Conveyor Load Management Station for Transport Unit Optimization
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Solution Overview
Problem
Conventional automated picking systems in overhead conveyor systems face inefficiencies due to long access times in long-term storage, high costs from oversized transport units for mixed goods, and complexity from using multiple types of transport units, leading to reduced volume efficiency and increased costs.
Innovation Solution
A load management station with a dual conveyor system, transfer stations, and actuators like robot arms for efficient retrieval and reorganization of units of goods, allowing for flexible handling and optimized loading of transport units, eliminating the need for interfaces between different conveyor systems and enabling efficient sorting and reorganization of units within the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional automated picking systems use long-term storage areas with multiple transport unit types, then goods can be stored and retrieved, but access times increase and system complexity increases
Solution Approach 1:
The storage area is divided into multiple bays with storage containers arranged in rows, allowing parallel access to different goods locations. The picking station is segmented into multiple picking positions that can simultaneously handle different picking orders, reducing overall access time through concurrent operations.
Solution Approach 2:
A single standardized transport unit type is used across all conveyor systems, allowing the same transport units to serve multiple functions: storing goods in long-term storage, buffering in short-term storage, and conveying to picking stations. This eliminates the need for interface conversions between different transport unit types, reducing access time and system complexity.
2Adaptability or versatility
If conventional systems use oversized transport units to accommodate mixed goods of different sizes and weights, then all goods can be transported, but volume efficiency decreases and costs increase
Solution Approach 1:
Storage containers are designed with adjustable shelving and configurable internal structures that can be locally adapted to match the specific dimensions and requirements of different goods. This allows standardized transport units to efficiently accommodate various goods types without excessive empty space, maintaining volume efficiency while preserving adaptability.
3Adaptability or versatility
If conventional systems use multiple types of transport units for different goods, then goods can be optimized for their specific characteristics, but device complexity increases and maintenance costs increase
Solution Approach 1:
A single standardized transport unit design is implemented across all conveyor systems (first conveyor, second conveyor, and pickup conveyor). This universal transport unit can handle all goods types through configurable storage containers rather than requiring different transport unit variants, significantly reducing device complexity and maintenance requirements while maintaining operational versatility.
4Adaptability or versatility
If manual insertion of units of goods into transport elements is used, then flexible handling of different goods is possible, but productivity decreases and operational costs increase
Solution Approach 1:
Storage containers are designed with self-opening mechanisms that automatically open when the transport unit arrives at the picking station, eliminating the need for manual intervention. The system uses automated detection to identify which containers need to be opened and opens them accordingly, maintaining handling flexibility while dramatically increasing productivity through automation.
Data Source
AI summary
A station (3) for managing the load of transport units of a conveyor system includes a first conveyor (21) and a second conveyor (25) with a plurality of transport units (4, 4′, 4″); at least one transfer station (31), arranged for receiving units of goods (9), wherein the at least one transfer station (31) has a third conveyor (32) for conveying units of goods (9); a retrieval station (36) for retrieving units of goods from a transport unit (4″) of the first conveyor (21) and for transferring the retrieved units of goods to said transfer station; and a transfer station (37, 37′) for transferring units of goods from said transfer station to a transport unit (4, 4′) of the second conveyor. The first conveyor (21) and the second conveyor (25) are functionally connected by a conveyor system (10).