A gripping device for a depaletizing system

Abstract

A gripping device (102) of a depalletizing system (100) for depalletizing one or more units stacked in layers comprises of a belt drive mechanism (202). The belt drive mechanism (202) comprises of a belt (208), wherein at least a portion of the belt (208) defines a vertical path. The vertical path defined by the belt (208) is configured to be parallel to a pallet of one or more units that are to be depalletized. The belt (208) is provided with a plurality of teeth (210), wherein the plurality of teeth (210) provided on at least a portion of the belt (208) interface with the one or more units to lift the one or more units.

Description

A GRIPPING DEVICE FOR A DEPALETIZING SYSTEMBACKGROUNDField of the invention

[0001] The present invention relates to depalletizing systems, specifically to an improved design of a gripping device for a depalletizing system for handling stacks of one or more units.Brief statement of the prior art

[0001] In industries such as manufacturing, warehousing, and materials handling, depalletizing systems are essential for efficient handling and transport of stacked units, including empty bags commonly used in cement, chemical, and food industries. Depalletizing systems automate the process of lifting and moving units from pallets that are stacked in layers, enhancing productivity while reducing the need for manual labour.

[0002] A prevalent method in conventional depalletizing systems involves the use of suctionbased gripping mechanisms, which rely on creating a vacuum seal to lift and transfer individual units or units that are bundled / tied together. While these systems work in clean, controlled environments, they often encounter substantial limitations in more challenging industrial settings, such as cement factories and other similar environments with high dust levels. In these dusty environments, suspended particulates can quickly clog the suction mechanism, causing a loss of vacuum pressure and rendering the system unable to grip items effectively. This results in frequent operational interruptions, equipment downtime, and increased maintenance costs, as filters and components must be cleaned or replaced regularly to maintain the vacuum system’s performance.

[0003] Additionally, suction-based depalletizing systems may struggle with items that have irregular surfaces or materials that do not easily form an airtight seal, further limiting their utility in environments handling varied packaging or bag materials. In addition, suction based depalletizing system may also be ineffective when the stack of items to be transferred are not bundled or tied together. These limitations highlight the need for an alternative depalletizing solution that can operate reliably in dust-laden industrial settings without relying on vacuum-based mechanisms.

[0004] In light of the foregoing, there is a need for an improved and efficient depalletizing system that address the shortcomings of conventional depalletizing systems.OBJECT OF THE INVENTION

[0005] It is an object of the present invention to overcome or at least alleviate one or more of the above problems of the prior art and / or provide the user with a useful or commercial choice.

[0006] It is an object of the present invention to provide a gripping device for a depalletizing system.

[0007] It is a further object of the present invention to provide an alternative to the prior art.SUMMARY OF THE INVENTION

[0008] In an embodiment, a gripping device for a depalletizing system is disclosed, wherein the gripping device comprises of a belt drive mechanism, wherein the belt drive mechanism comprises of a belt that defines a vertical path. The vertical path defined by the belt is configured to be parallel to at least one side of a pallet of one or more units that are required to be depalletized. The belt is provided with a plurality of teeth, wherein the plurality of teeth provided on at least a portion of the belt is configured to interface with the one or more units to lift the one or more units from the pallet of one or more units.

[0009] In an embodiment, the belt drive mechanism comprises of at least two rotating members wherein the at least two rotating members are disposed along the vertical path. The at least two rotating members are spaced apart, and the belt is configured to be looped around the at least two rotating members. A drive member is provided, wherein the drive member is configured to be operably coupled to at least one rotating member, wherein rotation of the at least one rotating member in a first direction enables the belt to be driven in the first direction thereby lifting the one or more units interfacing with the belt. Axes of rotation of the three rotating members are configured to be perpendicular to at least a portion of the belt that defines the vertical path.

[0010] In an embodiment, the gripping device comprises of a first mechanism, wherein the first mechanism is configured to be operably coupled to the belt drive mechanism, to linearly move the belt drive mechanism between an extended position and a retracted position.

[0011] In an embodiment, the gripping device comprises of a retractable base plate configured to be operated between a first position and a second position, wherein, in the second position, the retractable base plate is configured to provide support to the one or more units lifted by the belt of the belt drive mechanism. The retractable base plate is operably coupled to a second mechanism, wherein the second mechanism enables actuation of the retractable base plate between the first position and the second position.

[0012] In an embodiment, the gripping device comprises a first gripping member configured to extend towards the retractable base plate, when the retractable base plate is in the second position, for gripping the one or more units lifted by the belt drive mechanism between the retractable base plate and the first gripping member. The first gripping member is provided with a third mechanism, wherein the third mechanism is operably coupled with the first gripping member to enable movement of the first gripping member.

[0013] In an embodiment, the gripping device comprises of a holding member. The holding member is provided with a fourth mechanism, wherein the fourth mechanism is configured to be operably coupled to the holding member for extending or retracting the holding member. The holding member, in the extended state, is configured to interface with at least a portion of the one or more units for holding the stack of one or more units in place while the belt drive mechanism of the gripping device is configured to lift the one or more units from the pallet of one or more units.

[0014] In an embodiment, the gripping device further comprises of a distance measurement module and a control module, wherein the distance measurement module, comprising of but not limited to laser setup, is configured to scan the pallet to determine position of the pallet of the one or more units stacked in layers and determine distance of the gripping device from the pallet of the one or more units stacked in layers.

