Dual-Zone Palletizing Layout With Movable Safety Wall
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Solution Overview
Problem
Existing palletization facilities require operators to stop the workstation when accessing finished pallets, leading to production losses due to the need for complete enclosure or sensor-based slowdowns.
Innovation Solution
A movable separating wall alternately isolates depositing zones from the workstation, allowing operators to safely access one zone while the workstation continues operating in the other, using a robot with gripping means and detection systems to manage the wall's movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed enclosure with doors is used to secure the facility, then operator safety is improved, but production stops when operators need to access finished pallets
Solution Approach 1:
The facility is divided into multiple depositing zones (first and second zones) that can be independently accessed. The separating wall divides the enclosure into separate sections, allowing operators to access one zone while the robot works in another zone, thus maintaining production continuity while ensuring operator safety.
Solution Approach 2:
The separating wall is made movable between different positions (first position and second position) rather than being fixed. This dynamic element allows the facility to transition between different operational modes: when the wall is in the first position, the first zone is secured; when moved to the second position, the second zone is secured. This enables continuous operation while maintaining safety.
2Reliability
If the workstation is stopped to allow operator access, then operator safety is ensured, but production losses occur
Solution Approach 1:
The robot completes palletizing in the first depositing zone before the separating wall moves to secure it. This preliminary completion of work in one zone allows the operator to safely access and remove the finished pallet without interrupting the robot's ongoing work in the second zone, eliminating production downtime.
Solution Approach 2:
The system is designed to maintain continuous productive action by having the robot alternately work in two depositing zones. While the operator accesses one zone to remove finished pallets, the robot continues palletizing in the other zone, ensuring that the useful action of palletizing never stops.
3Reliability
If sensors are used to detect operators and slow down the robot, then operator safety is improved, but productivity decreases due to slowdowns
Solution Approach 1:
Instead of using sensors to slow down the entire workspace, the facility is segmented into separate depositing zones with a physical separating wall. This allows the robot to maintain full speed in the active zone while the operator safely accesses the secured zone, eliminating the need for speed reduction and maintaining high productivity.
Data Source
AI summary
Described is a facility for palletising products and a method for palletising products. The facility has a pick area for picking up the products, and two place areas for placing products on pallets. The facility includes a work station situated between the two place areas and the facility includes a separating wall that moves between a first position between the work station and the first place area, and a second position between the work station and the second place area, so as to alternately separate one of the two place areas from the work station.