Auxiliary Load Carrier Transfer for Automated Order Picking
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Solution Overview
Problem
Existing loading systems require multiple expensive and time-consuming conveying means for roll containers, leading to high costs and inefficiencies due to the need for numerous roll containers and frequent maintenance at various loading sites, where roll containers with wobbly side walls often jam, causing faults and increased downtimes.
Innovation Solution
The system uses transportable auxiliary load carriers to stack articles, which are then automatically transferred onto ready targeted load carriers, reducing the number of loading stations and utilizing a commissioning vehicle to streamline the process, allowing for efficient loading and minimizing the need for expensive conveying means by using roll containers with grid structures and height-adjustable pallets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple expensive conveying means are used for roll containers, then loading can be performed at multiple loading sites, but system cost and complexity increase significantly
Solution Approach 1:
The patent introduces auxiliary load carriers as intermediary devices between the single conveying means and the targeted load carriers. These auxiliary carriers are loaded with articles at a commissioning station and then used to transfer articles to multiple targeted load carriers at a loading station, eliminating the need for multiple expensive conveying means while maintaining loading versatility
Solution Approach 2:
The single conveying means is designed to handle both auxiliary load carriers and targeted load carriers. The auxiliary load carriers serve multiple functions: they are loaded with articles, transported to the loading station, and then used to supply multiple targeted load carriers, making the conveying system universal and multi-functional
2Adaptability or versatility
If numerous roll containers are bound in the loading system, then loading can be performed at multiple loading sites, but the number of roll containers required and maintenance needs increase
Solution Approach 1:
Auxiliary load carriers act as intermediaries that consolidate articles before transfer to targeted load carriers. This reduces the need for numerous roll containers bound in the system, as auxiliary carriers are reused multiple times to supply different targeted load carriers at different loading sites
Solution Approach 2:
The system recovers and reuses auxiliary load carriers after they have transferred articles to targeted load carriers. The empty auxiliary carriers are returned to the commissioning station for reloading, creating a circular flow that reduces the total quantity of roll containers needed in the system
3Productivity
If conventional loading methods are used with fixed shafts and lifting means, then articles can be stacked onto targeted load carriers, but loading time is excessive
Solution Approach 1:
Articles are pre-loaded onto auxiliary load carriers at a commissioning station before being transferred to the loading station. This preliminary action allows the actual loading process at the loading station to be much faster, as articles are already arranged and ready for transfer to targeted load carriers
Solution Approach 2:
The patent replaces the conventional mechanical stacking system (fixed shaft with lifting means) with a gravity-based transfer system. The bottom of the auxiliary load carrier is shifted laterally to allow articles to slide down by gravity onto the targeted load carrier, eliminating the need for complex lifting and stacking mechanisms
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
This approach reduces the number of roll containers in the system, decreases maintenance requirements, and lowers travel times by enabling faster loading and unloading, thus minimizing downtime and operational costs while maintaining efficient article distribution to targeted load carriers.
Implementation Method 1
the auxiliary load carrier together with quantity of articles, which is conveyed on a feeding conveying means, is gripped from below on the bottom side at a reloading site and transferred and positioned into a suspended position
Implementation Method 2
the lift for the lifting and positioning of a kept-ready, empty targeted load carrier at the bottom side of the suspended auxiliary load carrier
Implementation Method 3
by means of a lateral shifting of the bottom of the suspended auxiliary load carrier in the direction of transfer, the quantity of articles is transferred to the targeted load carrier
Data Source
AI summary
A method and loading system for order-picking articles in the form of individual articles and/or pack units, in which requested articles are packed, in accordance with the orders, onto destination load carriers and despatched. The requested articles (2) which are to be order-picked, in at least one order-picking station (4), are arranged and/or stacked in the pattern of the destination load carrier (3) on requested and transportable auxiliary load carriers (6), each provided for an order or part of an order. The auxiliary load carrier (6) together with a quantity of articles, provided as layers and/or stacks, to be conveyed to a loading station (5) is automatically transferred as a unit onto a placed-in-position destination load carrier (3) supplied, wherein preferably rolling containers and pallets are used as the destination load carriers.