[0015] In an embodiment, the control module is configured to receive inputs from the distance measurement module, wherein the control module is configured to determine alignment and distance of the gripping device with respect to the pallet of one or more units for depalletizing the one or more units.

[0016] In an embodiment, the depalletizing system comprising the gripping device is provided with a cartesian setup with one or more horizontal and vertical structures, wherein at least one among the one or more horizontal and vertical structures is configured to receive the gripping device. The cartesian setup is configured to enable movement of the gripping device along X-axis, Y-axis and Z-axis.

[0017] In an embodiment, the depalletizing system comprising the gripping device comprises of a first conveyor, an intermediate conveyor, and a second conveyor. The first conveyor is configured to receive at least one pallet of one or more units stacked in layers to be depalletized. The intermediate conveyor is configured to receive the stack of one or more units depalletized from the pallet of one or more units by the gripping device. The second conveyor is configured to receive the one or more units from the intermediate conveyor.

[0018] The technical effect of the disclosed gripping device for a depalletizing system centres on its ability to depalletize units with efficiency and precision. The belt drive mechanism, equipped with teeth for engaging and lifting items directly from the pallet, enables accurate and reliable handling, which is essential for automated environments like warehouses and packaging facilities.

[0019] Stability during lifting is enhanced through the use of a retractable base plate and gripping member, which together secure items and reduce the risk of slippage or damage. This design is particularly advantageous for handling fragile or irregular items. Additionally, the holding member’s retractable design allows the gripping device to adjust to various unit sizes andconfigurations, making it versatile across multiple depalletizing tasks.

[0020] Automated positioning, achieved via a laser-equipped distance measurement module and control module, enables precise alignment with pallets, minimizing setup time and manual adjustments. Integrated with a multi -conveyor system, the device enables a seamless transition of depalletized units through the processing chain, supporting high-throughput operations by reducing bottlenecks. Together, these technical effects improve the speed, reliability, and adaptability of the depalletizing process, making the system ideal for high-demand automated settings.BRIEF DESCRIPTION OF DRAWINGS

[0021] Embodiments are illustrated, by way of example and not limitation, in the figures of the accompanying drawings, in which like references indicate similar elements and in which:

[0022] FIG. 1 illustrates a perspective view of a depalletizing system 100 comprising of a gripping device 102, in accordance with an embodiment.

[0023] FIG. 2 A illustrates a perspective view of the gripping device 102, in accordance with an embodiment.

[0024] FIG. 2B illustrates a side planar view of the gripping device 102, in accordance with an embodiment.

[0025] FIG. 2C illustrates another side planar view of the gripping device 102, in accordance with an embodiment.

[0026] FIGs. 3 A-3B illustrates a flowchart of a process of depalletizing pallet of one or more units, in accordance with an embodiment.

[0027] FIGs. 4A-4M illustrates steps of the process of depalletizing pallet of one or more units, in accordance with an embodiment.DETAILED DESCRIPTION

[0028] Referring to FIG. 1, a depalletizing system 100 comprising a gripping device 102 for depalletizing one or more units stacked in layers is disclosed. The one or more units may be, but not limited to, one or more empty bags that may be stacked in layers to form a pallet(s) of empty bags.

[0029] In an embodiment, the depalletizing system 100 comprising the gripping device 102 may be provided with a cartesian setup 104, wherein the gripping device 102 of the depalletizing system 100 may be provided on the cartesian setup 104. The cartesian setup 104 may be configured to enable movement of the gripping device 102 along any of X-axis, Y-axis and Z-axis.

[0030] In an embodiment, the cartesian setup 104 may comprise of combination of horizontal andvertical structures that form a guide system for the gripping device 102 that enable the movement of the gripping device 102 along any of the X-axis, Y-axis and Z-axis. The gripping device 102 may be operably disposed on any one of the vertical or horizontal structures in a manner that the gripping device 102 may be movable to a required position along the X-axis, Y-axis and Z-axis. The movement of the gripping device 102 on the horizontal or vertical structures may be enabled by any known mechanical operating means.

[0031] In an embodiment, the depalletizing system 100 may be provided with a first conveyor 106, an intermediate conveyor 108 and a second conveyor 110, wherein the first conveyor 106 may be configured to receive pallets of one or more units stacked in layers and deliver the pallet(s) of one or more units within the proximity of the cartesian setup 104 comprising the gripping device 102, more preferably within the proximity of the gripping device 102 provided on the cartesian setup 104.

[0032] In an embodiment, the first conveyor 106 may be, but not limited to, a roller bed conveyor, wherein the pallet(s) of one or more units may be received by the first conveyor 106, and wherein the first conveyor 106 may be configured to direct the pallet(s) of one or more units under the cartesian setup 104 comprising the gripping device 102.

[0033] In an embodiment, the gripping device 102 may be operably coupled to any one of the horizontal or the vertical structure through a rotatable coupling setup, wherein the rotatable coupling setup may enable the gripping device 102 to be aligned with any one of side surfaces of the pallet(s) of one or more units received on the first conveyor 106.

[0034] In an embodiment, the intermediate conveyor 108 may be provided as a part of the cartesian setup 104, or adjacent to the cartesian setup 104, wherein the intermediate conveyor 108 may be provided with a lift mechanism that may be configured to enable the intermediate conveyor 108 to traverse vertically. The lift mechanism may be configured to operate independent of the gripping device 102. The intermediate conveyor 108 may be provided with a conveyor setup, wherein the intermediate conveyor 108 may be provided with conveyor bed, wherein the conveyor bed may be configured to receive stack(s) of one or more units. The intermediate conveyor 108 may be configured to align with the gripping device 102 via the lift mechanism during the depalletizing of the one or more units for receiving the one or more units.

