Automated product loading onto a pallet
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Solution Overview
Problem
The manual loading and unloading of garments onto pallets for embellishment is a time-consuming and repetitive process, affecting the quality of the operation due to positioning, orientation, and alignment issues.
Innovation Solution
An automated system using a material manipulator and product loading assembly to position and secure garments on a pallet, employing support arms and mechanical fingers to grip and smooth the garments, ensuring precise alignment and orientation for embellishment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading and unloading of garments onto pallets is used, then flexibility and adaptability are maintained, but the process is time-consuming and repetitive, reducing productivity
Solution Approach 1:
The system enables automated self-loading of garments onto pallets through the product loading assembly that automatically positions and secures garments without manual intervention, transforming a manual service into an autonomous process
Solution Approach 2:
Manual mechanical operations are replaced with an automated product loading assembly that uses mechanical fingers, support arms, and positioning mechanisms to perform loading tasks, substituting human labor with automated mechanical systems
2Manufacturing precision
If manual positioning and alignment of garments is performed, then adaptability to different garment types is maintained, but positioning precision and consistency deteriorate due to repetitive manual operations
Solution Approach 1:
The system performs preliminary positioning actions by pre-aligning garments on the product loading assembly before transfer to the pallet, ensuring precise positioning is achieved in advance rather than during final placement
Solution Approach 2:
Manual positioning operations are replaced with automated mechanical positioning mechanisms including support arms and alignment fingers that consistently achieve precise positioning without human intervention
3Productivity
If manual loading procedures are used, then system complexity is kept simple, but the repetitive nature of the task reduces operator efficiency and increases errors
Solution Approach 1:
The loading system is segmented into distinct functional modules including the product loading assembly, support arms, mechanical fingers, and positioning mechanisms, allowing each component to perform a specific function independently
Solution Approach 2:
The product loading assembly is designed as a universal mechanism that can handle different garment types and sizes through adjustable support arms and positioning elements, providing multi-functionality without requiring multiple specialized devices
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system significantly reduces the time and effort required for loading garments, improving the consistency and quality of the embellishment process by ensuring precise positioning and alignment.
Implementation Method 1
Air dispensed by the material manipulator can separate the edge of the opening for gripping by mechanical fingers
Data Source
AI summary
Various examples are provided related to automation of pallet loading. In one example, a method includes positioning, by a material manipulator, an opening of a product; inserting a product loading assembly of a pallet loading system through an opening of the product, where the product loading assembly can hold the product during manipulation of the product and the pallet loading system can position the product for loading on a pallet; and transferring the product onto the pallet using the product loading assembly. The product can be a portion of a product or a garment or portion of a garment. The product can be smoothed on a surface of the pallet. The pallet can secure the product to the pallet by a pallet clamp. The product on the pallet can be embellished by processing equipment or workstation.