Automated Mixed Pallet Assembly with Layer Handling and Direct Retrieval
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Solution Overview
Problem
Traditional methods for assembling mixed pallets in warehouses are inefficient, time-consuming, and expose human operators to danger, while semi-automated or automated techniques require large floor space and are slow due to the need for multiple AGVs to constantly transport and assemble pallets.
Innovation Solution
Automated warehouse facilities equipped with conveyor systems, layer handling devices, and item retrieval devices that operate in delayering and palletizing modes to efficiently assemble mixed pallets, allowing for automated separation, storage, and assembly of heterogeneous layers and items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual assembly techniques are used, then flexibility in assembling mixed pallets is maintained, but productivity is low and human operators are exposed to harmful factors
Solution Approach 1:
The system uses robotic arms with grippers that automatically grasp and place items on pallets without human intervention. The control system autonomously manages the assembly process, retrieving items from storage locations and positioning them according to order requirements, thereby maintaining flexibility while eliminating manual labor and improving productivity
Solution Approach 2:
The patent replaces manual mechanical assembly with an automated robotic system. Robotic arms equipped with adaptive grippers substitute human operators, performing item retrieval and pallet assembly operations. This substitution eliminates exposure to harmful factors and significantly increases assembly speed while maintaining operational flexibility through programmable control
2Extent of automation
If automated guided vehicles are used, then automation is improved, but large floor space is required and device complexity increases
Solution Approach 1:
The system merges the storage function and retrieval function into a single integrated structure. Storage racks are positioned directly adjacent to the robotic assembly station, allowing the robotic arm to retrieve items and place them on pallets without requiring separate transport areas or pathways. This consolidation eliminates the need for large floor space dedicated to AGV operations
Solution Approach 2:
The patent extracts the transport function from the system by eliminating AGVs entirely. Instead of using autonomous vehicles to move items between storage and assembly areas, the system uses a robotic arm with extended reach that directly accesses items from storage racks and places them on pallets at the assembly station, removing the need for transport pathways and reducing floor space requirements
3Extent of automation
If automated guided vehicles are used, then automation is improved, but productivity decreases due to constant replenishment and transport operations
Solution Approach 1:
The robotic arm operates continuously without interruption, retrieving items from storage racks and placing them on pallets in an unbroken sequence. The system eliminates the idle time associated with AGV travel, replenishment, and repositioning. The robotic arm maintains constant productive action by immediately transitioning from one item placement to the next, significantly improving assembly efficiency
Solution Approach 2:
Items are pre-positioned in storage racks in the exact locations where they will be retrieved for assembly. The control system pre-plans the assembly sequence and positions items accordingly, allowing the robotic arm to perform continuous retrieval operations without waiting for replenishment. This preliminary arrangement eliminates downtime and maintains continuous productive action
Data Source
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AI summary
This disclosure is directed to automated warehouse facilities that are configured to assemble mixed pallets. The warehouse facilities can include one or more layer handling devices that are configured to remove layers from pallets in a delayering operational mode, and to add layers to pallets in a palletizing operation mode. The warehouse facilities also may include one or more item retrieval devices that are configured to retrieve individual items from storage racks. The warehouse facilities can include other automated devices as well.