[0035] In an embodiment, the second conveyor 110 may be provided to receive the stack of one or more units from the intermediate conveyor 108. The second conveyor 110 may be configured to then transfer the stack of one or more units to required destination for further processing. The second conveyor 110 may be provided with, but not limited to, a conveyor belt 208 setup that enables transfer of stack of one or more units.

[0036] In an embodiment, the intermediate conveyor 108 may be positioned between the firstconveyor 106 and the second conveyor 110, in a manner that the transfer of the depalletized one or more units may be from the first conveyor 106 to the intermediate conveyor 108 and then to the second conveyor 110.

[0037] Referring to FIGs. 2A-2C, the gripping device 102 comprises of a belt drive mechanism 202, a retractable base plate 204 and a first gripping member 206 that may be configured to enable depalletizing of one or more units from the pallet(s) of one or more units. The gripping device 102 may be configured to enable lifting, gripping and transferring of the stack of one or more units from the pallet(s) of one or more units, thereby enabling depalletizing of one or more units from the pallet(s) of one or more units.

[0038] In an embodiment, the gripping device 102 may be configured to align with the pallet(s) of one or more units, through the cartesian setup 104, for depalletizing the one or more units.

[0039] In an embodiment, the belt drive mechanism 202 of the gripping device 102 comprises of a belt 208 that may define a vertical path, wherein the vertical path defined by the belt 208 may be configured to be parallel / substantially parallel to the pallet(s) of one or more units stacked in layers for depalletizing the one or more units. The belt 208 may be provided with plurality of teeth 210, wherein the plurality of teeth 210 may be provided along entire length of the belt 208. The plurality of teeth 210 may be spaced apart in a manner that a space may be defined between two adjacent teeth 210. The plurality of teeth 210 provided on at least a portion of the belt 208 may be configured to interface with the stack of one or more units to lift the one or more units from the pallet(s) of one or more units stacked in layers, wherein the one or more units may be received by the space defined between two adjacent teeth 210 during the depalletizing of the one or more units.

[0040] In an alternate embodiment, the belt 208 may be provided with a plurality of teeth 210, wherein the plurality of teeth 210 may be provided along at least a portion of length of the belt 208.

[0041] In an embodiment, the belt drive mechanism 202 comprises of at least three rotating members 212a, 212b, 212c, wherein at least two rotating members 212a, 212b among the at least three rotating members 212a, 212b, 212c may be disposed along the vertical path defined by at least a portion of the belt 208, and the other rotating member 212c may be provided at an offset from the at least two rotating members 212a, 212b defining the vertical path. The at least three rotating members 212a, 212b, 212c may be spaced apart. The belt 208 provided with the plurality of teeth 210 may be configured to be looped around the at least three rotating members 212a, 212b, 212c. Each of the at least three rotating members 212a, 212b, 212c may define axis of rotation, wherein axes of rotation of the at least three rotating members 212a, 212b, 212c may be perpendicular to the vertical path defined by at least a portion of the belt 208.

[0042] In an alternate embodiment, the belt drive mechanism 202 may be provided with tworotating members 212a, 212b disposed along the vertical path, wherein the two rotating members 212a, 212b may be spaced apart. The belt 208 provided with the teeth 210 may be configured to be looped around the two rotating members 212a, 212b. Each of the rotating member 212a, 212b may define an axis of rotation, wherein axes of rotation of the two rotating members 212a, 212b may be perpendicular to the vertical path defined by the belt 208.

[0043] In an embodiment, a drive member 214 may be provided, wherein the drive member 214 may be configured to be operably coupled to at least one rotating member 212c among the at least two / three rotating members 212a, 212b, 212c. The drive member 214 may be, but not limited to, a motor provided with a shaft, wherein the shaft may be operably connected to the at least one rotating member among the at least two / three rotating members 212. The drive member 214 may be configured to rotate at least one rotating member 212c in either a first direction or a second direction, based on the requirement. The rotation of the at least one rotating member 212c in the first direction enables the belt 208 along with the remaining rotating members 212a, 212b to be driven in the first direction, which in turn enables the lifting of the one or more units interfacing with the belt 208.

[0044] In an embodiment, the first direction may be counter-clockwise direction, and the second direction may be clockwise direction, wherein the counter-clockwise direction movement of the rotating members 212 enables the belt 208 to be driven in the counter-clockwise direction thereby enabling lifting of the one or more units that interface with the belt 208.

[0045] In an embodiment, surface of the rotating members 212a, 212b, 212c interfacing with the belt 208 may be plane surface, and similarly the surface of the belt 208 interfacing with rotating members 212a, 212b, 212c may also be plane surface. However, in an alternate embodiment, the interfacing surfaces of the rotating members 212a, 212b, 212c and the belt 208 may be provided with complimenting teeth that may be interact with each other to offer better grip and transmission.

