Container Exchange Layout for Simultaneous Loading and Unloading
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Solution Overview
Problem
Existing container changing devices for production lines face interruptions in component supply due to the need for manual forklift operation and simultaneous unloading/loading limitations, leading to increased logistics space requirements and accessibility issues.
Innovation Solution
A container changing device with motorized transfer devices and a traversing unit allows for automatic and simultaneous loading/unloading of containers without a forklift, utilizing conveyor belts and telescopic lifting forks to manage container movement and support, reducing the need for multiple container stands and optimizing logistics space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If containers are arranged side-by-side along the production line to ensure continuous component supply, then component availability is improved, but the overall space requirement of the line increases significantly
Solution Approach 1:
The container exchange device introduces a vertical dimension by stacking containers in multiple levels (first container position at lower level, second container position at upper level). This allows the system to store multiple containers without increasing the horizontal footprint along the production line, thereby maintaining component availability while reducing space requirements.
Solution Approach 2:
The container exchange device acts as an intermediary buffer between the production line and the container storage area. It temporarily holds multiple containers in its multi-level structure, allowing the production line to continuously access components without requiring multiple container positions along the line itself.
2Area of stationary object
If containers are arranged one behind the other to reduce space requirements, then space usage is improved, but the container at the front is blocked by containers behind it, making it inaccessible
Solution Approach 1:
The device transitions from horizontal container arrangement to vertical stacking, with containers positioned at different heights (lower level and upper level). This vertical arrangement eliminates the blocking problem where front containers are obscured by rear containers, as each container is accessible from its own level without being blocked by others.
Solution Approach 2:
The container storage space is segmented into multiple independent levels (first container position and second container position). Each level operates independently with its own access point, allowing containers to be loaded and unloaded without interference from containers at other levels, thus maintaining accessibility while saving space.
3Ease of operation
If a forklift is used to manually exchange containers between the production line and travel path, then container exchange capability is provided, but assembly is interrupted during the time between removal of empty container and delivery of full one
Solution Approach 1:
The container exchange device pre-positions multiple full containers in its multi-level structure before they are needed at the production line. When the production line needs components, a full container is already available in the first container position, eliminating the waiting time that would occur with manual forklift exchange. The system performs the preparation action in advance, ensuring continuous assembly.
Solution Approach 2:
The device enables continuous container exchange operations by maintaining a ready supply of full containers in its storage positions. While one container is being used at the production line, another full container is already positioned and ready for immediate transfer, ensuring that the assembly process experiences no interruptions and useful action continues without pause.
4Productivity
If multiple container positions are provided on the travel path to enable simultaneous loading and unloading, then loading and unloading can occur simultaneously, but the logistics space requirements increase
Solution Approach 1:
The container exchange device utilizes vertical space by stacking container positions at different levels (lower level and upper level) within a compact structure. This allows the system to provide multiple container positions that can operate simultaneously for loading and unloading operations without requiring proportional increases in horizontal logistics space.
Solution Approach 2:
The device combines multiple container storage and exchange functions into a single integrated structure. By merging the first container position and second container position into one unified exchange device with shared support structures and transfer mechanisms, the system achieves simultaneous loading and unloading capabilities while minimizing the total logistics space required compared to separate container positions.
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
Enables continuous component supply to production lines with reduced logistics space requirements and improved accessibility by decoupling loading/unloading processes, allowing for efficient container swapping without manual forklift intervention.
Implementation Method 1
a traversing unit (8) which is movable in the vertical direction relative to the base frame (7)
Implementation Method 2
a conveyor belt (13) arranged in the horizontal direction parallel to the production line (5)
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a container-exchanging device, comprising a component removal station and a container loading station for exchanging containers between a production line and a road of a production system, comprising a main frame, a moving unit, and a first transfer device, the moving unit being vertically movable relative to the main frame and the first transfer device being horizontally movable relative to the main frame and the first transfer device having a first container carry-along device. The problem addressed by the invention is that of creating a container-exchanging device for a production line of a production system, said container-exchanging device being characterized by automatic loading and unloading of the containers located in the container-exchanging device. Furthermore, the unloading and loading processes should be able to proceed simultaneously. In addition, the loading and unloading should be possible without a forklift, and furthermore only a small logistics area should be required. Said problem is solved in that the container-exchanging device (1) has a second transfer device (10) and said second transfer device (10) is connected to the moving unit (8) and can be moved horizontally relative to the main frame (7) and that the second transfer device (10) has a second container carry-along device (17) and that the first transfer device (9) and/or the second transfer device (10) can be moved out of the main frame (7) on a side (15) of the container-exchanging device (1) facing the road (6).