Automated Crane Coil Stacking with Dunnage Boards
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Solution Overview
Problem
Current methods lack an efficient and automated system for storing coils of varying widths and diameters in a warehouse, leading to suboptimal space utilization and potential damage during transportation and storage.
Innovation Solution
An automated overhead crane system that arranges coils in lines with parallel axes, using a method involving associating, defining, and placing coils within predetermined ranges to create zones for efficient stacking, with the crane autonomously placing coils to maximize speed while minimizing damage, and a facility with a database and computing system for precise coil identification and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If coils are stored in stacks two or more high to maximize space utilization, then warehouse space efficiency is improved, but the risk of coil damage and bridging increases
Solution Approach 1:
The patent introduces dunnage boards as intermediary elements placed between coils in vertical stacks. These wooden boards act as mediators that distribute the weight of upper coils evenly across lower coils, preventing direct contact points that cause bridging and damage. This allows safe stacking of coils two or more high while maintaining space efficiency.
Solution Approach 2:
The patent applies prior cushioning by placing protective dunnage boards between coils before stacking them vertically. This preventive measure cushions the lower coils from the weight and potential damage of upper coils, eliminating the need to store coils individually on the ground while protecting against bridging and deformation.
2Adaptability or versatility
If manual methods are used to store and retrieve coils, then flexibility in handling varying coil dimensions is maintained, but productivity and labor efficiency deteriorate
Solution Approach 1:
The patent implements parameter changes by using a computer vision system that dynamically adapts to varying coil parameters (dimensions, weight, position). The system captures images, processes them to determine coil characteristics, and automatically adjusts crane positioning and lifting parameters accordingly. This enables automated handling of coils with varying dimensions while maintaining the flexibility to accommodate different sizes and shapes.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated system combining computer vision, computational processing, and automated crane control. Instead of workers manually assessing and positioning coils, the system uses image capture, processing, and automated positioning to achieve faster, more consistent storage and retrieval operations.
3Productivity
If automated overhead crane systems are implemented, then productivity and consistency in coil handling are improved, but the complexity of the storage system increases
Solution Approach 1:
The patent applies self-service by enabling the automated crane system to independently assess coil dimensions, calculate optimal storage positions, and execute placement operations without continuous human intervention. The computer vision system automatically captures images, processes them to determine coil parameters, and controls the crane's movements, making the system self-sufficient while maintaining high productivity.
Solution Approach 2:
The patent implements feedback through the computer vision system that continuously monitors coil positions, dimensions, and storage arrangement. The system captures images, processes them to verify correct placement, and can adjust subsequent operations based on observed conditions, ensuring consistent and accurate automated handling while managing system complexity through intelligent control.
4Area of stationary object
If coils are arranged in dense stacks to maximize space, then warehouse capacity is improved, but the difficulty of retrieving specific coils increases
Solution Approach 1:
The patent applies preliminary action by maintaining and utilizing a database that records the precise location, dimensions, and identification of each stored coil. Before retrieval operations begin, the system queries this database to determine the optimal sequence and method for accessing the required coil, even within dense multi-layer stacks. This preliminary planning enables efficient retrieval from compact arrangements.
Solution Approach 2:
The patent uses dunnage boards as intermediaries that not only protect coils during stacking but also create accessible layers within the stack structure. These boards provide reference points and physical access pathways that facilitate the identification and retrieval of specific coils from dense multi-layer arrangements, reducing retrieval difficulty while maintaining high storage density.
Data Source
AI summary
An arrangement of coils of varying widths and diameters in a warehouse having an automated crane wherein: the coil axes are parallel; the coils are arranged in lines, the coil widths in each line falling within a first predetermined range associated with the line, the coil diameters in each line falling within a second predetermined range associated with the line and the coil axes in each line being orientated perpendicularly to said each line; the lines define (i) rows of coils; (ii) a bottom layer of coils; and (iii) one or more upper layers of coils; each upper layer coil is supported by a pair of lower layer coils in a line; the first and second predetermined ranges associated with the line in which said each coil is arranged are the same as those associated with the line in which the supporting coils are arranged.