[0046] In an embodiment, length of the belt 208 of the belt drive mechanism 202 may be determined based on the spacing between the rotating members 212. This spacing may be configured to optimize the belt's lifespan while maintaining appropriate tension for effective lifting of one or more units. By increasing length of the belt 208, the belt’s longevity may be enhanced, as this adjustment may reduce the frequency with which any given section of the belt 208 contacts the one or more units during each complete rotation cycle of the belt 208 around the rotating members 212a, 212b, 212c. However, providing larger spacing between the rotating members 212a, 212b, 212c may affect the overall tension in the belt 208. Therefore, an optimal balance of spacing between the rotating members 212a, 212b, 212c may be necessary to maintain sufficient tension in the belt 208, while also ensuring that the belt’s length is adequate to offer extended lifespan.

[0047] In an embodiment, the gripping device 102 may be provided with a first mechanism 216, wherein the first mechanism 216 may be configured to be operably coupled to the belt drive mechanism 202. The first mechanism 216 may be, but not limited to, a pneumatic piston cylinder with slider base arrangement, wherein the belt drive mechanism 202 may be configured to be operably disposed on the slider base and the pneumatic piston cylinder may be operably coupled to belt drive mechanism 202. Actuation of the pneumatic piston cylinder may enable movement of the belt drive mechanism 202 on the slider base thereby enabling traversing of the belt drive mechanism 202 between extended position and retracted position on the slider base.

[0048] In an embodiment, the gripping device 102 comprises of the retractable base plate 204. The retractable base plate 204 may be provided, but not limited to, adjacent to the belt drive mechanism 202. The retractable base plate 204 may be configured to be operated between a first position and a second position, wherein the first position may refer to a retracted state of the retractable base plate 204 and the second position may refer to an extended state of the retractable base plate 204.

[0049] In an embodiment, the retractable base plate 204 may be provided with, but not limited to, a first inclined surface 218, wherein the first inclined surface 218 may be configured to interface with the one or more units by positioning the retractable base plate 204 in the second position i.e., under the stack of one or more units lifted by the gripping device 102 and provide support to the lifted one or more units.

[0050] In an embodiment, the retractable base plate 204 may be configured to be operated between the first position and the second position by a second mechanism 220. The second mechanism 220 may be, but not limited to, a pneumatic piston cylinder mechanism. Any known mechanical linkage setup may be provided between the retractable base plate 204 and the pneumatic piston cylinder mechanism, wherein the mechanical linkage setup enables transfer of motion from the pneumatic piston cylinder mechanism to the retractable base plate 204 thereby enabling movement of the retractable base plate 204 between the first position and the second position.

[0051] In an embodiment, the retractable base plate 204, when in the second position (extended position), may be configured to provide support to the one or more units that may be lifted by the belt drive mechanism 202, as the belt 208 interfaces with the one or more units. The retractable base plate 204 may be configured to be positioned / operated into the second position, when the one or more units are lifted by the belt 208 due to the interfacing of the belt 208 with the one or more units, and thereby creates a space between the one or more units lifted by the belt 208 and the unit(s) below them that are yet to be depalletized.

[0052] In an embodiment, the gripping device 102 may be provided with the first gripping member 206, wherein the first gripping member 206 may be provided towards an anterior portion of the gripping device 102. The first gripping member 206 may be configured to extend towards or retractaway from the retractable base plate 204. The first gripping member 206 may be configured to extend toward the retractable base plate 204, when the retractable base plate 204 is in the second position. The first gripping member 206 may be configured to extend towards the retractable base plate 204 to enable gripping of the one or more units between the retractable base plate 204 and the first gripping member 206. The first gripping member 206 may be provided with a third mechanism 222, wherein the third mechanism 222 may be operably coupled to the first gripping member 206 to enable movement of the first gripping member 206 i.e., extending towards or retracting away from the retractable base plate 204. The third mechanism 222 may be, but not limited to, a pneumatic piston cylinder arrangement.

[0053] In an embodiment, the first gripping member 206 may be provided with, but not limited to, a second inclined surface 224, wherein the second inclined surface 224 of the first gripping member 206 may be configured to compliment the first inclined surface 218 of the retractable base plate 204. The complimenting first inclined surface 218 of the retractable base plate 204 and the second inclined surface 224 of the first gripping member 206 may offer better grip of the one or more units between the retractable base plate 204 and the first gripping member 206.

[0054] In an embodiment, when the retractable base plate 204 is in the second position, the first inclined surface 218 of the retractable base plate 204 and the second inclined surface 224 of the first gripping member 206 may be parallel to each other and may be provided such that the first inclined surface 218 of the retractable base plate 204 and the second inclined surface 224 of the first gripping member 206 face each other.

[0055] In an embodiment, the gripping device 102 may further comprise of a holding member 226, wherein the holding member 226 may be provided with a fourth mechanism 228 for extending or retracting the holding member 226. The fourth mechanism 228 may be configured to be operably coupled to the holding member 226. The fourth mechanism 228 may be, but not limited to, a pneumatic piston cylinder mechanism that may be configured to enable extension and retraction of the holding member 226 in the extended state and the retracted state, respectively. The holding member 226 may be configured to interface with at least a portion of the pallet of one or more units for holding the stack of one or more units in place while the belt drive mechanism 202 of the gripping device 102 may be configured to lift the one or more units from the pallet of one or more units, when the holding member 226 is in the extended state.

[0056] In an embodiment, the holding member 226 may be provided in the form of, but not limited to, a solid sheet metal plate, wherein the stack of one or more units may be held in position as at least a portion of the solid sheet metal plate is pushed towards the stack of one or more units while the belt drive mechanism 202 of the gripping device 102 may be configured to lift the stack of one or more units from the pallet(s) of one or more units.

