Automatic pallet alignment system and method employed thereof
The automatic pallet alignment system uses pneumatic and electric motors for non-contact alignment, addressing pallet damage and inefficiencies in existing methods, achieving high precision and flexibility across various pallet types and sizes.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ALLIGATOR AUTOMATIONS INDIA PTE LTD
- Filing Date
- 2025-12-13
- Publication Date
- 2026-06-25
AI Technical Summary
Current pallet alignment methods, whether manual, mechanical, or pneumatic, often result in pallet damage due to friction and require manual intervention, lacking precision and flexibility for various pallet types and sizes.
An automatic pallet alignment system using pneumatic cylinders and electric motors for non-contact alignment, achieving ±3 mm accuracy, accommodating different pallet materials and sizes, and integrating seamlessly with conveyor systems.
The system ensures precise alignment without pallet damage, reduces maintenance, and enhances operational efficiency by minimizing friction and manual intervention, suitable for diverse industrial applications.
Smart Images
Figure IB2025062828_25062026_PF_FP_ABST
Abstract
Description
“AUTOMATIC PALLET ALIGNMENT SYSTEM AND METHOD EMPLOYED THEREOF”TECHNICAL FIELD
[0001] The present invention relates to automated pallet handling and alignment systems designed for precise and efficient stacking and orientation. More specifically, this invention pertains to a pallet alignment system that utilizes non-contact mechanisms to align pallets with high accuracy across multiple axes, preventing physical contact between pallets to eliminate potential damage during alignment and optimize downstream handling processes.BACKGROUND
[0002] In industrial and commercial sectors, the efficient handling, stacking, and movement of goods rely significantly on the use of pallets. These platforms, commonly made from wood or metal, play a crucial role in logistics operations by facilitating the storage and transport of products across industries such as FMCG, cement, oil and gas, paper, and battery manufacturing. However, properly aligning stacks of pallets for dispensing or further processing has long been a challenge, with current methods often resulting in inefficiencies and potential damage to the pallets.
[0003] One prevalent method involves manual alignment, where workers physically adjust pallet stacks to ensure they are properly organized for dispensing or storage. While this approach is simple, it is labor-intensive, prone to errors, and time-consuming, leading to higher operational costs. The manual handling of pallets also increases the risk of damage due to mishandling or improper stacking techniques.
[0004] Mechanical alignment systems have been introduced to automate the process and reduce manual labor. These systems often involve mechanical arms or guides that push or pull pallets into position. While these systems improve efficiency, they typically require direct contact between the pallets, which introduces friction. This friction can cause scratches, dents, or even structural damage to the pallets, especially in the case of fragile materials. Additionally, these mechanical systems can be complex and prone to breakdowns, resulting in increased maintenance requirements and operational delays.
[0005] Pneumatic systems have also been used in some pallet alignment solutions. However, these systems still require the pallets to be closely packed, and in many cases, the pneumatic mechanisms come into direct contact with the pallets during the alignment process. This can lead to similar issues of friction and damage. Additionally, pneumatic systems often lack the precision required for handling different types of pallets, which can affect the overall accuracy of the alignment.
[0006] In certain cases, conveyor systems are employed in combination with manual alignment checks. While the conveyor helps move pallet stacks through the alignment process, workers are still required to intervene at various points to ensure proper alignment. This hybrid approach, though slightly more efficient than fully manual methods, still does not address the issues of potential pallet damage and the need for continuous worker involvement.
[0007] In light of the aforementioned discussion, there exists a need for a system with novel methodologies that can eliminate the drawbacks of existing pallet alignment solutions, ensuring precise alignment without the risk of pallet damage and reducing the reliance on manual intervention.SUMMARY
[0008] The following presents a simplified summary of the disclosure in order to provide a basic understanding of the reader. This summary is not an extensive overview of the disclosure and it does not identify key / critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.
[0009] Exemplary embodiments of the present disclosure are directed towards automatic pallet alignment system and method employed thereof.
[0010] An objective of the present invention is directed towards providing a system for aligning pallet stacks in an automated and precise manner, without the need for manual intervention.
[0011] Another objective of the present invention is directed towards eliminating the risk of pallet damage during the alignment process by ensuring that pallets do not make contact witheach other, thus preventing friction, scratches, or structural damage.
[0012] Another objective of the present invention is directed towards designing an alignment system that accommodates various types of pallets, including wooden and metal pallets, and different configurations without limitations on pallet materials or stack sizes.
[0013] Another objective of the present invention is directed towards creating a system that uses a combination of pneumatic cylinders and electric motors to achieve 100% alignment accuracy within ±3 mm, improving the overall efficiency of the palletizing process.
