Case Order Sequencing Conveyors With Non-Accumulating Buffers

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Solution Overview

Problem

Current automated case order sequencing systems face challenges with high costs, poor reliability, and inefficient space utilization, limiting their adoption in the market, especially for slower-moving products.

Innovation Solution

The implementation of non-accumulating case conveyors with a chain-based system that minimizes product contact and pressure, uses a 90-degree case transfer method for gentle handling, and incorporates a common input and output conveyor to reduce capital and operational costs while maintaining high throughput and space efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated case order sequencing systems are implemented, then productivity and reliability are improved, but cost and device complexity increase

Engineering Contradiction:

Improveorder preparation throughputVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system is divided into independent functional modules: receiving conveyors, buffer conveyors, case transfer devices, and dispensing conveyors. Each module operates semi-independently, allowing for easier maintenance and reduced overall system complexity while maintaining high productivity through coordinated operation of these segmented components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The case buffer conveyors serve multiple functions: they temporarily store cases from receiving conveyors, queue cases for dispensing, and facilitate transfer between different conveyor sections. This multi-functionality reduces the need for separate specialized components, thereby reducing device complexity while maintaining high order preparation throughput.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If traditional roller conveyors are used, then ease of manufacture is improved, but product damage increases due to product contact and pressure

Engineering Contradiction:

Improveconveyor system manufacturingVSAvoidproduct damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The harmful element of direct product contact with conveyor rollers is eliminated by extracting the rolling contact mechanism and replacing it with a chain-driven belt system. Cases are conveyed on flat belts that minimize contact pressure and friction, significantly reducing product damage while maintaining ease of manufacture through the use of standard chain and belt components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A flat belt intermediary is introduced between the drive mechanism and the cases. The belt acts as a mediator that transfers motion smoothly without the high-point contact pressure of rollers, reducing mechanical stress on cases while the chain drive provides the necessary power transmission.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If accumulating conveyors are used, then productivity is improved, but space utilization deteriorates

Engineering Contradiction:

Improvecase dispensing rateVSAvoidconveyor system space

Core Design Contradiction:

ProductivityVSVolume of moving object

Solution Approach 1:

The conveyor system uses dynamic chain-driven belts that can adjust their motion characteristics based on operational needs. The chains allow for compact positioning of drive mechanisms and flexible routing of conveyors, maintaining high dispensing rates while reducing the overall space footprint compared to traditional accumulating roller conveyor systems.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system utilizes vertical stacking of conveyor levels and multi-layer chain arrangements to achieve high productivity within a compact horizontal footprint. By transitioning from horizontal expansion to vertical utilization, the system maintains high case dispensing rates while optimizing space utilization in the vertical dimension.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Productivity

If case buffer conveyors with multiple moving parts are used, then productivity is improved, but reliability deteriorates due to wear and maintenance requirements

Engineering Contradiction:

Improvethroughput rateVSAvoidsystem reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system replaces complex mechanical roller mechanisms with a simpler chain-driven belt system. The chain drive provides reliable power transmission with fewer contact points and less friction, reducing wear and maintenance requirements while maintaining high throughput rates. The flat belt conveyance method eliminates roller bearing wear and reduces mechanical failure points.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2655220B1Automated case order sequencing method and system

Publication Date: 2021.10.27 3584925 CANADA DRL SYST

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AI summary

A system and method for automatically preparing client orders in a distribution facility, where the inputs to the system are complete pallets of cases of individual products and the outputs of the system are client order pallets of mixed products. Specifically, the methods and systems are for conveying, storing, and dispensing cases using automated case order sequencing typically using non-product-dedicated and non-accumulating buffer conveyors.