Combined Load Unit Handling with AGV Layer Transfer
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Solution Overview
Problem
Existing systems for creating combined load units (UDCs) in production plants are inflexible, not easily scalable, maintenance-intensive, and unreliable due to the use of conveyors and manual operations, leading to inefficiencies and potential product damage.
Innovation Solution
An apparatus and method utilizing autonomously guided vehicles and specialized trays to handle and stabilize layers of SKUs, combined with a wrapping device for final stabilization, allowing for flexible and efficient formation of combined load units with different product types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conveyors are used to transfer SKUs from mother UDCs to combined UDCs, then automated handling is achieved, but the system becomes rigid, maintenance-intensive, and difficult to scale
Solution Approach 1:
The system divides the automated handling function into discrete mobile robotic units that can operate independently. Each robot is a self-contained module with picking and transfer capabilities, replacing the monolithic conveyor system. This segmentation allows individual robots to be added, removed, or repositioned without affecting the entire system, achieving automation while maintaining flexibility and reducing maintenance complexity.
2Adaptability or versatility
If manual picking is used to create combined UDCs, then system flexibility is maintained, but speed and reliability are reduced and operator safety is compromised
Solution Approach 1:
The mobile robotic units are equipped with sensors, navigation systems, and automated picking mechanisms that enable them to autonomously locate mother UDCs, select required SKUs, and transfer them to combined UDCs without human intervention. The robots self-manage their operations including navigation, picking decisions, and placement, thereby maintaining system flexibility while dramatically improving speed and reliability.
3Productivity
If mobile robots are used for automated picking, then operational speed improves, but the risk of product damage increases due to automated gripping
Solution Approach 1:
The robotic gripping mechanism incorporates sensors and control systems that dynamically adjust gripping parameters such as force magnitude, contact point location, and grip duration based on real-time detection of SKU characteristics. This parameter adaptation allows the robot to handle different product types with appropriate force levels, maintaining high operational speed while minimizing the risk of product damage through precise, adaptive gripping control.
Data Source
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AI summary
An apparatus (1) for making combined load units, or UDCs, made up of packages of products or SKUs of different types, obtained from mother UDCs (105) of uniform packages or SKUs, or from partially depalletized UDCs (114), i.e., a pallet of uniform packages or SKUs from which only a few layers have been picked, includes a depalletizing island (100) to depalletize the mother UDCs (105), a first automated warehouse (200) for layers (110) of packages or uniforms SKUs, a second automated warehouse (300), or an approach warehouse (250), intended for the de-filmed mother UDCs (105) and/or the partially depalletized UDCs (114), a first palletizing island (400) for making combined UDCs with layers of packages formed by single different SKUs or by small groups of different SKUs within the same layer, in addition or as an alternative to the previous palletizing island (400) a second palletizing island (500) for the creation of combined UDCs with uniform SKU layers, a wrapping island (600) for combined UDCs, a fleet of first autonomously guided shuttles (700) equipped with an upper plane (701) capable of supporting a layer (110) of packages or SKUs, and a fleet of second shuttles (800) equipped with an upper surface (801) capable of supporting a mother UDC (105) of packages or uniform SKUs or a combined UDC, and at least one forklift truck (850) equipped with forks, automatically or manually guided; methods are also provided for making combined load units, or UDCs.