Depalletizing Station Multi-Pallet Handling
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Solution Overview
Problem
Existing depalletizing systems require significant manual intervention and space for buffer storage, leading to inefficiencies in supplying packaging devices with outer packaging, especially when space is limited and format changes are necessary.
Innovation Solution
A depalletizing station with a physically demarcated danger area, equipped with manipulators and horizontal conveyor systems, allows for continuous supply of outer packaging by enabling simultaneous handling and switching between multiple pallets, reducing the need for extensive buffer storage and facilitating quick format changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual pallet replacement is performed, then the depalletizer can be operated, but production time is lost during pallet changes and significant manual intervention is required
Solution Approach 1:
The system performs preliminary actions by having multiple pallets pre-positioned in the danger zone before they are needed. The depalletizer can switch between pre-positioned pallets without stopping, as new pallets are already in place and ready for immediate use, eliminating waiting time during pallet changes
Solution Approach 2:
The system ensures continuous operation by maintaining multiple pallets in the danger zone simultaneously. The depalletizer operates continuously on one pallet while another pallet is being prepared or positioned, ensuring no interruption in the depalletizing process and eliminating downtime
2Reliability
If buffer systems are added to ensure sufficient outer packaging supply, then packaging device operation is maintained, but space requirements increase significantly
Solution Approach 1:
The system transitions from horizontal buffer storage to vertical stacking of multiple pallets in the danger zone. By utilizing the vertical dimension and stacking pallets one on top of another, the system achieves reliable supply continuity without requiring additional horizontal buffer storage space
Solution Approach 2:
The danger zone acts as an intermediary space that temporarily holds multiple pallets. This intermediary area allows the system to maintain supply reliability by having backup pallets ready, without requiring dedicated buffer storage space outside the operational zone
3Productivity
If multiple pallets are positioned in the danger zone, then continuous supply is ensured without large buffer spaces, but safety requirements and physical space constraints are increased
Solution Approach 1:
The system extracts and isolates the multiple pallets within a physically demarcated danger zone. By concentrating all pallet storage and manipulation activities within this defined safety boundary, the system can implement targeted safety measures and monitoring without affecting the rest of the facility
Data Source
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AI summary
A depalletizing station (1) for outer packaging is disclosed. The depalletizing station (1) forms a physically delimited danger zone (6) and comprises at least one manipulator (15) arranged within the physically delimited danger zone (6) and at least one horizontal conveyor (20) extending section by section into the physically delimited danger zone (6). The at least one manipulator (15) is designed to remove outer packaging from a pallet (5) and to position the removed outer packaging on a section (26) of the at least one horizontal conveyor (20) extending into the danger zone (6). Furthermore, the danger zone (6) is physically delimited in such a way that at least two pallets (5) with outer packaging stacked on them can be positioned together within the danger zone (6).