The second lifting device 4 has a similar structure to the first lifting device 2, and also includes a corresponding lifting platform (not shown) for carrying the material packaging box 6.

[0103] The overhead roller conveyor line 3 includes multiple conveying rollers 3-1. The multiple conveying rollers 3-1 drive four driven rollers (not shown) through an active roller. They are arranged in sequence to convey the material packaging box 6 received from the output position 2-5 of the first lifting device 2 to the input position 4-1 of the second lifting device 4.

[0104] Along the length of the overhead roller conveyor line 3, protective devices 3-2, maintenance platforms 3-3, and multiple spaced ceiling tie rods 3-4 installed on the protective devices 3-2 are provided on both sides. The protective devices 3-2 may be a visible protective net 3-2-1 and / or a guardrail 3-2-2.

[0105] The overhead roller conveyor line 3 may also be equipped with a maintenance ladder 3-5, through which maintenance personnel can access the maintenance platform 3-3 from the ground via the maintenance ladder 3-5.

[0106] like Figure 12 As shown, a visible protective net 3-2-1 is installed on one side of the overhead roller conveyor line 3, while a guardrail 3-2-2 is installed on the other side of the overhead roller conveyor line 3 and the maintenance platform 3-3.

[0107] The overhead roller conveyor line 3 is supported on the ground by overhead roller support frames 3-6.

[0108] The overhead roller conveyor 3 is positioned at a higher height than the roller conveyor 1, for example, but not limited to, a height of 2.6 meters above the ground. This arrangement of the overhead roller conveyor 3 facilitates the passage of operators beneath it.

[0109] like Figure 11-17 As shown, the overhead roller conveyor line 3 has a partitioned design. As shown in the figure, at one end near the first lifting device 2, a fireproof partition 3-7 is installed above the overhead roller conveyor line 3, and a fireproof double door 3-8 is installed below the overhead roller conveyor line 3 (see figure). Figure 14 The fireproof partition 3-7 is provided with a fireproof partition opening 3-7-1, through which the overhead roller conveyor line 3 passes.

[0110] like Figure 15 and Figure 16 As shown, a fire door 3-10 is provided on the side of the fireproof partition 3-7 facing the second lifting device 4. The overhead roller conveyor line 3 has an overhead roller tilting mechanism 3-9.

[0111] The automated material handling system is connected to a fire alarm system (not shown). When the automated material handling system receives a fire alarm message (e.g., but not limited to, receiving fire signals from smoke detectors, temperature sensors, etc.), the overhead roller tilting mechanism 3-9 automatically tilts (see...). Figure 15 and Figure 17(a)-(c)) thereby disconnecting the overhead roller conveyor line 3, so that the fire door 3-10 can roll down through the disconnected overhead roller conveyor line 3 to close the fireproof partition opening 3-7-1, thereby separating the area above the overhead roller conveyor line 3 on both sides of the fireproof partition 3-7, and the fireproof double door 3-8 automatically closes to separate the area below the overhead roller conveyor line 3 on both sides of the fireproof double door 3-8.

[0112] After the fire alarm is cleared, the fire door 3-10 rises and opens the fireproof partition opening 3-7-1, the overhead roller tilting mechanism 3-9 resets, the overhead roller conveyor line 3 resumes operation, and the fireproof double door 3-8 opens automatically.

[0113] The fire alarm system can also consider adding a programmable logic controller (PLC) (not shown) and connecting the PLC to the backup fire power supply to achieve independent control of the overhead drum tilting mechanism 3-9.

[0114] The drive system (not shown) of the fire door 3-10 typically employs an electric motor (such as a DC motor or servo motor), driven by a reducer (not shown) and a chain or belt (not shown) to achieve rapid raising and lowering of the fire door 3-10. In the event of a fire, the electric motor can respond quickly, causing the fire door 3-10 to descend. For example, but not limited to, the door curtain 3-10-1 of the fire door 3-10 is typically made of multi-layered composite materials, including a PVC base fabric, fire-resistant and heat-insulating materials, etc. These materials not only have good fire resistance but are also relatively lightweight. For example, but not limited to, the expected opening size of the fire door is 110 cm wide and 120 cm high.

