Gravity Transfer Order Picking System for Automated Cargo Grouping

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Solution Overview

Problem

Existing order picking systems are inefficient in handling and packaging diverse general cargo, particularly in the business-to-customer (B2C) sector, as they require manual labor to pack goods in suitable containers, which is labor-intensive and time-consuming.

Innovation Solution

An order picking system featuring a horizontally movable transfer element and a suspension conveyor system that groups general cargo by gravity onto a conveyor, allowing for synchronized and aligned transfer to a grouping space, followed by automated packaging using a transfer device and alignment module, enabling efficient formation of commissioning groups for direct packaging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual labor is used to pack goods in suitable containers, then flexibility in handling diverse general cargo is maintained, but labor intensity and time consumption increase significantly

Engineering Contradiction:

ImproveFlexibility in handling diverse cargoVSAvoidPackaging efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system uses gravity as a natural force to automatically transfer and group goods from the suspension conveyor to the packaging area, eliminating the need for manual intervention in the transfer process. The goods self-guide along the gravity transfer path and self-group in the designated areas, achieving automated operation while maintaining flexibility for diverse cargo types

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The gravity transfer system serves multiple functions: it transfers goods from the suspension conveyor, groups them by destination, and positions them for packaging. This multi-functional design handles diverse general cargo (parcels, boxes, books, magazines, clothing) through a single unified system, improving both productivity and flexibility

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If automated grouping systems are implemented, then productivity and packaging efficiency improve, but system complexity increases

Engineering Contradiction:

ImprovePackaging efficiencyVSAvoidSystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system replaces complex mechanical transfer mechanisms (motors, belts, rollers) with a gravity-based transfer system. Goods are transferred passively along gravity-fed paths from the suspension conveyor to grouping areas, eliminating the need for active mechanical propulsion while achieving automated grouping and positioning

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The gravity transfer path acts as an intermediary between the suspension conveyor and the packaging area. Instead of directly coupling complex mechanical systems, the gravity transfer mechanism mediates the transfer process, simplifying the overall system architecture while maintaining high productivity

Inventive Principle:

Principle #24Intermediary (Mediator)

3Extent of automation

If gravity-driven transfer is used, then energy consumption is reduced and automation is improved, but control precision over cargo positioning may deteriorate

Engineering Contradiction:

ImproveAutomation levelVSAvoidCargo positioning precision

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The system performs preliminary grouping and positioning of goods during the gravity transfer process itself. By designing the gravity transfer path with specific slopes, curves, and stopping zones, the system pre-positions goods in designated grouping areas before packaging begins, ensuring precise positioning without requiring active control during the transfer phase

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The suspension conveyor operates in periodic cycles, delivering goods to the gravity transfer system at regular intervals. This periodic input, combined with the gravity transfer mechanism, creates predictable positioning patterns that ensure precise cargo placement in grouping areas while maintaining high automation levels

Inventive Principle:

Principle #19Periodic action

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

This system significantly reduces labor intensity and shipping costs by automating the grouping and packaging process, ensuring efficient preparation and dispatch of varied goods with minimal manual intervention.

Implementation Method 1

a transfer device with a horizontally movable transfer element, by means of which general cargo conveyed one after the other can be gravity-driven grouped to a grouping space

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS20240311753A1Order picking system

Publication Date: 2024.09.19 FERAG AG

AI summary

An order picking system (1) for transporting and providing general cargo (S, S′) and associated method includes a feeding device (2) with a suspension conveyor (21) for feeding the general cargo (S, S′), and a delivery station (22) for delivering the general cargo (S, S′) from the suspension conveyor (2.1) to a transfer device (3) for grouping the conveyed general cargo (S, S′), which transfer device (3) includes a horizontally movable transfer element (31) by which the general cargo (S, S′) can be grouped gravity-driven onto a grouping space (P).