Horizontal Motorized Dynamic System for Pallet Racks
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Solution Overview
Problem
Existing pallet-carrier racks face limitations in length and height due to gravity-based systems, leading to wasted space, inaccuracy in pallet movement, and high operational complexity, along with economic unfeasibility and inability to control pallets individually.
Innovation Solution
A horizontal motorized dynamic system with motorized pulleys or conveyor rollers controlled by electronic boards for each pallet position, allowing precise movement and elimination of gravity-based issues, enabling efficient and versatile pallet handling without the need for sensors or complex motor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gravity-based conveyor tracks with slope are used, then pallet movement is enabled, but space is lost and storage levels are wasted
Solution Approach 1:
The patent replaces the gravity-based mechanical system with an electric motorized system. Each roller is equipped with an independent motor that can be controlled to move pallets horizontally without requiring a slope, thereby eliminating the space loss associated with gravity-based systems while maintaining efficient pallet movement capability
Solution Approach 2:
The conveyor system is divided into multiple independently controlled roller segments. Each roller can be individually actuated by its own motor, allowing precise control over pallet movement. This segmentation enables the system to move pallets without requiring a continuous slope, thus preserving storage space while maintaining operational ease
2Ease of operation
If gravity-based rollers are used for pallet movement, then pallets can move along the track, but reliability and accuracy are harmed due to influence from humidity, pallet quality, and load variation
Solution Approach 1:
The patent replaces the passive gravity-based mechanical system with an active electric motorized system. Each roller's motor can be precisely controlled to compensate for variations in pallet quality, load weight, and environmental conditions, ensuring reliable and accurate pallet arrival at the destination regardless of these influencing factors
Solution Approach 2:
The system incorporates sensors that detect the presence and position of pallets on the conveyor track. This feedback information is used by the control system to adjust the rotation of individual rollers, ensuring accurate pallet movement and arrival even when pallet characteristics or load conditions vary
3Extent of automation
If sensors and transmission belts between rollers are used, then motorized control is achieved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the complex transmission belt system from between rollers. Instead of using belts to transmit power from one roller to another, each roller is equipped with its own independent motor, simplifying the overall system structure while maintaining full motorized control capability
Solution Approach 2:
Each roller is equipped with its own independent motor, making it self-sufficient and eliminating the need for complex inter-roller transmission systems. This self-service approach reduces device complexity while maintaining automation, as each component operates independently without requiring sophisticated coordination mechanisms
4Reliability
If individual motorized rollers with independent control are implemented, then pallet capacity and accuracy increase, but manufacturing and assembly complexity increases
Solution Approach 1:
The system is divided into modular roller units, each with its own motor and control capabilities. This segmentation allows for standardized manufacturing of individual modules that can be easily assembled and replaced, reducing the overall manufacturing and assembly complexity despite the sophisticated functionality of each unit
Solution Approach 2:
The patent employs universal motorized roller modules that can be used in various positions and configurations within the conveyor system. This universality simplifies manufacturing by standardizing components and eases assembly by allowing interchangeable modules, thereby reducing complexity while maintaining high pallet handling accuracy through individual control
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 system increases pallet capacity and accuracy, reduces operational complexity, and provides a cost-effective solution with enhanced safety and reliability, allowing for flexible and efficient dynamic pallet racking across various locations and applications.
Implementation Method 1
motorized-driven pulleys or motorized conveyor rollers
Implementation Method 2
rollers have a built-in motor on the inside which enable them to rotate and hence rotate all other non-motorized rollers disposed along the conveyor track
Data Source
AI summary
A horizontal motorized dynamic system for pallet-carrier racks, which allows the formation of a motorized dynamic system as a specific, stand-alone electromechanical structure based on a horizontal conveyor track with motorized pulleys or motorized conveyor rollers controlled by electronic boards for each pallet position. The system is intended for dynamic pallet level racking on selective pallet-carrier racks in order to provide, in an extremely practical, safe and economical manner, complete optimization and excellent performance in the manufacturing, assembly and operating procedures of pallet-carrier racks. This is combined with extraordinary structural performance and high level economy of materials and space, and is based on a motorized dynamic system of high strength, safety and versatility.