[0115] As described above, after the overhead roller conveyor 3 transports the material packaging box 6 to the other end of the overhead roller conveyor 3, a height sensor 8 installed at or near the other end of the overhead roller conveyor 3 measures the height of the material packaging box 6 and transmits the measured height information to the second lifting device 4. The second lifting device 4 determines the stopping height of the material packaging box 6 relative to the belt conveyor 5 based on the received height information, that is, the corresponding layer of the belt conveyor 5.

[0116] For example, but not limited to, the height sensor 8 can use a red laser or an infrared laser.

[0117] The material packaging boxes 6 are detected by height sensor 8. Next, the height sensor function program (not shown) determines the category of each material packaging box 6 and counts it. The automated material handling system counts the number of material packaging boxes 6 in each category. The automated material handling system performs post-processing on the classification and counting results, including removing duplicate counts and detecting outliers. Then, the automated material handling system can make corresponding decisions based on this data.

[0118] like Figure 18 and Figure 19 As shown, the belt conveyor line 5 has a multi-layer structure, for example, but not limited to, having three layers, namely, a first layer 5-1, a second layer 5-2, and a third layer 5-3.

[0119] To avoid affecting personnel loading and unloading goods and the overall height of the conveyor belt, the second lifting device 4 transports the larger material packaging boxes 6 from the first layer at the highest point into the conveyor belt 5, and so on.

[0120] The first layer 5-1 can be set to a height of less than or equal to 65 cm for the input material packaging box 6; the second layer 5-2 can be set to a height of less than or equal to 55 cm for the input material packaging box 6; and the third layer 5-3 can be set to a height of less than or equal to 25 cm for the input material packaging box 6.

[0121] In the belt conveyor line 5, adjacent layers are staggered along the width of the belt conveyor line 5. That is, each layer is aligned on one side of the width of the belt conveyor line 5, and each layer is not aligned on the other side. Furthermore, the width of each layer decreases sequentially from bottom to top along the height of the belt conveyor line 5. For example, but not limited to, the second layer is staggered 50 cm away from the operator relative to the third layer. The first layer is also staggered 50 cm away from the operator relative to the second layer. This staggered arrangement facilitates the operator's access to the material packaging boxes 6.

[0122] Each layer of belt conveyor 5 has a length of, for example but not limited to, 8 meters and is designed in two sections, each with a load capacity of 300 kg. For example but not limited to, the speed of each layer of belt conveyor 5 is approximately 30 meters per minute. This receiving speed depends on the incoming material speed at the front end, which determines the production capacity.

[0123] Priority can be determined based on the storage status of a single layer. When the first priority layer is full, the second priority layer is moved on. The specific external dimensions of the material packaging boxes 6 in each layer can be adjusted through the operation interface (not shown).

[0124] like Figure 18 As shown, each layer of the belt conveyor line 5 is equipped with a pair of sensors 5-6 at the belt inlet 5-4 and belt tail 5-5 (the pair of sensors 5-6 are arranged on both sides of the belt conveyor line 5 along the width direction of the belt conveyor line 5). When the pair of sensors 5-6 at the belt inlet 5-4 detects the material packaging box 6 (for example, the material packaging box 6 blocks the detection beam emitted by the pair of sensors 5-6), the corresponding layer of the belt conveyor line 5 starts to run to receive the material packaging box 6.

[0125] When the pair of sensors 5-6 located at the belt inlet 5-4 no longer detect the material packaging box 6, for example, but not limited to, after one second, the corresponding layer of the belt conveyor 5 stops, so that the material packaging box 6 can be transported forward one after another with intervals relative to each other until the corresponding layer of the belt conveyor 5 is full.

[0126] When the pair of sensors 5-6 located at the tail of the belt 5-5 detect the material packaging box 6, it indicates that the corresponding layer of the belt conveyor 5 has been completely filled. The drive mechanism (not shown) of the belt conveyor 5 then stops the corresponding layer and stops receiving material packaging boxes 6.

[0127] The foregoing disclosure provides illustrations and descriptions, but is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Modifications and variations can be made based on the above disclosure, or modifications and variations can be derived from the practice of the embodiments.

