Bi-directional Palletizer Cell for Mixed Case Handling
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Solution Overview
Problem
Conventional automated storage and retrieval systems face inefficiencies in handling non-standard pallet loads, particularly in depalletization and palletization processes, as they are often incompatible with mixed case pallets, leading to reduced throughput and the need for special manual handling and accounting procedures.
Innovation Solution
The implementation of a bi-directional automation augmented palletizer/depalletizer cell that can interface with both standard and non-standard pallet loads, using a common palletizer and depalletizer interface, and a controller that identifies incompatible configurations to generate a bypass path, allowing for continuous operation and integration with the automated storage and retrieval system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional automated depalletizers are used for standard pallet loads, then automation efficiency is high, but the system cannot handle non-standard pallet loads (mixed case pallets) requiring manual intervention
Solution Approach 1:
The patent implements a single depalletizer system that can handle both standard and non-standard pallet loads by incorporating a controller that identifies pallet types and routes them appropriately. The system uses a common palletizer and depalletizer interface with a bypass path that allows the same equipment to serve multiple functions - processing standard pallets through the automated interface and diverting non-standard pallets for manual handling, thereby achieving universality without requiring separate dedicated systems for each pallet type
2Productivity
If manual handling procedures are implemented for non-standard pallet loads, then adaptability increases, but throughput decreases and continuous operation is disrupted
Solution Approach 1:
The patent introduces a controller as an intermediary component that acts as a mediator between the automated depalletizer interface and manual handling procedures. The controller identifies incompatible pallet configurations and generates bypass paths, enabling the system to automatically route non-standard pallets to manual handling areas while keeping standard pallets in the automated flow. This intermediary control mechanism maintains high throughput by minimizing manual intervention to only when necessary, rather than requiring manual handling for all pallets
3Adaptability or versatility
If separate systems are used for standard and non-standard pallet loads, then handling capability improves, but system complexity and cost increase
Solution Approach 1:
The patent merges the handling of standard and non-standard pallet loads into a single integrated depalletizer system. Instead of maintaining separate automated systems for different pallet types, the invention combines them into one system with a common interface, using a controller to manage the routing logic. The bypass path mechanism allows the same physical equipment to serve both pallet types, reducing the number of separate systems needed while maintaining full handling capability for different pallet configurations
Data Source
AI summary
An automated storage and retrieval system includes a storage array of storage locations for case units. An in-out case conveyor is capable of bi-directionally transporting case units to and from the storage array, and an in-out loaded pallet conveyor is capable of bi-directionally transporting loaded pallets towards and away from the storage array. A palletizer-depalletizer cell includes a bi-directional pallet transport system with more than one independently driven pallet transports, each with a different pallet holder independently movable relative to a cell frame. Placement of case units commissioning a pallet layer loading a pallet, and removal of case units decommissioning a pallet layer unloading another pallet are both effected at the common pallet layer interface at a predetermined level of the cell frame. The pallet transports independently index a first and a second of the different pallet holders, each independently holding the pallet loading at the common pallet layer interface.