Automated Case Sequencing Using Crane and Gravity Guides
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Solution Overview
Problem
Current automated case order sequencing systems face high costs, poor reliability, and inefficient space utilization, limiting their adoption in the market, especially for slower-moving products.
Innovation Solution
The use of a crane instead of conveyors to move cases, combined with an algorithm to optimize case orientation and loading, and the integration of partial pallet handling systems to reduce costs and improve space efficiency, along with gravity-powered case guides for efficient product movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated case order sequencing systems are implemented, then productivity and reliability are improved, but cost and device complexity increase
Solution Approach 1:
The system is divided into independent functional modules: depalletizing station, case guides for different products, sequencing conveyor, and palletizing station. Each module operates independently, allowing the system to achieve high automation without requiring a monolithic complex structure. This modular segmentation reduces overall system complexity while maintaining high productivity.
Solution Approach 2:
The sequencing conveyor serves multiple functions: it transports cases from case guides, sequences them according to order requirements, and delivers them to the palletizer. This multi-functional design reduces the number of separate devices needed, thereby reducing device complexity while maintaining high automation capability.
2Extent of automation
If conventional conveyor systems are used, then automation is achieved, but space utilization deteriorates
Solution Approach 1:
The system transitions from horizontal conveyor-based case movement to vertical gravity-powered case guides. Cases move vertically down inclined guides under gravity, then horizontally along a sequencing conveyor. This dimensional change allows compact vertical stacking of case guides, dramatically improving space utilization while maintaining full automation.
Solution Approach 2:
The case guides are positioned at different heights, utilizing gravity to move cases from higher to lower positions. By positioning case guides to take advantage of gravitational potential energy, the system eliminates the need for powered conveyors in vertical movements, reducing both space requirements and energy consumption while maintaining automation.
3Device complexity
If crane-based handling is implemented, then cost per product and space efficiency are improved, but maintenance access becomes more difficult
Solution Approach 1:
The crane system is designed as a separate, extractable module that can be removed from the facility for maintenance. By isolating the complex crane mechanism as a discrete unit, maintenance personnel can access and service the crane without disassembling the entire sequencing system, thereby maintaining low device complexity while improving ease of repair.
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 cost per product, enhances space efficiency, and maintains high throughput rates, making it economically viable to automate both faster and slower-moving products, while also improving maintenance access and reducing noise.
Implementation Method 1
gravity-powered case guides for efficient product movement
Implementation Method 2
gravity-powered case guides for efficient product movement
Data Source
AI summary
An automated case order preparation system including a crane for transporting groups of depalletized product cases to temporary storage on shelving, and to a plurality of gravity-powered case guides, for accumulating and dispensing cases to fulfill client order pallets.