[0057] In an embodiment, the depalletizing system 100 comprising of the gripping device 102 may be further provided with a distance measurement module 230 and a control module (not shown in the figures). The distance measurement module 230 may be configured to determine distance of the gripping device 102 from the pallet(s) of one or more units received on the first conveyor 106. The distance measurement module 230 may also be configured to scan the pallet(s) of one or more units that are received on the first conveyor 106 for depalletizing, to determine the position of the pallet(s) of one or more units on the first conveyor 106 with respect to the cartesian setup 104 on which the gripping device 102 is disposed.

[0058] In an embodiment, the distance measurement module 230 may be provided on at least a portion of the gripping device 102, in a manner that the distance measurement module 230 may be disposed adjacent to the portion of the belt 208 of the belt drive mechanism 202 that defines the vertical path. The distance measurement module 230 may be disposed adjacent to the belt 208 such that the laser emitted from the distance measurement module 230 may be parallel to the vertical path defined by the belt 208 of belt drive mechanism 202.

[0059] In an embodiment, the control module may be configured to receive inputs from the distance measurement module 230 for further processing. The control module may be configured to determine a reference position for positioning of the gripping device 102 with respect to the pallet(s) of one or more units received on the first conveyor 106, upon receiving inputs from the distance measurement module 230 regarding the initial position of the pallet(s) of one or more units on the first conveyor 106 with respect to the cartesian setup 104. The reference position of the gripping device 102 may be determined to position the gripping device 102 towards the pallet(s) of one or more units before the process of depalletizing begins.WORKING

[0060] Referring to FIGs. 3A-3B, a depalletizing process by a depalletizing system 100 comprising the gripping device 102 is now described in greater detail.

[0061] In an embodiment, at step 302, pallet(s) of one or more units stacked in layers are first transported onto the first conveyor 106.

[0062] At step 304, the pallet(s) of one or more units received on the first conveyor 106 are then transported towards the cartesian setup 104 of the depalletizing system 100 provided with the gripping device 102 through the first conveyor 106.

[0063] Once the pallet(s) of one or more units are transported towards the cartesian setup 104 of the depalletizing system 100, at step 306, the distance measurement module 230 provided on the gripping device 102 may be configured to perform an initial scan of the pallet(s) of one or more units, by the distance measurement module 230, to determine an initial position of the pallet(s) of one or more units on the first conveyor 106 with respect to the cartesian setup 104 (also refer FIG.4A).

[0064] After the initial position of the pallet(s) of one or more units with respect to the cartesian setup 104 is determined, at step 308, the control module may be configured to determine a reference position for the gripping device 102 with respect to the initial position of the pallet(s) of one or more units.

[0065] At step 310, the gripping device 102 is positioned at the determined reference position with respect to the pallet(s) of one or more units (also refer FIG. 4B).

[0066] At step 312, the gripping device 102 is moved towards the pallet(s) of one or more units with the distance measurement module 230 continuously monitoring the distance of the gripping device 102 with respect to the pallet(s) of one or more units (also refer FIG. 4C). As the gripping device 102 approaches the pallet(s) of one or more units, at step 314, the distance measurement module 230 detects change in the distance. Upon detecting change in the distance, at step 316, the gripping device 102 is then moved away from the pallet(s) of one or more units for a predetermined distance, such that the gripping device 102 is positioned at a particular distance from the pallet(s) of one or more units and also such that the portion of the belt 208 defining the vertical path is maintained parallel to at least one side of the pallet(s) (along height of the pallet) of one or more units (also refer FIG. 4D).

[0067] At step 318, the holding member 226 is configured to extend towards the pallet(s) of one or more units such that the holding member 226 presses against the one or more units thereby holding the one or more units over the one or more units stacked in layers in place (also refer FIG. 4E-4F). At step 320, the gripping device 102 may be configured to be, but not limited to, simultaneously lowered vertically along with holding member 226.

[0068] At step 322, the belt 208 of the belt drive mechanism 202 is configured to be driven by actuating the drive mechanism to rotate the rotating members 212 in counter-clockwise direction, thereby enabling the belt 208 to be driven in counter-clockwise direction i.e., the belt 208 moves in the counter-clockwise direction (the portion of the belt 208 that defines the vertical path moves vertically up).

[0069] At step 324, the gripping device 102 is gradually moved towards the pallet(s) of one or more units with the belt drive mechanism 202 being driven in the counter-clockwise direction as the gripping device 102 is moved towards the pallet(s) of one or more units. As the gripping device 102 approaches the pallet(s) of one or more units, the belt 208 is configured to interface with the one or more units, wherein the plurality of teeth 210 provided on the belt 208 interface with the one or more units thereby lifting the one or more units, as the portion of the belt 208 defining the vertical path that interface with the one or more units moves vertically up (belt 208 driven in counter-clockwise direction) (also refer FIG. 4G-4H). As the holding member 226 is lowered tohold the one or more units in place, only a portion of the one or more units interfacing with the belt 208 are lifted thereby creating a gap between the one or more units lifted by the gripping device 102 and the stack of one or more units in the pallet(s) of one or more units. As the belt 208 approaches the one or more units, the laser is configured to detect if the one or more units underneath have depressions, so that the portion of the belt 208 drive configured to interface with the one or more units corrects the vertical position to adapt to the deformations of the one or more units.