[0128] Even if a specific combination of features is recited in the claims and / or disclosed in the specification, such combinations are not intended to limit the disclosure of various embodiments. In fact, many of these features can be combined in ways not specifically recited in the claims and / or not specifically disclosed in the specification. Although each dependent claim listed below may depend directly on only one claim, the disclosure of various embodiments includes each dependent claim in combination with every other claim in the claim set.

[0129] Unless explicitly stated otherwise, no element, action, or instruction used herein should be construed as critical or necessary. Furthermore, as used herein, the articles “a” and “an” are intended to include one or more items and are interchangeable with “one or more.” Additionally, as used herein, the article “the” is intended to include one or more items referenced in combination with the article “the” and is interchangeable with “one or more.” Furthermore, as used herein, the term “set” is intended to include one or more items (e.g., related items, unrelated items, a combination of related and unrelated items, etc.) and is interchangeable with “one or more.” In case of intent only… Figure 1 In cases involving items, the phrase "only one" or similar language is used. Additionally, as used herein, the term "having" and its variations are intended to be open-ended terms. Furthermore, the phrase "based on" is intended to mean "at least partially based on," unless otherwise explicitly stated. Additionally, as used herein, the term "or" is intended to be inclusive when used in series and may be used interchangeably with "and / or," unless otherwise explicitly stated (e.g., if used in conjunction with "or" or "only one of them").

Claims

1. An automated material handling system, characterized in that, The automated material handling system includes: Roller conveyor (1), which is configured to convey material (6); A lifting device is connected to one end of the roller conveyor (1) and is configured to receive the material conveyed by the roller conveyor (1); A belt conveyor (5) is connected to the lifting device. The belt conveyor (5) has a multi-layer structure, each layer having a different height to accommodate materials (6) of different heights conveyed by the lifting device. A height sensor (8) is configured to measure the height of the material (6); The lifting device determines the stopping height of the material (6) relative to the belt conveyor (5) based on the height measurement results from the height sensor (8).

2. The automated material handling system according to claim 1, characterized in that, The lifting device includes a first lifting device (2) and a second lifting device (4); The first lifting device (2) is connected to one end of the roller conveyor (1) and is used to lift the material (6) from the roller conveyor (1) to the output position (2-5) of the first lifting device (2) above the roller conveyor (1). The automated material transfer system also includes an overhead roller conveyor line (3), one end of which is connected to the first lifting device (2) for conveying the material (6) from the first lifting device (2) to the other end of the overhead roller conveyor line (3); The second lifting device (4) is connected to the other end of the overhead roller conveyor line (3) and is used to lower the material (6) from the overhead roller conveyor line (3) to the stopping height; The belt conveyor (5) is connected to the second lifting device (4) for receiving and conveying the material (6). The height sensor (8) is installed at the other end of the overhead roller conveyor line (3) to measure the height of the material (6) and send the height measurement result to the second lifting device (4). The second lifting device (4) determines the stopping height of the material (6) relative to the belt conveyor line (5) based on the received height measurement result.

3. The automated material handling system according to claim 1, characterized in that, The roller conveyor line (1) includes multiple roller conveyor line sections (1-1), each roller conveyor line section (1-1) includes a roller conveyor line base (1-1-1) and at least one roller conveyor line turning part (1-1-2), the turning part (1-1-2) is rotatably connected to one end of the roller conveyor line base (1-1-1) for turning 90 degrees when needed to leave a passage for people to pass through.

4. The automated material handling system according to claim 3, characterized in that, Along the conveying direction of the roller conveyor line (1), anti-collision guardrails (1-2) are respectively installed on both sides of each roller conveyor base (1-1-1); and / or Along the conveying direction perpendicular to the roller conveyor line (1), anti-collision guardrails (1-2) are provided on both sides of the corresponding roller conveyor line base (1-1-1).

5. The automated material handling system according to any one of claims 3 to 4, characterized in that, A safety light curtain (1-8) is also provided on the roller conveyor base (1-1-1). The safety light curtain (1-8) is located below the roller conveyor tilting section (1-1-2) and is used to detect people or obstacles and pause the tilting operation of the roller conveyor tilting section (1-1-2) when a person or obstacle is detected.

6. The automated material handling system according to any one of claims 3 to 4, characterized in that, The automated material handling system also includes a barcode scanning device (7), which is set on or near the roller conveyor base (1-1-1) for reading the label information on the material (6) and transmitting the label information to a designated computer to achieve material tracking.