[0014] Another objective of the present invention is directed towards providing a system that minimizes maintenance requirements by using an efficient, reliable mechanism that operates without direct mechanical contact between pallets.
[0015] Another objective of the present invention is directed towards enabling seamless integration of the pallet aligner into existing conveyor and pallet dispenser systems, thereby enhancing automation and streamlining operations in warehouse environments.
[0016] Another objective of the present invention is directed towards creating a system that can handle any number of pallets in a stack without limitations, offering flexibility in terms of stack size for various industrial applications.
[0017] Another objective of the present invention is directed towards providing an efficient pallet alignment system that can be utilized in various industries, including warehouses for FMCG products, cement, oil & gas, the paper industry, and the battery industry, to enhance automation and streamline palletizing operations across diverse sectors.
[0018] According to an exemplary aspect, an automatic pallet alignment system for facilitating the efficient handling of a stack of pallets.
[0019] According to another exemplary aspect, the system includes a conveyor belt positioned adjacent to a plurality of support columns, configured to receive, hold, and move the pallet stack, wherein the conveyor belt is controlled by a control unit.
[0020] According to another exemplary aspect, the system includes a first set of pneumatic cylinders and a second set of pneumatic cylinders operatively connected to the control unit.
[0021] According to another exemplary aspect, the support columns, positioned on either side of the pallet stack, each equipped with alignment rollers configured to engage with the edges of the pallets to facilitate precise lateral alignment.
[0022] According to another exemplary aspect, support columns include rods extending partially into cutouts in the pallet stack, activated by the first set of pneumatic cylinders configured for half-stroke operation to provide stability during alignment.
[0023] According to another exemplary aspect, the first set of pneumatic cylinders configured to control the movement and retraction of the rods, enabling secure engagement and disengagement with the pallet stack.
[0024] According to another exemplary aspect, electric motors operatively connected to a chain mechanism and configured to incrementally lift and separate each pallet within the stack through the alignment rollers, thereby creating controlled gaps between the pallets for non-contact alignment.
[0025] According to another exemplary aspect, the control unit configured to activate the first set of pneumatic cylinders to fully insert the rods into the pallets after creating the gaps, thereby aligning the pallets perpendicularly to the conveyor belt direction.
[0026] According to another exemplary aspect, the control unit further configured to activate the second set of pneumatic cylinders for adjusting the pallets to align with the conveyor’s running direction.
[0027] According to another exemplary aspect, the electric motors configured to arrange the pallets together after alignment to eliminate gaps between adjacent pallets, thereby enhancing the structural integrity of the stack.
[0028] According to another exemplary aspect, the first set of pneumatic cylinders configured to retract the rods from the stack of pallets, and the second set of pneumaticcylinders configured to retract, thereby preparing the aligned stack for seamless transfer to downstream processing operations, including transport of the stack of pallets.BRIEF DESCRIPTION OF THE DRAWINGS
[0029] In the following, numerous specific details are set forth to provide a thorough description of various embodiments. Certain embodiments may be practiced without these specific details or with some variations in detail. In some instances, certain features are described in less detail so as not to obscure other aspects. The level of detail associated with each of the elements or features should not be construed to qualify the novelty or importance of one feature over the others.
[0030] FIG.1A is a schematic diagram illustrates automatic pallet alignment system, in accordance with one or more exemplary embodiments.
[0031] FIG. IB and FIG.1C are schematic diagram illustrates front view and perspective view of the automatic pallet alignment system, in accordance with one or more exemplary embodiments.
[0032] FIG. 2A and FIG. 2B are schematic diagrams illustrate the front view and perspective view of the automatic pallet stack system with rods partially inserted into a stack of pallets, in accordance with one or more exemplary embodiments.
[0033] FIG. 3A and FIG. 3B are schematic diagrams illustrate both the front view and the perspective view of the automatic pallet alignment system for creating a gap between individual pallets, in accordance with one or more exemplary embodiments.
[0034] FIG. 4A and FIG. 4B are schematic diagrams illustrate both the front view and the perspective view of the automatic pallet alignment system with rod fully inserted into a stack of pallets, in accordance with one or more exemplary embodiments.
[0035] FIG. 5A and FIG. 5B are schematic diagrams illustrate the front views of a stack of pallets before and after alignment to a perpendicular position relative to the conveyor direction, in accordance with one or more exemplary embodiments.
[0036] FIG. 5C and FIG. 5D are schematic diagrams illustrate the perspective views of a stack of pallets, showing their positioning both before and after alignment in the direction of conveyor movement, in accordance with one or more exemplary embodiments.
[0037] FIG. 6A and FIG. 6B are schematic diagrams illustrate the front view and perspective view of a stack of pallets, depicting their final placement after alignment with no gaps between them, in accordance with one or more exemplary embodiments.