[0070] As the one or more units are lifted by the belt 208, at step 326, the retractable base plate 204 is operated to assume the second position (extended position) from the first position (retracted position). The retractable base plate 204, when in the second position is configured to provide support to the one or more units that are lifted by the belt 208 of the belt drive mechanism 202 (refer FIG. 4I-4J).

[0071] At step 328, the first gripping member 206 is configured to be extended towards the retractable base plate 204. The first gripping member 206 is extended towards the retractable base plate 204 until the one or more units lifted by the belt 208 are gripped between the retractable base plate 204 (in the second position) and the extended first gripping member 206 in a manner that at least a portion of one or more units are squeezed between the retractable base plate 204 and the first gripping member 206 (also refer FIG. 4K-4L).

[0072] Once the one or more units are gripped between the retractable base plate 204 and the first gripping member 206, at step 330, the holding member 226 is retracted and the gripping device 102 is then gradually moved away from the pallet(s) of one or more units thereby lifting the one or more units that are gripped by the gripping device 102 to transfer the one or more units lifted onto the intermediate conveyor 108 (also refer FIG. 4M). Each time a stack of one or more units is picked, information relating to its position in the horizontal plane is stored by the control module. As the one or more units run out from the pallet(s) of one or more units, the information relating to the position in the horizontal plane may be used to update the actual position of the pallet (which may be tilted or deformed).

[0073] The gripping device 102 gripping the one or more units is then moved towards the intermediate conveyor 108, wherein the intermediate conveyor 108 is configured to align with the height of the gripping device 102 by the lift mechanism provided for the vertical movement of the intermediate conveyor 108. The one or more units gripped by the gripping device 102 are then disposed over the intermediate conveyor 108 by retracting the first gripping member 206 and the retractable base plate 204.

[0074] Once the one or more units are disposed over the intermediate conveyor 108, at step 332, the intermediate conveyor 108 is then configured to move down vertically to align with the secondconveyor 110, to transfer the one or more units received by intermediate conveyor 108 to the second conveyor 110. The one or more units received by the second conveyor 110 may then be transferred to required sections of processing plant for further processing.

[0075] The alignment of the intermediate conveyor 108 with the gripping device 102 and the second conveyor 110 reduces the overall time required for transferring of the one or more depalletized units thereby improving the overall efficiency of the system. Furthermore, energy consumption is also drastically reduced as the intermediate conveyor 108 is of lighter weight.

[0076] Once the above steps are completed, the process may be repeated from step 310 to step 332.

[0077] The provision of the belt drive mechanism 202 of the gripping device 102 as disclosed in the foregoing with the rotating members 212 spaced apart and a belt 208 looped around the rotating members 212 wherein at least a portion of the belt 208 defines a vertical path enables lifting of one or more units from the pallet(s) of one or more units stacked in layers irrespective of whether the one or more units are bundled or tied together. The disclosed gripping device 102 operates effectively for handling units that may be deformed or irregularly shaped, as well as for lifting units in stacks where one or more layers are misaligned. It is specifically designed to accommodate situations where the stacking of units lacks uniform alignment across layers, ensuring stable and secure lifting even when individual layers or units are not perfectly positioned.

[0078] Furthermore, the cartesian setup 104 provided for the depalletizing system 100 offers several practical advantages over a robotic system, especially for cement factories. Unlike complex robotic setups, a cartesian system uses familiar, proven technologies like AC / DC motors, belt 208s, pulleys, and linear guides and components that workers in cement plants are already experienced with. This makes the equipment easier for the existing workforce to operate and maintain without needing specialized training in robotics.

[0079] Setting up and maintaining a cartesian system is straightforward, as it does not require robot-specific expertise, and the plant’s team would be able to handle it with minimal downtime or complications. Additionally, safety is more manageable because the system’s parts only move within the designated work area, which helps avoid unexpected movements and simplifies safety protocols.

[0080] Another significant benefit is the independence from robot suppliers. When using a cartesian setup 104, there’s no reliance on external support from a robotics company. This reduces the need for costly and sometimes slow technical assistance, giving the plant more control over its operations and fewer delays. In short, a cartesian setup 104 is simpler, more reliable, and easier to manage, making it a practical choice for cement factories looking for efficiency without the complexity of robotics.

[0081] The distance measurement module 230 setup provided with the current depalletizing system 100 offers significant advantages over a camera-based vision system, particularly in the demanding conditions like cement factory. The single-point measurement laser is built to perform reliably in dusty environments where a camera setup may struggle. The distance measurement module 230 setup can be effectively used to measure distances up to 15 meters, proving robustness and accuracy in challenging atmospheres.

[0082] One of the key benefits of this distance measurement module 230 setup is its simplicity as it is a single-part, plug-and-play solution that requires no calibration. It provides a straightforward, single measurement rather than an image, making verification easy with a standard measuring tape. The system uses a basic unshielded, 3 -wire cable, making it both easy to install and cost-effective to maintain.

[0083] In contrast, a vision system brings several challenges that can complicate operations. Camera setups need controlled, stable lighting to function accurately; even sunlight through a window may interfere with the results. Vision systems also require frequent cleaning to stay functional in dusty environments and rely on model training whenever new packaging designs or graphics are introduced. Additionally, cameras may impose restrictions on bag graphics, adding complexity to packaging design.

