PLC-Controlled Conveyor Optical Recognition for Order Selection
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Solution Overview
Problem
Current material handling systems in the warehousing and distribution industry face challenges such as slow order selection speed, inefficiency in handling a wide variety of item sizes, high energy consumption, and the need for excessive physical space, as well as difficulties in software integration and cost associated with implementing item-on-demand systems.
Innovation Solution
The use of PLC-controlled discharge conveyors with a Self-Controlled Sheetfeed Optical Recognition Scanner, which modifies order selection forms to barcode or OCR fonts, allowing for efficient item detection and conveyance, reducing energy consumption, and optimizing space usage through modular cubical arrangements and rear loading features, enabling a high-speed order selection process without major software integration changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional order selection methods are used, then system complexity is low, but order selection speed is slow
Solution Approach 1:
The patent replaces manual mechanical order selection with an automated optical recognition system. The scanner reads barcodes on items, and the PLC automatically controls conveyors to deliver items, substituting human mechanical selection with optical-electrical-mechanical automation, thereby increasing speed while managing complexity through standardized components
Solution Approach 2:
The system enables self-service order selection where the optical scanner and PLC control system automatically identify items and control conveyors without human intervention. The system serves itself by using barcode data to automatically trigger the appropriate conveyor sequences, eliminating the need for manual order processing
2Use of energy by moving object
If traditional material handling systems are used, then energy consumption is high, but handling capability is reliable
Solution Approach 1:
The PLC controls conveyors to operate periodically rather than continuously. Conveyors are activated only when specific items need to be delivered based on order requirements, creating intermittent operation cycles that reduce energy consumption while maintaining reliable handling capability when needed
Solution Approach 2:
The system dynamically adjusts conveyor operation based on real-time order requirements. The PLC monitors the order list and activates only the necessary conveyors at the appropriate times, creating a dynamic energy-efficient operation mode that maintains reliability by activating systems only when required
3Productivity
If item-on-demand systems are implemented, then productivity increases, but space requirements increase
Solution Approach 1:
The patent utilizes vertical space by implementing multi-level conveyor systems and stacking items vertically on conveyors. The PLC controls vertical movement and positioning, transforming the space utilization from two-dimensional horizontal layout to three-dimensional vertical arrangement, thereby increasing productivity without proportionally increasing floor space
4Speed
If optical recognition scanning is used as prime mover, then order selection speed increases, but measurement precision requirements increase
Solution Approach 1:
The system prepares items by ensuring barcodes are properly positioned and illuminated before scanning occurs. The conveyor system positions items at optimal scanning angles and distances, and lighting is pre-adjusted for barcode visibility, ensuring high measurement precision is achieved consistently at high speeds without requiring complex real-time adjustments
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
This solution significantly increases productivity by enabling high-speed order selection, efficiently handling various item sizes, minimizing energy usage, and optimizing space, while reducing the need for extensive software integration, thus enhancing profitability and operational efficiency.
Implementation Method 1
Self-Controlled Sheetfeed Optical Recognition Scanner, which modifies order selection forms to barcode or OCR fonts, allowing for efficient item detection
Implementation Method 2
PLC controlled discharge conveyors utilizing a specifically designed Self Controlled Sheetfeed Optical Recognition Scanner as a prime mover discharges an item or items for conveyance to a packing area
Data Source
AI summary
An order selection process is provided for the selecting of a plurality of a predetermined item or items from a stocked picking location in an order selection system.