[0038] FIG. 7A and FIG. 7B are schematic diagrams depict the front view and perspective view of the pallet stack alignment system at the final stage, in accordance with one or more exemplary embodiments.
[0039] FIG. 8 is a flowchart depicting an exemplary method for aligning a stack of pallets using an automatic pallet alignment system, in accordance with one or more exemplary embodiments.DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0040] It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
[0041] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.
[0042] Referring to FIG.1A is schematic diagram 100a illustrates automatic pallet alignment system, in accordance with one or more exemplary embodiments. Referring to FIG. IB andFIG.1C are schematic diagrams 100b, 100c illustrates front view and perspective view of the automatic pallet alignment system, in accordance with one or more exemplary embodiments. The system 100a, 100b, 100c includes pallets 102, two pair of support columns 104, alignment rollers 106, chain mechanism 108, electric motors 110, a conveyor 111, a control unit 112, and a first set of pneumatic cylinders 114a, a second set of pneumatic cylinders 114b. The system 100a, 100b, 100c is configured to handle and precisely align pallets 102 through a combination of non-contact alignment mechanisms and multi-stage orientation adjustments, ensuring each pallet is accurately positioned for downstream processing.
[0043] The system 100a, 100b, 100c is configured to perform aligning and orientating pallets 102 within the system, the pallets 102 may be made of wood, metal, plastic or other materials commonly used in warehouse and distribution environments. The two pair of support columns 104 may be served as the main structural support and house the alignment rollers 106.
[0044] The alignment rollers 106 may be positioned along the lengths of the support columns 104 to guide the pallets 102 into precise alignment without direct contact. The alignment rollers 106 engage with the edges of the pallets 102 to provide lateral alignment, gradually adjusting the position of the pallet as it passes through the system. The alignment rollers 106 may also aid in minimizing friction and reducing wear on the pallet edges. The chain 108 may run through the support columns 104 and is responsible for coordinating the movement of the alignment rollers 106 along with the pallet. The chain mechanism 108 helps in synchronizing the motion of the rollers 106, ensuring smooth transitions and precise control of the pallet’s lateral within the alignment system.
[0045] The electric motors 110 may be positioned at the top of each support column, electric motors 110 drive the chain mechanism 108 and alignment rollers 106. The electric motors 110 control the movement of the alignment rollers 106 and, by extension, the pallet 102, and providing power to move the pallet along its path within the alignment system. The electric motors 110 are synchronized to ensure even and controlled movement along both sides of the pallet.
[0046] The electric motors 110 may be positioned at the top of each support column, electric motors 110 drive the chain mechanism 108 and alignment rollers 106. The electric motors110 control the movement of the alignment rollers 106, which in turn guide the pallets 102, providing the power needed to move the pallet along its path within the alignment system 100a, 100b, 100c. The electric motors 110 are synchronized to ensure even and controlled movement along both sides of the pallet.
[0047] The conveyor 111 is operable to receive and support a stack of pallets fed into the support columns 104 for multi-stage alignment with precision. After aligning, the stack of pallets can be moved flexibly onto a forklift.
[0048] The control unit 112 may be located between the support columns 104 at bottom side, the control unit 112 may be configured to perform alignment process. It contains a motor and gear system that manages the primary positioning of the pallets 102 as it enters the alignment system. The control unit 112 performs initial broad positioning, setting the groundwork for finer alignment stages. Further the control unit 112 includes sensors configured to monitor the alignment of the pallet stack during the alignment process, providing real-time feedback to ensure precise positioning and adjustment of the pallets.
[0049] The first set of pneumatic cylinders 114a are positioned at the bottom of the support columns 104 to provide multi-stage, fine-tuning alignment capabilities. The first set of pneumatic cylinders 114a, and the second set of pneumatic cylinders 114b engage to make high-precision adjustments to the pallet’s position. The first set of pneumatic cylinders 114a, and the second set of pneumatic cylinders 114b enable fine corrections in both orientation and lateral positioning, ensuring that the pallets 102 is accurately aligned before it moves to the next stage of processing.
[0050] According to the exemplary embodiments of the present disclosure, upon entry into the alignment system 100a, 100b, 100c the pallets 102 first encounters the control unit 112, which performs broad positioning to align the pallet 102 within the system framework. The electric motors 110 then activate, driving the chain mechanism 108 and the alignment rollers 106, which gently guide the pallet along the support columns 104 with non-contact precision. The alignment rollers make 106 continuous, minute adjustments to keep the pallet centered and properly aligned laterally as it progresses through the system.
