Heterogeneous Palletization With Partial Layers
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Solution Overview
Problem
Existing methods for palletizing articles of varying dimensions are inefficient, resulting in layouts with a low number of placed objects and stability issues due to the complexity of layer dimensions and the restrictive nature of traditional layered solutions.
Innovation Solution
A palletization process that generates a stable arrangement of articles by forming complete and partial layers of articles with similar heights, using a computer-controlled loading device to optimize the placement on a container, thereby maximizing the number of articles placed and enhancing stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional layered solutions with interchangeable layers of the same dimensions are used, then the arrangement is simple to design, but the number of articles placed is reduced due to restrictiveness
Solution Approach 1:
The patent segments the container surface into multiple zones, each capable of receiving different types of layers (complete layers, partial layers, mixed layers). This segmentation allows the system to move away from uniform interchangeable layers to customized layer configurations in different zones, thereby increasing the number of articles placed while maintaining design simplicity through systematic zone management.
Solution Approach 2:
The patent introduces dynamic layer configurations where layers can vary in dimensions and composition across different zones of the container. Instead of static uniform layers, the system dynamically adapts layer parameters (width, length, article composition) to match the specific characteristics of each zone and the available article inventory, maximizing space utilization.
2Quantity of substance
If layers of any dimensions are placed without precise rules, then the number of articles placed increases, but the stability of the arrangement deteriorates
Solution Approach 1:
The patent applies local quality by assigning different stability requirements and layer configurations to different zones of the container. Certain zones are designated for complete layers with high stability requirements, while other zones can accommodate partial layers with more flexible configurations. This localized approach allows the system to maximize article placement in flexible zones while maintaining overall stability through stable zone configurations.
Solution Approach 2:
The patent introduces spacer elements as intermediaries between layers to enhance stability. These spacers act as mediators that provide structural support and distribute loads across the arrangement, enabling the system to achieve higher article density while maintaining stability. The spacers are strategically placed at critical locations where stability is most needed.
3Stability of the object's composition
If complete layers occupying entire surface area are used, then stability is enhanced, but the volume loss increases due to inability to place small quantity articles
Solution Approach 1:
The patent employs partial layers that occupy only a portion of the container surface area rather than requiring complete layers. This partial action principle allows the system to place articles in zones where they fit efficiently without forcing complete layer formation, thereby reducing volume loss. Partial layers can be combined with complete layers in a hybrid approach that optimizes both stability and space utilization.
4Adaptability or versatility
If heterogeneous articles of variable dimensions are placed, then adaptability increases, but the complexity of layer design increases
Solution Approach 1:
The patent implements a self-service approach where the system automatically determines optimal layer configurations based on article dimensions and container zones. The control system autonomously calculates layer parameters, assigns articles to appropriate zones, and generates placement instructions without requiring complex manual design intervention. This automation handles the complexity of heterogeneous article arrangement while maintaining adaptability.
Data Source
AI summary
A palletisation method, wherein: articles (i) are transported towards a loading point, the articles (i) are loaded by a loading device onto a container arranged in the loading station, the loading device being controlled by a computer control device, the method further including generating a stable arrangement of the articles (i) on the container upstream of their loading, the stable arrangement includes placing articles having substantially similar heights to form layers, wherein a partial layer having a first height occupies part of the container and at least one complementary partial layer having a second height occupies a second unoccupied part such that the entire surface area of the container is occupied.