Carousel Pallet Sorting for Compact Multi-Type Stacking
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Solution Overview
Problem
Existing pallet sorting and stacking systems are limited in their ability to simultaneously sort and stack a large number of different pallet types due to the restricted working area of robot arms, requiring complex and costly setups with large installation spaces.
Innovation Solution
The use of movable pallet stacking stations on a carousel system, allowing the robot arm to efficiently access multiple stacking positions by rotating the carousels, combined with a double-fork gripper for nesting pallets, enables simultaneous sorting and stacking of multiple pallet types within a compact space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If stationary pallet stacking positions are used within the robot arm's working area, then the robot arm can serve multiple pallet stacking locations, but the number of pallet types that can be sorted simultaneously is limited due to the restricted working area
Solution Approach 1:
The patent applies the dynamics principle by replacing stationary pallet stacking positions with movable pallet stacking stations mounted on carousels. The carousels can rotate to bring different stacking positions into the robot arm's working area as needed, allowing the system to handle many more pallet types without expanding the physical installation space. This dynamic configuration enables the robot arm to access multiple stacking positions sequentially rather than requiring all positions to be simultaneously accessible.
Solution Approach 2:
The patent implements another dimension by introducing rotational movement through carousels. Instead of arranging stacking positions only in the horizontal plane within the robot arm's reach, the system uses vertical carousels that rotate to bring different levels and positions into the working area. This adds a rotational dimension to the stacking position access, dramatically increasing the number of pallet types that can be handled within the same footprint.
2Productivity
If multiple stationary pallet stacking positions are arranged within the robot arm's working radius, then more pallet types can be sorted, but the device complexity and installation space increase significantly
Solution Approach 1:
The patent applies merging by combining multiple pallet stacking stations onto single rotating carousels. Instead of having separate stationary positions distributed throughout the working area, multiple stacking stations are consolidated onto carousel structures that rotate into position. This reduces the overall system complexity by centralizing the stacking positions on movable platforms rather than requiring complex fixed infrastructure throughout the workspace.
Solution Approach 2:
The patent implements universality by designing the carousels to serve multiple functions: they act as both storage platforms for pallet stacks and as positioning mechanisms that bring the correct stacking position into the robot arm's reach. The same carousel structure provides both the stacking surface and the rotational positioning capability, eliminating the need for separate positioning mechanisms for each stacking position.
3Adaptability or versatility
If a large number of stationary pallet stacking positions are provided, then more pallet types can be handled, but the processing time increases due to longer travel distances
Solution Approach 1:
The patent applies preliminary action by pre-positioning multiple pallet stacking stations on the carousels before the sorting process begins. The carousels can be rotated in advance to bring the required stacking positions into the robot arm's working area, eliminating the need for the robot arm to travel long distances during the sorting process. The system prepares the stacking positions beforehand, so when a pallet needs to be sorted, the correct position is already in place.
Solution Approach 2:
The patent uses the carousel as an intermediary between the robot arm and the multiple stacking positions. Instead of the robot arm directly accessing distant stationary positions, the carousel acts as a mediator that brings the stacking positions close to the robot arm's working area. This intermediary mechanism significantly reduces the travel distance and time required for the robot arm to deposit pallets.
Data Source
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AI summary
Known devices for sorting pallets based on their pallet type comprise a pallet feeder, preferably a detection unit for detecting the pallet type of the pallets fed in, a robot with a robot arm rotatable about a vertical axis, and several pallet stacking stations for receiving pallets sorted by pallet type in stacks, forming sorted pallet stacks. The robot arm is designed to remove a pallet from at least one receiving point of the pallet feeder and to deposit the pallet on one of the pallet stacking stations.In order to provide a device for sorting pallets based on their pallet type, which enables simultaneous sorting of pallets with as many different pallet types as possible, it is proposed according to the invention that the device comprises a first pallet stacking carousel on which several of the pallet stacking locations are arranged, wherein each of these pallet stacking locations can be brought into a first stationary pallet storage position, which is served by the robot arm, by rotating the pallet stacking carousel.