[0051] When the pallets 102 reaches its designated position, the first set of pneumatic cylinders 114a, and the second set of pneumatic cylinders 114b engage to perform fine-tuned, multi-stage alignment adjustments. The first set of pneumatic cylinders 114a, and the second set of pneumatic cylinders 114b provide the final orientation corrections, refining the alignment to meet the precise standards required for downstream operations. After these adjustments, the pallets 102 is positioned accurately and prepared for transfer onto the conveyor belt 111 or similar mechanism for further transportation or subsequent processing.
[0052] The non-contact, precision pallet alignment system 100a, 100b, 100c offers several significant advantages. By integrating multi-stage orientation using synchronized motors 110, alignment rollers 106, the control unit 112, and pneumatic cylinders 114a, 114b, the system 100a, 100b, 100c achieves exceptional alignment accuracy without direct physical contact. This design reduces wear on pallets 102, minimizes maintenance requirements, and optimizes efficiency, making it well-suited for high-volume warehousing and distribution environments.
[0053] According to the exemplary embodiments of the present disclosure, an automatic pallet alignment system for facilitating the efficient handling of a stack of pallets include a conveyor belt positioned adjacent to a plurality of support columns, configured to receive, hold, and move the pallet stack, The conveyor belt is controlled by a control unit. A first set of pneumatic cylinders 114a and a second set of pneumatic cylinders 114b operatively connected to the control unit. The plurality of support columns, positioned on either side of the pallet stack, each equipped with alignment rollers configured to engage with the edges of the pallets to facilitate precise lateral alignment. The plurality of rods extending partially into cutouts in the pallet stack from the support columns, activated by the first set of pneumatic cylinders 114a configured for half-stroke operation to provide stability during alignment. The first set of pneumatic cylinders 114a configured to control the movement and retraction of the rods, enabling secure engagement and disengagement with the pallet stack. The electric motors operatively connected to a chain mechanism and configured to incrementally lift and separate each pallet within the stack through the alignment rollers, thereby creating controlled gaps between the pallets for non-contact alignment. The control unit configured to activate the first set of pneumatic cylinders 114a to fully insert the rods into the pallets after creating the gaps, thereby aligning the pallets perpendicularly to the conveyor belt direction. The control unit further configured to activate the second set of pneumatic cylinders 114b for adjusting the pallets to align with the conveyor’s running direction. The plurality of electricmotors configured to arrange the pallets together after alignment to eliminate gaps between adjacent pallets, thereby enhancing the structural integrity of the stack and the first set of pneumatic cylinders 114a configured to retract the rods from the stack of pallets, and the second set of pneumatic cylinders 114b configured to retract, thereby preparing the aligned stack for seamless transfer to downstream processing operations, including transport of the stack of pallets.
[0054] Referring to FIG. 2A and FIG. 2B are schematic diagrams 200a, 200b illustrate the front view and perspective view of the automatic pallet stack system with rods partially inserted into a stack of pallets, in accordance with one or more exemplary embodiments. The diagrams 200a, 200b depicting the system used to align and support the pallets within the alignment zone. The system 200a, 200b includes support columns 104 on either side of the pallet stack, each equipped with alignment rollers 106 positioned along the length of the columns. These rollers 106 engage with the edges of the pallets 102 to guide them into precise alignment. Additionally, the alignment system 200a, 200b features rods that partially extend into cutouts in the pallet stack 102, providing stability and securing the pallets during the multi-stage alignment process.
[0055] FIG. 2A presents the front view, highlighting the arrangement of the support columns and alignment rollers, as well as the rods controlled by a first set of pneumatic cylinders 114a for precise lateral and directional alignment. FIG. 2B, the perspective view, shows the spatial arrangement of these components in relation to the pallet stack 102, including the electric motors 110 that drive the chain mechanism 108 and alignment rollers 106 for synchronized movement. The control unit 112 is positioned at the base of the support columns 104 and contains the main motor and gear systems (not disclosed) responsible for primary positioning to the pallet stack 102. Together, these diagrams 200a, 200b provide a comprehensive view of the system components involved in achieving non-contact, multi-stage alignment, demonstrating how the support columns, rollers, pneumatic cylinders, and motors function in unison to precisely position the pallet stack for downstream handling.
[0056] Referring to FIG. 3A and FIG. 3B are schematic diagrams 300a, 300b illustrate both the front view and the perspective view of the automatic pallet alignment system for creating a gap between individual pallets, in accordance with one or more exemplary embodiments.
