Automated Feed Conveyor System for Picking Station
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Solution Overview
Problem
The existing picking stations for automatic picking and packaging are inefficient due to manual feeding of packaging machines, leading to slow operations.
Innovation Solution
An improved picking station with an automated feed conveyor system, automated reloading devices, and unloading devices that facilitate the efficient feeding and unloading of articles into dispatch packages, allowing for fully automated processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual feeding of packaging machine is used, then device complexity is reduced, but productivity decreases and loss of time increases
Solution Approach 1:
The feed conveyor system is divided into multiple bottom shelves (first bottom shelf, second bottom shelf) with individual closable bottom openings. Each shelf can be independently controlled to release articles one at a time or in stacks, enabling segmented processing that increases productivity while maintaining manageable system complexity through modular design
Solution Approach 2:
Articles are pre-positioned on the bottom shelves before the packaging process begins. The first bottom shelf holds articles that fall individually onto the second bottom shelf, which then presents ready-formed stacks to the packaging machine. This preliminary arrangement eliminates manual feeding time and significantly boosts productivity
2Productivity
If automated feed conveyor system with multiple bottom shelves is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
Multiple bottom shelves are vertically stacked and integrated into a single feed conveyor system. The first bottom shelf and second bottom shelf work together in sequence - the first releases articles that accumulate on the second, forming stacks that are then presented to the packaging machine. This merging of multiple shelves into one coordinated system increases article feeding efficiency while consolidating control mechanisms
Solution Approach 2:
The feed conveyor system employs a nested structure where the first bottom shelf is positioned above and feeds into the second bottom shelf. Articles fall from the first shelf into the second, creating a nested flow path that maximizes vertical space utilization and enables continuous automated feeding without requiring extensive horizontal expansion
3Loss of time
If automated reloading device is added, then loss of time decreases, but device complexity increases
Solution Approach 1:
The automated reloading device pre-positions articles onto the bottom shelves before they are needed by the packaging machine. By anticipating the need for articles and preparing them in advance on the first and second bottom shelves, the system eliminates supply interruptions and minimizes loss of time, while the reloading device integrates seamlessly with the existing conveyor structure
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
The solution significantly enhances the efficiency and speed of the picking and packaging process, enabling fully automated supply, picking, packaging, and transportation of articles, improving overall operational efficiency.
Implementation Method 1
a first bottom opening arranged in the first bottom shelf is opened for one article at a time, the article falls through the first bottom opening
Implementation Method 2
a second bottom opening in the second bottom shelf is opening after a stack has been formed, and the article stack is conveyed, by the feed conveyor system
Data Source
AI summary
A picking station (19) as well as a storage and order-picking system (1) for automatic picking and automatic packaging of articles (10a . . . 10p) is specified. An automated packaging machine (25) and a goods-out conveyor system (20) as well as different types of picking zones (24a . . . 24f), in which the articles (10a . . . 10p) for an order are picked and prepared for the packaging process, are included thereby. In particular, the articles (10a . . . 10p) are stacked on top of each other to form an article stack (41) and are subsequently discharged onto an automated feed conveyor system (26) leading to the automated packaging machine (25) or directly into the automated packaging machine (25). Moreover, a method for operating the picking station (19) described and/or the storage and order-picking system (1) described is specified.