[0084] Moreover, vision systems tend to be costly, with expensive spare parts like optics and lights that drive up maintenance costs. In short, distance measurement module 230 setup is a more practical, reliable, and affordable choice for cement factories, offering accuracy and ease of use without the complications of a camera-based system.

[0085] In an alternate embodiment, the cartesian setup disclosed and discussed in the foregoing may be replaced with a robotic system, wherein the robotic system may enable achievement of movement in all the required degrees of freedom. The robotic system may be employed if the robotic setup offers better results and has comparatively lower maintenance than the cartesian setup.

[0086] The detailed description described in the foregoing includes references to the accompanying drawings, which form a part of the detailed description. The drawings show illustrations in accordance with example embodiments. These example embodiments, which may be herein also referred to as “examples” are described in enough detail to enable those skilled in the art to practice the present subject matter. However, it may be apparent to one with ordinary skill in the art, that the present invention may be practised without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to unnecessarily obscure aspects of the embodiments. The embodiments can be combined, other embodiments can be utilized, or structural, logical, and design changes can be made withoutdeparting from the scope of the claims. The foregoing detailed description is, therefore, not to be taken in a limiting sense, and the scope is defined by the appended claims and their equivalents.

[0087] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or,” such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated.

[0088] Furthermore, the processes described above is described as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be re-arranged, or some steps may be performed simultaneously.

[0089] Although embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the system and process or method described herein. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

[0090] Many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. It is to be understood that the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the personally preferred embodiments of this invention.

Claims

CLAIMS1. A gripping device (102) of a depalletizing system (100) for depalletizing one or more units stacked in layers, the gripping device (102) comprising a belt drive mechanism (202), wherein: the belt drive mechanism (202) comprises of a belt (208) that defines a vertical path; the belt (208) is provided with a plurality of teeth (210); the vertical path defined by the belt (208) is configured to be parallel to at least one side of a pallet of one or more units; and the plurality of teeth (210) provided on at least a portion of the belt (208) is configured to interface with the one or more units to lift the one or more units.

2. The gripping device (102) of the depalletizing system (100) according to claim 1, wherein the belt drive mechanism (202) comprises: at least two rotating members (212a, 212b) disposed along the vertical path; and a drive member (214) configured to be operably coupled to at least one rotating member, wherein: the at least two rotating members (212a, 212b) are spaced apart; axes of rotation of the at least two rotating members (212a, 212b) is perpendicular to the vertical path defined by the belt (208); the belt (208) is configured to be looped around the at least two rotating members (212a, 212b); and rotation of the at least one rotating member in a first direction enables the belt (208) to be driven in the first direction thereby lifting the one or more units that interface with the belt (208).

3. The gripping device (102) of the depalletizing system (100) according to claim 1, wherein the belt drive mechanism (202) comprises: three rotating members (212a, 212b, 212c) wherein at least two rotating members (212a, 212b) are disposed along the vertical path; a drive member (214) configured to be operably coupled to at least one rotating member, wherein: the three rotating members (212) are spaced apart; axes of rotation of the three rotating members (212) are perpendicular to the vertical path defined by the belt (208);the belt (208) is configured to be looped around the three rotating members (212a, 212b, 212c); and rotation of the at least one rotating member in a first direction enables the belt (208) to be driven in the first direction thereby lifting the one or more units that interface with the belt (208).

4. The gripping device (102) of the depalletizing system (100) according to any one of claims 2 or 3, wherein the gripping device (102) comprises of a first mechanism (216), wherein the first mechanism (216) is configured to be operably coupled to the belt drive mechanism (202) to linearly move the belt drive mechanism (202) between an extended position and a retracted position.

5. The gripping device (102) of the depalletizing system (100) according to claim 4, wherein the first mechanism (216) comprises: a pneumatic piston cylinder; and a slider base arrangement, wherein, the pneumatic piston cylinder is configured to be operably coupled to the belt drive mechanism (202); the belt drive mechanism (202) is configured to be disposed over the slider base, wherein the belt drive mechanism (202) is configured to traverse on the slider base; and actuation of the pneumatic piston cylinder enables movement of the belt drive mechanism (202) on the slider base thereby enabling back and forth movement of the belt drive mechanism (202) over the slider base.

6. The gripping device (102) of the depalletizing system (100) according to any one of claims 2 or 3, wherein at least portions of the belt (208) and the rotating members (212) interfacing with each other are provided with complimenting teeth, wherein the teeth provided on the rotating members (212a, 212b, 212c) interact with the teeth provided on the belt (208) to enable transmission from the rotating members (212a, 212b, 212c) to the belt (208).

7. The gripping device (102) of the depalletizing system (100) according to claim 1, wherein the gripping device (102) comprises a retractable base plate (204) configured to be operated between a first position and a second position, wherein, in the second position, the retractablebase plate (204) is configured to provide support to the one or more units lifted by the belt (208) of the belt drive mechanism (202).

8. The gripping device (102) of the depalletizing system (100) according to claim 7, wherein the retractable base plate (204) is operably coupled to a second mechanism (220), wherein the second mechanism (220) enables actuation of the retractable base plate (204) between the first position and the second position.

9. The gripping device (102) of the depalletizing system (100) according to claim 8, wherein the retractable base plate (204) is provided with a first inclined surface (218), wherein the first inclined surface (218) is configured to interface and provide support for the one or more units lifted by the belt (208) of the belt drive mechanism (202).