[0057] The system includes an electric motor 110 connected to a chain mechanism 108 designed to lift each pallet within a stack incrementally. In operation, the electric motor 110 activates the chain mechanism, which gently lifts and slightly separates each pallet, creating a controlled gap. This separation process allows for precise alignment without any direct contact between adjacent pallets 102, which helps prevent friction and physical damage during the alignment procedure. By maintaining a gap between pallets 102, the system 110 minimizes wear and tear on the pallet surfaces, enhancing durability and ensuring that each pallet 102 is optimally positioned for subsequent stacking, palletizing, or dispensing operations. This multi-stage gap creation also contributes to alignment accuracy by holding each pallet steady, allowing for further alignment adjustments as needed in subsequent stages. This non-contact approach enhances the system’s adaptability to various pallet types and materials, further broadening its application across multiple industries.
[0058] Referring to FIG. 4A and FIG. 4B are schematic diagram 400a, 400b illustrate both the front view and the perspective view of the automatic pallet alignment system with rod fully inserted into a stack of pallets, in accordance with one or more exemplary embodiments.
[0059] The automatic pallet alignment system with rod fully inserted into a stack of pallets for pallet aligned in one direction. The system 400a, 400b include the control unit 112 may be configured to activate the first set of pneumatic cylinders 114a to extend, thereby the rods 109 to be fully inserted into designated cutouts within each pallet 102 after the creating gap between the pallets 102. The insertion is strategically configured to achieve precise positioning of each pallet 102, as the rods 109 stabilize the pallets 102 against unwanted movement or misalignment. The rods 109 securely engage each pallet in the stack 102, ensuring uniform alignment with an accuracy of ±3mm, regardless of pallet type or material.
[0060] The full insertion of the rods 109 is critical for maintaining stability across the stack during the alignment process, as it prevents shifts or deviations that could otherwise disrupt downstream processes, such as palletizing or loading. This precision configuration feature also enhances the system's adaptability, accommodating various pallet configurations while ensuring that each is perfectly aligned for subsequent operations. The robust design and precise control over the rod insertion mechanism make the pallet alignment system effective and reliable across different industrial applications.
[0061] Referring to FIG. 5A and FIG. 5B are schematic diagrams 500a, 500b illustrate the front views of a stack of pallets before and after alignment to a perpendicular position relative to the conveyor direction, in accordance with one or more exemplary embodiments. The diagram 500a, 500b may include pallets 102, two pair of support columns 104, alignment rollers 106, chain mechanism 108, electric motors 110, a conveyor 111, a central unit 112, and the first set of pneumatic cylinders 114a, and the second set of pneumatic cylinders 114b.
[0062] In FIG. 5 A, the stack of pallets 102 is shown in its initial position before alignment. At this stage, the pallets 102 may be offset or misaligned in relation to the conveyor’s movement path, necessitating realignment for accurate processing. In FIG. 5B, the first stage of alignment has been completed, and the stack of pallets 102 is positioned relative to the conveyor 111 direction. This orientation adjustment is achieved using a combination of pneumatic and mechanical components that precisely reposition each pallet for accurate alignment. By ensuring that the pallets 102 are correctly oriented, the system prepares them for subsequent processing stages, facilitating seamless integration into downstream operations.
[0063] Referring to FIG. 5C and FIG. 5D are schematic diagrams 500c, 500d illustrate the perspective views of a stack of pallets, showing their positioning both before and after alignment in the direction of conveyor movement, in accordance with one or more exemplary embodiments. In FIG. 5C, the stack of pallets is shown before alignment in the direction of conveyor 111 movement. At this stage, while the pallets 102 have been aligned perpendicularly, they have not yet been adjusted to precisely align with the conveyor’s forward path. This intermediate step ensures that pallets 102 are first correctly oriented but are not yet set in the exact direction needed for smooth downstream operations. At this stage, the second set of pneumatic cylinders 114b are in retracted position.
[0064] In FIG. 5D, the alignment system activates additional second set of pneumatic cylinders 114b or other actuators to guide each pallet 112 into perfect alignment with the conveyor’s 111 forward direction. This second alignment phase ensures that each pallet is accurately oriented in the conveyor’s 111 movement direction, eliminating potential misalignments that might disrupt subsequent handling processes, such as automated stacking, sorting, or loading.
[0065] This two-stage, multi-axis alignment approach allows the system 500a, 500b to achieve exact orientation in both perpendicular and conveyor-aligned directions, creating a seamless transition into subsequent processing steps. By aligning pallets with this degree of precision, the system 500c, 500d enhances the reliability and efficiency of automated handling, reducing the risk of misalignment and optimizing the transfer and stacking process. This capability is particularly valuable in applications requiring consistent orientation and precise placement, making the system adaptable to a variety of operational environments and pallet types.
