Beverage Crate Palletizing System with Buffer Track Circuit
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Solution Overview
Problem
Existing palletizing systems for beverage crates require large spaces due to the need for extensive comb or accumulation tracks, which are costly and inefficient in terms of space utilization, especially when operating on a single level.
Innovation Solution
A method that incorporates a detection device with a computer unit to manage the sequence and storage of crates on an infeed line, using a network of ejectors and buffer tracks to efficiently load crates onto pallets in layers, allowing for flexible palletization and reduced space requirements by connecting the buffer track to the infeed line before and after the last ejector, enabling partial occupancy of pallet layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional comb tracks are used to accumulate crates for palletizing, then crates can be sorted and palletized, but the space requirement becomes extremely large
Solution Approach 1:
The system divides the palletizing process into multiple layers, with each layer handled by separate ejectors and buffer tracks. This segmentation allows crates to be accumulated and palletized in a more compact arrangement, reducing the overall space requirement while maintaining sorting and palletizing capabilities
Solution Approach 2:
The patent introduces a vertical layer dimension to the palletizing process, transitioning from traditional single-level comb track accumulation to multi-layer pallet formation. This dimensional change enables more efficient space utilization by stacking crates vertically rather than requiring extensive horizontal comb tracks
2Adaptability or versatility
If multiple ejectors are positioned at distances from one another on the feed track with comb tracks adjoining each ejector, then crates can be sorted by type, but the system requires an extremely large amount of space
Solution Approach 1:
The patent merges the buffer track function with the feed track by connecting the buffer track to the feed track in the circuit before and after the last ejector. This integration allows the same track space to serve multiple purposes - both as feed track and buffer track - thereby reducing the overall space requirement while maintaining crate type sorting capability
Solution Approach 2:
The feed track is designed to serve multiple functions: it acts as both the initial feed track for incoming crates and as a buffer track for accumulating crates waiting to be palletized. This multi-functionality eliminates the need for separate dedicated buffer tracks, reducing space requirements while maintaining sorting versatility
3Productivity
If comb tracks with capacity corresponding to at least one full pallet are used, then crates can be accumulated for palletizing, but the length of the comb track becomes around 18 meters, requiring large space
Solution Approach 1:
The buffer track accumulates crates in advance before they are needed for palletizing, allowing the system to prepare crates ahead of time. This preliminary accumulation action eliminates the need for long comb tracks by storing crates in a compact buffer area that can be accessed when needed, reducing track length while maintaining productivity
Solution Approach 2:
The system dynamically adjusts the operation of ejectors based on real-time crate detection and buffer track status. Ejectors are activated only when crates are ready for palletizing, allowing for flexible and efficient operation that reduces the need for long fixed-length comb tracks while maintaining high productivity
Data Source
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AI summary
Palletizing system for beverage crates comprising at least one feed conveyor, wherein the feed conveyor has at least one detection device for the beverage crates, wherein the feed conveyor has several diverters arranged in series, wherein each diverter is followed by a discharge conveyor leading to a palletizing station where a palletizing head loads a pallet with beverage crates layer by layer, wherein the at least one feed conveyor is connected to at least one buffer conveyor in a circuit, wherein the connection of the at least one buffer conveyor to the feed conveyor in the transport direction of the beverage crates takes place on the one hand before the detection device and on the other hand after the last diverter with the discharge conveyor to the palletizing station, wherein a discharge conveyor for beverage crates follows the feed conveyor.