Air Cargo Bundle Contouring for Unit Load Device Volume Utilization
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Solution Overview
Problem
Current automated systems for loading baggage and cargo onto air transport unit load devices are inefficient, with slow loading cycles and suboptimal space utilization, leading to low productivity and high operational costs, and have not provided a reasonable payback despite attempts at automation.
Innovation Solution
A method and system that consolidates items into bundles matching the contour of unit load devices, using adjustable jigs and manipulators to optimize volume utilization, allowing for efficient loading and secure, ergonomic, and safe operation by dividing the unit load device volume into sub-volumes and manipulating the device during loading to ensure optimal placement of bundles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If piece-wise robotic loading is used, then automation is achieved, but loading speed and space utilization deteriorate
Solution Approach 1:
The loading process is segmented into two distinct phases: consolidation phase where items are grouped into bundles, and loading phase where bundles are transported and placed. This segmentation allows different optimization strategies for each phase, enabling high-speed automated bundle handling while maintaining flexible consolidation processes.
Solution Approach 2:
Multiple individual items are merged into consolidated bundles that match the contour and volume of unit load devices. This merging reduces the number of separate loading operations required and improves space utilization by eliminating gaps between individual items.
2Extent of automation
If piece-wise robotic loading is used, then automation is achieved, but space utilization deteriorates
Solution Approach 1:
Bundles are designed with specific local qualities - their contours are tailored to match the specific geometry of target compartments within unit load devices. This local adaptation ensures optimal fit and maximizes space utilization in each specific loading location.
Solution Approach 2:
Items are pre-consolidated into bundles with optimized shapes before the loading process begins. This preliminary action of shaping bundles to match target compartments eliminates the need for complex real-time adjustment during loading and ensures optimal space utilization from the start.
3Volume of moving object
If manual loading is used, then space utilization is optimized, but labor costs and ergonomics worsen
Solution Approach 1:
The consolidation table acts as an intermediary device where items are manually or semi-automatically grouped into bundles. This intermediary step separates the consolidation function from the loading function, allowing automated robots to handle only the bundle transport and placement, thereby improving ergonomics while maintaining space optimization.
4Extent of automation
If traditional automated loading is used, then automation is achieved, but loading cycle time increases
Solution Approach 1:
The system enables continuous useful action by having robots retrieve bundles from consolidation tables and immediately load them into unit load devices without idle waiting time. The consolidation and loading processes run in parallel, maximizing equipment utilization and minimizing cycle time.
Solution Approach 2:
Bundles are prepared in advance during the consolidation phase, so that when robots begin loading, ready-to-load bundles are already available. This eliminates waiting time during the loading phase and significantly reduces overall cycle time.
Data Source
AI summary
According to an example aspect of the present invention, there is provided method of preparing a plurality of items for air transport, in which method a plurality of items is consolidated into a bundle which has a shape corresponding to the contour or part of the contour of a unit load device. The bundle is loaded into the unit load device so as to populate the volume or part of the volume of the unit load device.