[0066] Referring to FIG. 6A and FIG. 6B are schematic diagrams 600a, 600b illustrate the front view and perspective view of a stack of pallets, depicting their final placement after alignment with no gaps between them, in accordance with one or more exemplary embodiments. In FIG. 6A, the front view of the stacked pallets shows them precisely aligned and positioned closely together, eliminating any space that could disrupt the stability or handling efficiency in downstream operations. This gap-free configuration is achieved through the system's alignment mechanism, which initially creates spacing between each pallet for adjustment, then utilizes the electric motor 110 to bring the pallets 102 together once the alignment process is complete. In FIG. 6B, the perspective view further illustrates the even and secure stacking achieved through the alignment system. By removing gaps between each pallet 102, the system not only enhances the stack’s structural integrity but also prepares the stack for smooth transfer onto the conveyor or subsequent stages, such as loading or further processing.
[0067] This final gapless arrangement is crucial for ensuring stability and uniformity in automated pallet handling. The electric motor-driven mechanism that bring the pallets 102 together ensures that they are consistently and compactly positioned, which reduces movement or shifting during transport and enhances handling safety. The capability to adjust, align, and finally stack pallets 102 without gaps demonstrates the system’s robust and precise control over pallet positioning, making it highly adaptable across different industries and pallet types.
[0068] Referring to FIG. 7A and FIG. 7B are schematic diagrams 700a, 700b illustrate the front view and perspective view of the pallet stack alignment system at the final stage, wherethe 109 rods retract to prepare the aligned stack of pallets 102 for onward movement, in accordance with one or more exemplary embodiments of the invention.
[0069] In FIG. 7A, the front view illustrates the second set of pneumatic cylinders 114b in a fully retracted position following the alignment and precise placement of the pallet stack 102. The rods 106, previously engaged with the pallet cutouts to secure and align the stack, are now completely withdrawn. This retraction enables the pallet stack to proceed unimpeded to the next processing phase, which may include transport or automated stacking operations. In FIG. 7B provides a perspective view of the system, showing the spatial orientation of the pallet stack as the rods retract. The stack, now precisely aligned, remains securely stacked and oriented in readiness for seamless transfer. Positioned at the end of the alignment zone with the rods 109 retracted, the pallet stack is now prepared for effortless integration with the conveyor system or other downstream material handling equipment. This final retraction step concludes the alignment process, demonstrating the system's capacity to align and stabilize pallets with high precision, subsequently retracting the alignment rods to clear the stack for the next processing stage. The use of the first and second set of pneumatic cylinders 114a, 114b for retraction serves to enhance operational efficiency while maintaining the noncontact alignment method. This feature reduces friction and minimizes the risk of pallet damage, thereby supporting consistent and reliable handling in automated pallet workflows.
[0070] Referring to FIG. 8 is a flowchart 800 depicting an exemplary method for aligning a stack of pallets using an automatic pallet alignment system, in accordance with one or more exemplary embodiments. As an option, the method 800 is carried out in the context of the details of FIG. 1A, FIG. IB, FIG.1C, FIG.2A, FIG.2B, FIG.3A, FIG.3B, FIG.4A, FIG.4B, FIG.5A, FIG.5B, FIG.5C, FIG.5D, FIG.6A, FIG.6B, FIG.7A, and FIG.7B. However, the method 800 is carried out in any desired environment. Further, the aforementioned definitions are equally applied to the description below.
[0071] The method commences at step 802, positioning the pallet stack on a conveyor belt adjacent to a plurality of support columns, the conveyor belt configured to be controlled by a control unit to transport the pallet stack through the alignment system. Thereafter, at step 804, utilizing alignment rollers on the support columns, positioned on either side of the pallet stack, to engage with the edges of the pallets, thereby facilitating precise lateral alignment. Thereafter, at step 806, activating a first set of pneumatic cylinders to extend rods partiallyinto cutouts in the pallet stack, the cylinders operate in a half-stroke configuration to provide initial stability for the alignment process. Thereafter, at step 808, operating the first set of pneumatic cylinders to control the movement and retraction of the rods, enabling secure engagement and disengagement with the pallet stack as required. Thereafter, at step 810, activating a plurality of electric motors connected to a chain mechanism to incrementally lift and separate each pallet within the stack, creating controlled gaps between the pallets for non-contact alignment through the alignment rollers. Thereafter, at step 812, instructing the control unit to activate the first set of pneumatic cylinders to fully insert the rods into the pallets after creating gaps, thereby aligning the pallets perpendicularly to the conveyor belt direction. Thereafter, at step 814, activating the second set of pneumatic cylinders to adjust the pallets to align with the conveyor’s running direction. Thereafter, at step 816, utilizing the electric motors to bring the pallets together after alignment, effectively eliminating gaps between adjacent pallets to enhance the structural integrity of the aligned stack. Thereafter, at step 818, operating the first set of pneumatic cylinders to retract the rods from the pallet stack, and retracting the second set of pneumatic cylinders to prepare the aligned stack for downstream processing, enabling seamless transfer of the aligned stack to downstream processing operations, including transport of the stack of pallets.
