Semi-Automatic Beverage Crate Sorting with Gravity Buffer Zones
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Solution Overview
Problem
Existing sorting systems for beverage crates require excessive space due to the need for multiple transport paths and storage locations, especially for slow-moving items, leading to inefficient use of space and increased operational costs.
Innovation Solution
A semi-automatic sorting method where goods are manually placed on buffer sections, with an identification device recognizing fast-moving items for automatic sorting and slower-moving items for semi-automatic or manual sorting, allowing for efficient use of space by removing items when a predetermined filling level is reached, using inclined buffer sections and conveyor elements to facilitate automatic removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple transport paths and storage locations are provided for different beverage crates, then sorting capability is improved, but space requirement increases unacceptably
Solution Approach 1:
The sorting system is divided into multiple sorting stations, each equipped with an identification device and buffer section. This segmentation allows different types of beverage crates to be sorted at different stations along a single linear transport path, eliminating the need for multiple parallel transport paths while maintaining comprehensive sorting capability.
Solution Approach 2:
Instead of expanding the system horizontally with multiple parallel transport paths, the invention extends the sorting process along the temporal dimension by introducing multiple sorting stations at different positions along a single continuous transport path. This allows sequential sorting of different crate types without requiring simultaneous parallel paths.
2Adaptability or versatility
If storage space is provided for slow-moving C-runners, then complete sorting capability is improved, but space utilization deteriorates due to unused space
Solution Approach 1:
Buffer sections are provided at each sorting station with capacity sufficient to handle both fast-moving and slow-moving items, but items are removed as soon as the buffer reaches a predetermined filling level. This ensures that space is allocated for all item types without permanently dedicating large portions to slow-moving items, thereby maintaining high space utilization.
Solution Approach 2:
The buffer sections are designed with dynamic filling levels rather than fixed allocations. The predetermined filling level triggers automatic removal of goods, allowing the system to adapt to varying item frequencies. This dynamic approach ensures that space previously allocated for slow-moving items is quickly released and reused, maximizing overall space utilization.
3Area of stationary object
If high storage facility is used for temporary storage, then space requirement is reduced, but loading and unloading work increases
Solution Approach 1:
The system employs automatic identification devices at each sorting station that detect beverage crate types and trigger automatic removal mechanisms. When a buffer section reaches its predetermined filling level, goods are automatically removed without manual intervention, eliminating the need for labor-intensive loading and unloading operations while maintaining compact space utilization.
Solution Approach 2:
The identification devices continuously monitor the types of beverage crates arriving and provide feedback to control the sorting process. This feedback mechanism ensures that goods are automatically removed from buffer sections at the optimal moment, preventing overflow and eliminating the need for manual high-storage facility operations.
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 space requirements, minimizes storage time, and lowers unit costs by efficiently sorting frequently occurring items automatically and less frequent items with a reasonable space requirement, while allowing for quick processing and reduced labor.
Implementation Method 1
The buffer section can, for example, be inclined downwards at an angle of 0.1° to 15°, in particular 2° to 8°
Data Source
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AI summary
The method involves performing the assignment of goods in a certain order according to a criterion. The semi-automatic sorting is performed by placing the goods manually on buffer zones (2-4) having a predetermined length. The goods are removed from the buffer zones, when predetermined fill level of the goods in the buffer zones is reached. The buffer zones are provided with the sliding elements for guiding the goods automatically in the end position (203) of the buffer zones. : An independent claim is included for a device for sorting goods. USE : Method for sorting goods e.g. beverage crate used for transporting beverage container sold in supermarket. ADVANTAGE : By placing the goods manually on buffer zone having a predetermined length and removing the goods from the buffer zone when predetermined fill level of the goods in the buffer zone is reached, the goods are sorted semi-automatically and efficiently in the minimum required space, and the continuous withdrawal of goods can be attained in timely manner. The goods can be placed on the head side and on an upper end of the buffer zones without additional aids such as motor-driven conveyor belts. DESCRIPTION OF DRAWINGS : The drawing shows a side view of the semi-automated sorting device. 1 : Sorting device 2-4 : Buffer zones 5 : Cross-conveyor 201 : Struts 203 : End position of the buffer zone.