Automated Gantry for Elongated Elements Order Preparation
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Solution Overview
Problem
Existing automated order preparation systems for elongated elements lack remote control capabilities for efficient manipulation and preparation of orders, leading to inefficiencies and increased manual labor due to the weight and size of the elements.
Innovation Solution
An automated system featuring a gantry with lift platform, hoists, and control panels for remote operation, allowing for simultaneous preparation of multiple orders with enhanced safety features such as anti-slip surfaces, fall protection, and volumetric sensors, enabling one operative to manage the system safely and efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling methods are used for elongated elements, then operational flexibility is maintained, but labor intensity and safety risks increase due to the weight and size of the elements
Solution Approach 1:
The patent replaces manual mechanical handling with an automated gantry system equipped with hoists and robotic manipulation devices. The gantry can automatically extract, transport, and position elongated elements (such as pipes or beams) without direct human contact, thereby maintaining operational flexibility while eliminating safety risks associated with manual handling of heavy and bulky materials.
2Device complexity
If sequential order preparation is used, then simple system structure is maintained, but productivity decreases due to time-consuming sequential processing
Solution Approach 1:
The patent segments the order preparation process into multiple independent working zones along the gantry system. Each zone can prepare different orders simultaneously, with the gantry able to service multiple storage locations and delivery points in parallel. This segmentation transforms sequential processing into concurrent operations, significantly improving productivity while maintaining a relatively simple modular system structure.
Solution Approach 2:
The patent introduces a spatial dimension to order preparation by arranging storage racks and working zones in three-dimensional space along the gantry's path. Multiple orders can be prepared at different heights and locations simultaneously, utilizing vertical and horizontal space efficiently. This dimensional approach allows parallel processing of multiple orders without requiring complex sequential coordination.
3Extent of automation
If remote control capabilities are added to the system, then automation level and safety improve, but device complexity increases
Solution Approach 1:
The patent introduces a centralized control system that acts as an intermediary between operators and the gantry mechanism. This control system receives commands, processes them through a coordinated control algorithm, and executes them via the gantry's drive and hoisting mechanisms. The intermediary control layer simplifies the interface for operators while managing the complexity of coordinating multiple gantry functions (movement, lifting, positioning) remotely.
Data Source
AI summary
Automated order preparation system for elongated elements which comprises: a moveable gantry (7) on guide tracks (13) mounted on the floor, an lift platform (1) secured on the moveable gantry and which can be lifted and lowered, a control panel (4) from which the longitudinal movements of the gantry (7) are made and the lifting and lowering of the platform, an unloading table (8) or fixed structure onto which the material is evacuated from the lift platform. Thanks to the system an automated order preparation system for elongated elements is achieved which can require the control of only one operative from a control panel and all executed with all possible safety means.