Conveyor System with Adjustable Surfaces for Pallet Wrapping
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Solution Overview
Problem
The delivery of products to stores from distribution centers is prone to errors and inefficiencies due to missing or mis-picked items on pallets, leading to significant additional operating costs.
Innovation Solution
A conveyor system that includes a validation system using machine learning to identify SKUs on pallets, allowing for real-time comparison with the pick list and enabling the addition or correction of missing or incorrect products, integrated with a pallet wrapping system that can handle both nestable and base board pallets without the need for a forklift, optimizing space usage by allowing for denser deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conveyor system is designed to accommodate both nestable and base board pallets, then versatility is improved, but device complexity increases due to the need for adjustable conveyor surfaces
Solution Approach 1:
The conveyor system employs adjustable conveyor surfaces that can dynamically change height positions to accommodate different pallet types. The conveyor surfaces are designed to be movable between at least two height positions, allowing the system to adapt to both nestable pallets and base board pallets without requiring separate conveyor systems for each pallet type.
Solution Approach 2:
The conveyor system is designed with universal functionality to handle multiple pallet types using the same equipment. By incorporating adjustable height mechanisms and configurable surface positions, a single conveyor system can serve both nestable and base board pallets, eliminating the need for dedicated conveyors for each pallet type and reducing overall system complexity.
2Area of stationary object
If parallel pallet wrapping systems are positioned with offset wrappers, then space utilization is improved, but device complexity increases due to coordination requirements
Solution Approach 1:
The patent positions parallel pallet wrapping systems with offset wrappers in the lateral direction, utilizing three-dimensional space more efficiently. Instead of aligning wrappers directly parallel to each other, the offset arrangement allows systems to be positioned closer together laterally, reducing the overall warehouse footprint by exploiting spatial dimensions beyond simple linear alignment.
Solution Approach 2:
The wrapping systems are designed as independent modular units with offset wrappers that can operate autonomously. Each wrapping system functions as a separate segment with its own wrapper positioned at a different lateral offset, allowing for independent operation and maintenance while achieving compact overall system arrangement.
Data Source
AI summary
A conveyor system includes a plurality of conveying surfaces spaced apart from one another. An upper floor between the plurality of conveying surfaces has an uppermost surface that is lower than an uppermost surface of the plurality of conveying surfaces and higher than a returning portion of the plurality of conveying surfaces. This permits the conveyor system to be used with nestable pallets and base board pallets. The conveyor system may be part of a pallet wrapping system having an infeed conveyor and an outfeed conveyor for receiving loaded pallets from tines of material handling equipment and for transferring wrapped loaded pallets to tines of material handling equipment.