Automated Container Picking Mixed Buffer
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Solution Overview
Problem
Existing automated container picking systems require large buffers and are inflexible due to the need for separate storage and handling of each type of container, leading to inefficient use of space and reduced flexibility in responding to changing demands.
Innovation Solution
The method involves alternating and variable separation of pack layers from different source pallets, storing them in magazines, and optionally palletizing target pallets with unseparated layers, allowing for flexible handling and reduced storage needs by using conveyor systems and grippers to manage packs as stacks, thereby minimizing handling times and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If separate buffers are provided for each container type, then automated picking can be performed, but the space requirement and system complexity increase significantly
Solution Approach 1:
The patent combines multiple buffer functions into a single mixed buffer where containers of different types are stored together. Instead of requiring separate dedicated buffers for each container type, the system uses one shared buffer that accommodates heterogeneous containers, thereby reducing total space requirements while maintaining automated picking capability
Solution Approach 2:
The mixed buffer serves multiple container types simultaneously, making it a universal storage solution. The buffer is designed to handle various container formats (different sizes, shapes, and types) without requiring type-specific buffer allocations, thus improving space utilization and reducing system complexity
2Extent of automation
If complete separation of source pallets is performed, then automated palletizing can be achieved, but handling time increases due to extensive separation and buffering operations
Solution Approach 1:
The system performs preliminary partial separation of pack layers from source pallets without requiring complete separation. By separating only what is immediately needed and allowing other layers to remain attached, the system reduces unnecessary handling operations and minimizes handling time while still enabling automated palletizing
Solution Approach 2:
Instead of performing complete separation of all pack layers from source pallets, the system applies partial separation only to the extent necessary for current palletizing requirements. This partial action approach avoids the time-consuming complete separation process while maintaining sufficient automation capability
3Quantity of substance
If large buffers are provided for all container types, then all containers can be accommodated, but the system becomes inflexible and space-intensive
Solution Approach 1:
The mixed buffer system is dynamic in its operation, allowing the buffer contents and retrieval patterns to adapt to changing order requirements. The system can flexibly retrieve different container types from the same buffer based on current demand, enabling the system to respond to varying quantities and types of containers without requiring pre-configured dedicated buffers for each scenario
Data Source
Figure 1
Figure 2A~2D
AI summary
An inventive method for the automated picking of containers (1A, 1B, 1C) comprises the steps: providing different source pallets (100A, 100B, 100C); and palletizing at least one target pallet (500); wherein layers of containers from different source pallets are alternately and/or variably separated and stored; and/or containers or groups of containers are stacked and stored (300A, 300B, 300C) and/or unstored before palletizing a target pallet (500); and/or a target pallet is optionally palletized with at least one unseparated layer of containers from a source pallet.