[0072] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.
[0073] In accordance with one or more exemplary embodiments, the control unit is configured to coordinate the operation of the first set of pneumatic cylinders and the second set of pneumatic cylinders, electric motors, and conveyor belt, thereby ensuring synchronized alignment and transfer of the stack of pallets.
[0074] In accordance with one or more exemplary embodiments, the control unit is configured to perform alignment on each pallet individually without any contact between adjacent pallets, thereby achieving a complete elimination of potential damage to the pallets during the alignment process.
[0075] In accordance with one or more exemplary embodiments, the electric motors are positioned at the top of the support columns and are configured to drive the chain and roller mechanisms, ensuring synchronized movement of the alignment components for precise positioning and separation of each pallet within the stack.
[0076] In accordance with one or more exemplary embodiments, the alignment rollers are adjustable to accommodate pallets of various sizes, allowing precise alignment and positioning of different pallet dimensions for efficient downstream processing.
[0077] In accordance with one or more exemplary embodiments, the control unit comprises sensors configured to monitor the alignment of the pallet stack during the alignment process, providing real-time feedback to ensure precise positioning and adjustment of the pallets.
[0078] In accordance with one or more exemplary embodiments, the rods are extendable and retractable via the first set of pneumatic cylinders, allowing for controlled engagement with the pallet stack during the alignment process.
[0079] In accordance with one or more exemplary embodiments, the control unit configured to adjust plurality of electric motor’s speed and force based on the weight of each pallet, thereby facilitating optimal separation and alignment in a variety of load conditions.
[0080] In accordance with one or more exemplary embodiments, the conveyor belt is equipped with a variable -speed drive to adjust the movement speed of the pallet stack, enabling a smooth transition from the alignment system to downstream processing stages.
[0081] In accordance with one or more exemplary embodiments, a method for aligning a stack of pallets using an automatic pallet alignment system.
[0082] In accordance with one or more exemplary embodiments, positioning the pallet stack on a conveyor belt adjacent to a plurality of support columns, the conveyor belt configured to be controlled by a control unit to transport the pallet stack through the alignment system.
[0083] In accordance with one or more exemplary embodiments, utilizing alignment rollers on the support columns, positioned on either side of the pallet stack, to engage with the edges of the pallets, thereby facilitating precise lateral alignment.
[0084] In accordance with one or more exemplary embodiments, activating a first set of pneumatic cylinders to extend rods partially into cutouts in the pallet stack, the cylinders operate in a half-stroke configuration to provide initial stability for the alignment process.
[0085] In accordance with one or more exemplary embodiments, operating the first set of pneumatic cylinders to control the movement and retraction of the rods, enabling secure engagement and disengagement with the pallet stack as required.
[0086] In accordance with one or more exemplary embodiments, activating a plurality of electric motors connected to a chain mechanism to incrementally lift and separate each pallet within the stack, creating controlled gaps between the pallets for non-contact alignment through the alignment rollers.
[0087] In accordance with one or more exemplary embodiments, instructing the control unit to activate the first set of pneumatic cylinders to fully insert the rods into the pallets after creating gaps, thereby aligning the pallets perpendicularly to the conveyor belt direction.
[0088] In accordance with one or more exemplary embodiments, activating the second set of pneumatic cylinders to adjust the pallets to align with the conveyor’s running direction.
[0089] In accordance with one or more exemplary embodiments, utilizing the electric motors to bring the pallets together after alignment, effectively eliminating gaps between adjacent pallets to enhance the structural integrity of the aligned stack.
[0090] In accordance with one or more exemplary embodiments, operating the first set of pneumatic cylinders to retract the rods from the pallet stack, and retracting the second set of pneumatic cylinders to prepare the aligned stack for downstream processing, enabling seamless transfer of the aligned stack to downstream processing operations, including transport of the stack of pallets.
[0091] Reference throughout this specification to “one embodiment”, “an embodiment”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment”, “in an embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0092] Although the present disclosure has been described in terms of certain preferred embodiments and illustrations thereof, other embodiments and modifications to preferred embodiments may be possible that are within the principles of the invention. The above descriptions and figures are therefore to be regarded as illustrative and not restrictive.
[0093] Thus the scope of the present disclosure is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.
