Ceramic Article Handling Layout for Automated Shipping Unit Formation
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Solution Overview
Problem
The existing methods for handling ceramic articles are labor-intensive, prone to human error, and pose safety risks due to manual handling of heavy storage units, leading to increased labor costs and operational inefficiencies.
Innovation Solution
A plant and method that automates the handling of ceramic articles by rearranging them into stable, easily graspable configurations using a handling machine and forming machine, allowing for automated formation of shipping units with reduced operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual handling methods are used to pick and sort ceramic articles from storage units, then flexibility in handling different order configurations is maintained, but labor costs increase, human error probability increases, and operator safety risks increase due to heavy weights
Solution Approach 1:
The handling plant is divided into distinct functional modules: a picking device for removing storage units, a conveying system for transportation, and a forming device for assembling shipping units. Each module operates independently but coordinates through a control unit, allowing automation while maintaining manageable system complexity through functional segmentation.
Solution Approach 2:
The forming device is designed to handle multiple types of ceramic articles and configure them into different shipping unit arrangements based on order requirements. The system can adapt to various storage unit configurations and produce different shipping unit types, providing universal functionality that reduces the need for specialized equipment for each task.
2Productivity
If multiple transfer devices and operators are used to prepare shipping units from storage units, then sorting operations can be performed, but the time required for preparation increases and operational efficiency decreases
Solution Approach 1:
The conveying device continuously transports storage units from the gathering area to the forming device without interruption. The forming device continuously receives storage units, picks ceramic articles, and assembles shipping units in an unbroken workflow. This continuous operation eliminates idle time between operations and maximizes productivity by keeping the system in constant productive motion.
Solution Approach 2:
Storage units are pre-positioned in the gathering area in ready-to-pick configurations before the forming process begins. The picking device is pre-configured with the necessary mechanisms for grasping and transporting storage units. This preliminary preparation eliminates setup time during actual shipping unit formation and allows the system to operate at maximum speed from the start of each batch.
3Object-affected harmful factors
If operators manually handle storage units with significant weights, then sorting can be performed with simple equipment, but operator injury risk increases and labor costs increase
Solution Approach 1:
The picking device uses mechanical grippers or clamps to grasp and lift storage units, replacing manual operator lifting. The conveying device uses automated mechanical transmission systems to transport heavy storage units, eliminating the need for operators to physically handle heavy loads. This substitution of manual mechanical effort with automated mechanical systems removes operators from hazardous positions while maintaining safe and efficient handling.
4Area of stationary object
If storage units are stacked on top of one another in gathering areas, then space utilization is improved, but the complexity of picking and transporting units increases
Solution Approach 1:
The conveying device acts as an intermediary between the stacked storage units in the gathering area and the forming device. It provides a controlled transmission path that simplifies the extraction and transport of storage units from stacks. The conveying system handles the complexity of retrieving units from stacked positions, leaving the forming device with a simple receiving and assembly task, thus maintaining ease of operation despite high space utilization.
Data Source
AI summary
A method and plant to handle ceramic articles; the plant comprises a gathering area comprising a plurality of first storage units, each having a group of ceramic articles placed on a first support structure according to a first given arrangement; a handling machine to re-arrange at least part of such ceramic articles on second support structures in such a way that they are placed according to a second given arrangement so that they can be picked up by a holding device, so as to create a plurality of second storage units; at least one first intermediate store to receive at least part of the second storage units; and a forming machine to form an order to be shipped, which is configured to transfer at least one first ceramic article from the second storage unit onto a third support structure so as to obtain a shipment unit.