Dynamic Vertical Module Transfer for Palletizing Throughput
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Solution Overview
Problem
Existing palletizing methods face inefficiencies due to the need for stationary support surfaces during layer transfer, leading to reduced throughput and increased time loss from potential collisions during vertical movement.
Innovation Solution
A method involving a first module with a stationary vertical position and a second module that can be vertically moved, along with a horizontal conveyor for transferring article layers, allowing for simultaneous vertical movement of both modules to achieve a common transfer position, thereby avoiding collisions and enhancing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support surfaces are kept stationary during layer transfer, then collision risks are reduced, but throughput and efficiency decrease due to waiting time and inability to perform simultaneous movements
Solution Approach 1:
The patent makes the support surfaces dynamic by enabling vertical movement of both the first support surface (grouping station) and the second support surface (loading station). This allows both surfaces to move vertically relative to each other to achieve a common transfer position, eliminating the need for stationary support surfaces and enabling simultaneous transfer and positioning operations.
Solution Approach 2:
The patent introduces a horizontal conveyor as an intermediary device between the two vertically moving support surfaces. This conveyor facilitates the actual layer transfer while the support surfaces perform vertical positioning movements, allowing independent optimization of transfer and positioning functions without collision risks.
2Device complexity
If a single stationary loading station is used, then device complexity is reduced, but time loss increases due to sequential operations and inability to pre-position
Solution Approach 1:
The loading station is transformed from a stationary structure to a dynamically movable support surface that can change its vertical position. This enables the loading station to move to different heights to receive layers from the grouping station and then move to the palletizing position, allowing overlapping of operations and eliminating waiting time.
Solution Approach 2:
The movable support surface allows preliminary positioning of the loading station at the desired height before the layer transfer begins. This pre-positioning eliminates waiting time during the transfer process, as the loading station is already in the correct position to receive and immediately process the incoming layer.
3Productivity
If support levels are moved apart during discharge, then palletizing efficiency improves, but device complexity increases due to multi-position requirements
Solution Approach 1:
The support levels are designed with dynamic positioning capability, allowing them to move vertically to different positions (apart or together) based on the operational phase. This dynamic behavior enables the support levels to optimize their configuration for each task: apart for efficient discharge and together for compact transfer, without requiring complex fixed multi-position mechanisms.
Data Source
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AI summary
A method for transferring a group of articles and/or article positions (3) from a first support level (11) of a first module (10) to a second support level (22) of a second module (20) is disclosed, the second module (20) being subordinate to the first module (10) in a conveying direction (FR) of the group of articles and/or article positions (3). Within the framework of the method, the first module (10) and the second module (20) are moved vertically relative to each other for a subsequent transfer of a group of articles and/or article positions (3) from the first support level (11) to the second support level (22).In the process, at least one horizontal conveying device (30) is provided between the first support level (11) of the first module (10) and the second support level (22) of the second module (20) in the conveying direction (FR), which transports at least one horizontal conveying device (30) articles of a respective article group and/or article position (3) for transfer from the first support level (11) of the first module (10) to the second support level (22) of the second module (20) in the direction of the second support level (22).