Claims
CLAIMS1. An automatic pallet alignment system for facilitating the efficient handling of a stack of pallets, comprising: a conveyor belt positioned adjacent to a plurality of support columns, configured to receive, hold, and move the pallet stack, wherein the conveyor belt is controlled by a control unit; a first set of pneumatic cylinders and a second set of pneumatic cylinders operatively connected to the control unit; the plurality of support columns, positioned on either side of the pallet stack, each equipped with alignment rollers configured to engage with the edges of the pallets to facilitate precise lateral alignment; a plurality of rods extending partially into cutouts in the pallet stack from the support columns, activated by the first set of pneumatic cylinders configured for half-stroke operation to provide stability during alignment; the first set of pneumatic cylinders configured to control the movement and retraction of the rods, enabling secure engagement and disengagement with the pallet stack; a plurality of electric motors operatively connected to a chain mechanism and configured to incrementally lift and separate each pallet within the stack through the alignment rollers, thereby creating controlled gaps between the pallets for noncontact alignment;the control unit configured to activate the first set of pneumatic cylinders to fully insert the rods into the pallets after creating the gaps, thereby aligning the pallets perpendicularly to the conveyor belt direction; the control unit further configured to activate the second set of pneumatic cylinders for adjusting the pallets to align with the conveyor’s running direction; the plurality of electric motors, configured to arrange the pallets together after alignment to eliminate gaps between adjacent pallets, thereby enhancing the structural integrity of the stack; and the first set of pneumatic cylinders configured to retract the rods from the stack of pallets, and the second set of pneumatic cylinders configured to retract, thereby preparing the aligned stack for seamless transfer to downstream processing operations, including transport of the stack of pallets.
2. The system as claimed in claim 1, wherein the control unit is configured to coordinate the operation of the first set of pneumatic cylinders and the second set of pneumatic cylinders, electric motors, and conveyor belt, thereby ensuring synchronized alignment and transfer of the stack of pallets3. The system as claimed in claim 1, wherein the control unit is configured to perform alignment on each pallet individually without any contact between adjacent pallets, thereby achieving a complete elimination of potential damage to the pallets during the alignment process.
4. The system as claimed in claim 1 , wherein the electric motors are positioned at the top of the support columns and are configured to drive the chain and roller mechanisms, ensuring synchronized movement of the alignment components for precise positioning and separation of each pallet within the stack.
5. The system as claimed in claim 1 , wherein the alignment rollers are adjustable to accommodate pallets of various sizes, allowing precise alignment and positioning of different pallet dimensions for efficient downstream processing.
6. The system as claimed in claim 1, wherein the control unit comprises sensors configured to monitor the alignment of the pallet stack during the alignment process, providing real-time feedback to ensure precise positioning and adjustment of the pallets.
7. The system as claimed in claim 1, wherein the rods are extendable and retractable via the first set of pneumatic cylinders, allowing for controlled engagement with the pallet stack during the alignment process.
8. The system as claimed in claim 1, wherein the control unit configured to adjust plurality of electric motor’s speed and force based on the weight of each pallet, thereby facilitating optimal separation and alignment in a variety of load conditions.
9. The system as claimed in claim 1, wherein the conveyor belt is equipped with a variable-speed drive to adjust the movement speed of the pallet stack, enabling a smooth transition from the alignment system to downstream processing stages.
10. A method for aligning a stack of pallets using an automatic pallet alignment system, comprising: positioning the pallet stack on a conveyor belt adjacent to a plurality of support columns, the conveyor belt configured to be controlled by a control unit to transport the pallet stack through the alignment system; utilizing alignment rollers on the support columns, positioned on either side of the pallet stack, to engage with the edges of the pallets, thereby facilitating precise lateral alignment;activating a first set of pneumatic cylinders to extend rods partially into cutouts in the pallet stack, the cylinders operate in a half-stroke configuration to provide initial stability for the alignment process; operating the first set of pneumatic cylinders to control the movement and retraction of the rods, enabling secure engagement and disengagement with the pallet stack as required; activating a plurality of electric motors connected to a chain mechanism to incrementally lift and separate each pallet within the stack, creating controlled gaps between the pallets for non-contact alignment through the alignment rollers; instructing the control unit to activate the first set of pneumatic cylinders to fully insert the rods into the pallets after creating gaps, thereby aligning the pallets perpendicularly to the conveyor belt direction; activating the second set of pneumatic cylinders to adjust the pallets to align with the conveyor’s running direction; utilizing the electric motors to bring the pallets together after alignment, effectively eliminating gaps between adjacent pallets to enhance the structural integrity of the aligned stack; and operating the first set of pneumatic cylinders to retract the rods from the pallet stack, and retracting the second set of pneumatic cylinders to prepare the aligned stack for downstream processing, enabling seamless transfer of the aligned stack to downstream processing operations, including transport of the stack of pallets.