7. The automated material handling system according to claim 2, characterized in that, The multi-layer structure of the belt conveyor (5) includes at least three layers, namely a first layer (5-1), a second layer (5-2) and a third layer (5-3). Each layer is aligned on one side in the width direction of the belt conveyor (5), and each layer is not aligned on the other side in the width direction of the belt conveyor (5). The width of each layer decreases sequentially from bottom to top in the height direction of the belt conveyor (5).

8. The automated material handling system according to claim 2, characterized in that, The overhead roller conveyor line (3) is provided with fireproof partitions (3-7) and fireproof doors (3-10). The fireproof partitions (3-7) have fireproof partition openings (3-7-1). The fireproof doors (3-10) close the fireproof partition openings (3-7-1) when a fire occurs, thereby separating the areas on both sides of the fireproof partitions (3-7) above the overhead roller conveyor line (3).

9. The automated material handling system according to claim 8, characterized in that, The overhead roller conveyor line (3) is equipped with an overhead roller turning mechanism (3-9). The automated material handling system is configured such that when a fire alarm is received, the overhead roller turning mechanism (3-9) turns over to disconnect the overhead roller conveyor line (3), thereby allowing the fire door (3-10) to roll down through the disconnected overhead roller conveyor line (3) for isolation. After the fire alarm is cleared, the fire door (3-10) rises and opens, the overhead roller turning mechanism (3-9) resets, and the overhead roller conveyor line (3) resumes operation.

10. The automated material handling system according to any one of claims 2 to 4, characterized in that, Alignment blocks (1-10) and pushers (1-11) are also provided on the roller conveyor base (1-1-1) adjacent to the first lifting device (2). The alignment block (1-10) is fixedly disposed on at least one side of the roller conveyor base (1-1-1) and configured such that the material (6) is aligned with the feed inlet (2-1) of the first lifting device (2); The pusher device (1-11) is located on the other side of the roller conveyor base (1-1-1) and is configured to push out toward the alignment block to push the material (6), thereby causing the material (6) to abut against the alignment block (1-10).

11. The automated material handling system according to any one of claims 2 to 4, characterized in that, A pair of sensors (5-6) are respectively installed at the belt inlet (5-4) and belt tail (5-5) of each layer of the belt conveyor line (5). When the pair of sensors (5-6) located at the belt inlet (5-4) detect the material (6), the corresponding layer of the belt conveyor (5) starts to run to receive the material (6). When the pair of sensors (5-6) located at the belt inlet (5-4) fail to detect material (6), the corresponding layer of the belt conveyor (5) stops. When the pair of sensors (5-6) located at the tail end (5-5) of the belt detect the material (6), the corresponding layer of the belt conveyor (5) stops and no longer receives material (6).

12. The automated material handling system according to any one of claims 2 to 4, characterized in that, The roller conveyor line (1) is equipped with a pair of sensors (1-9), which are used to detect the presence of the material (6) and to trigger the automatic start of the roller conveyor line (1).

13. The automated material handling system according to any one of claims 2 to 4, characterized in that, The roller conveyor line (1) is equipped with a pause button (1-3) and an emergency stop button (1-4). The pause button (1-3) is used to pause the conveying operation of the current roller conveyor line section without affecting the downstream roller conveyor line section. The emergency stop button (1-4) is used to stop the operation of the entire roller conveyor line (1).

14. The automated material handling system according to any one of claims 3 to 4, characterized in that, The roller conveyor line (1) is equipped with a rotary button (1-5) and a rotary motor (1-7). Pressing the rotary button (1-5) drives the roller conveyor line flipping section (1-1-2) to flip through the rotary motor (1-7) to create a passageway. The roller conveyor line (1) is also equipped with a rotation warning device (1-6), which emits an audible and visual alarm during the flipping process.

15. The automated material handling system according to claim 2, characterized in that, The first lifting device (2) includes a lifting platform (2-3), which is capable of lifting the material (6) from the lowering position (2-4) to the output position (2-5). The lifting platform (2-3) is configured to return to the lowered position (2-4) when no items are detected, and wait to reload materials (6).

16. The automated material handling system according to any one of claims 1 to 4, characterized in that, The material (6) is a material packaging box.

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