10. The gripping device (102) of the depalletizing system (100) according to claim 9, wherein the gripping device (102) comprises a first gripping member (206) configured to extend towards the retractable base plate (204), when the retractable base plate (204) is in the second position, for gripping the one or more units lifted by the belt drive mechanism (202) between the retractable base plate (204) and the first gripping member (206), wherein the first gripping member (206) is provided with a third mechanism (222) operably coupled to the first gripping member (206) to enable movement of the first gripping member (206).

11. The gripping device (102) of the depalletizing system (100) according to claim 10, wherein the first gripping member (206) is provided with a second inclined surface (224), wherein the second inclined surface (224) is configured to interface with the one or more units lifted by the belt (208) of the belt drive mechanism (202).

12. The gripping device (102) of the depalletizing system (100) according to claim 11, wherein, the first inclined surface (218) of the retractable base plate (204) and the second inclined surface (224) of the first gripping member (206) face each other; and the first inclined surface (218) of the retractable base plate (204) is and the second inclined surface (224) of the first gripping member (206) are parallel to each other.

13. The gripping device (102) of the depalletizing system (100) according to claim 1, wherein the gripping device (102) comprises of a holding member (226), wherein:the holding member (226) is provided with a fourth mechanism (228) for extending or retracting the holding member (226); the fourth mechanism (228) is configured to be operably coupled to the holding member (226); and the holding member (226), in the extended state, is configured to interface with at least a portion of the one or more units for holding the stack of one or more units in place while the belt drive mechanism (202) of the gripping device (102) is configured to lift the one or more units from the pallet of one or more units.

14. The gripping device (102) of the depalletizing system (100) according to claim 1, wherein the gripping device (102) comprises: a distance measurement module (230); and a control module, wherein, the distance measurement module (230) is provided on the gripping device (102); the distance measurement module (230) is configured to scan the pallet to determine position of the pallet of the one or more units stacked in layers; and the distance measurement module (230) is configured to determine distance of the gripping device (102) from the pallet of the one or more units stacked in layers.

15. A depalletizing system (100) comprising the gripping device (102) according to claim 14, wherein the control module is configured to receive inputs from the distance measurement module (230), wherein the control module is configured to determine alignment of the gripping device (102) with respect to the pallet of one or more units for depalletizing the one or more units.

16. The depalletizing system (100) comprising the gripping device (102) according to preceding claims, comprises a cartesian setup (104) with one or more horizontal and vertical structures, wherein: at least one among the one or more horizontal and vertical structures is configured to receive the gripping device (102); and the cartesian setup (104) is configured to enable movement of the gripping device (102) along X-axis, Y-axis and Z-axis.

17. The depalletizing system (100) comprising the gripping device (102) according to claim 16 further comprises:a first conveyor (106); an intermediate conveyor (108); and a second conveyor (110), wherein: the first conveyor (106) is configured to receive at least one pallet of one or more units stacked in layers to be depalletized; the intermediate conveyor (108) is configured to receive the stack of one or more units depalletized from the pallet of one or more units by the gripping device (102); and the second conveyor (110) is configured to receive the one or more units from the intermediate conveyor (108).

18. The depalletizing system (100) comprising the gripping device (102) according to claim 11, wherein: the intermediate conveyor (108) is further provided with a lift mechanism configured to operate independent of the gripping device (102); the intermediate conveyor (108) is configured to traverse vertically to align with the gripping device (102) to receive one or more units depalletized by the gripping device (102); and the intermediate conveyor (108) is further configured to traverse vertically to align with the second conveyor (110) to enable transfer of the received one or more units onto the second conveyor (110).

19. A method of depalletizing one or more units from a pallet comprising of one or more units stacked in layers utilizing the gripping device according to claims 1-14, the method comprises: receiving the pallet of one or more units stacked in layers on the first conveyor (106); transporting the pallet of one or more units towards the cartesian setup (104) comprising the gripping device (102); scanning, by the distance measurement module (230), the pallet of one or more units to determine an initial position of the pallet of one or more units on the first conveyor (106) with respect to the cartesian setup (104); determining, by the control module, a reference position for the gripping device (102) with respect to the initial position of the pallet of one or more units; positioning the gripping device (102) at the determined reference position with respect to the pallet of one or more units;moving the gripping device (102) towards the pallet of one or more units from the reference position while continuously monitoring distance, by the distance measurement module (230), of the gripping device (102) with respect to the pallet of one or more units; detecting, by the distance measurement module (230), a change in distance of the gripping device (102) with respect to the pallet of one or more units; retracting the gripping device (102) from the pallet of one more units for a predetermined distance; extending the holding member (226) towards the one or more units such that the holding member (226) presses against the one or more units; lowering the gripping device (102) towards the pallet of one or more units; actuating the belt drive mechanism (202) to drive the belt (208) in the first direction; moving the belt drive mechanism (202) towards the pallet of one or more units until the belt (208) interfaces with the one or more units, thereby lifting the one or more units interfacing with the belt (208); extending the retractable base plate (204) into the second position to provide support for the one or more units lifted by the belt (208); extending the first gripping member (206) towards the retractable base plate (204) to grip the one or more units between the retractable base plate (204) and the first gripping member (206); transferring the one or more units gripped between the retractable base plate (204) and the first gripping member (206) onto the intermediate conveyor (108); and transferring the one or more units received by the intermediate conveyor (108) onto the second conveyor (110).

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