Hybrid Palletizer with Compaction and Concurrent Wrapping
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Solution Overview
Problem
Current palletizing technologies are limited by slow throughput speeds, complex mechanisms, and the need for precise item placement, which restricts the ability to queue multiple layers during wrapping operations, leading to inefficiencies in load building and increased machine complexity.
Innovation Solution
A hybrid palletizer system with an oversized layer assembly platform that allows items to be roughly positioned and then compacted, combined with a pick-and-place device that provides both bottom support and a pinch-like grip, enabling faster movement and concurrent wrapping, while reducing the number of layer deposit cycles by stacking multiple layers at once.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional pick and place palletizing methods are used with precise item placement, then manufacturing precision is improved, but productivity deteriorates due to slow throughput speeds
Solution Approach 1:
The palletizing process is divided into two independent stages: rough positioning on an oversized layer assembly platform followed by compaction to final dimensions. This segmentation allows the robotic pick-and-place device to operate at high speeds without precision constraints, while the compaction mechanism handles the precision requirement separately, thereby resolving the contradiction between speed and precision.
Solution Approach 2:
An oversized layer assembly platform serves as an intermediary between the pick-and-place device and the final pallet load. This intermediate platform provides the necessary clearance for bottom support devices and allows rough positioning, while the compaction mechanism acts as a mediator to transform the loosely assembled layer into a tightly packed final configuration, enabling both high-speed operation and precise final placement.
2Manufacturing precision
If complex mechanisms are used for layer assembly and deposit, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The precision requirement is extracted from the pick-and-place operation and transferred to a dedicated compaction mechanism. The layer assembly platform is simplified to only provide support and positioning clearance, while the compaction mechanism separately handles the precision-packed final configuration, reducing overall system complexity while maintaining precision.
Solution Approach 2:
The compaction mechanism performs self-service by automatically transforming the loosely assembled layer into a tightly packed configuration without requiring complex coordination with the pick-and-place device. The system uses the natural deformation capability of the items during compaction to achieve precise final positioning, simplifying the overall control system.
3Productivity
If bottom support gripping devices are used for fast movement, then productivity is improved, but manufacturing precision deteriorates due to clearance requirements
Solution Approach 1:
The gripping function is segmented into bottom support for high-speed transport and a separate compaction mechanism for precise final placement. The bottom support device provides fast and secure gripping during movement, while the compaction mechanism handles the precision requirement by deforming items into tight configuration, allowing both high speed and precision to coexist.
Solution Approach 2:
Preliminary rough positioning is performed during high-speed transport using bottom support gripping, followed by preliminary compaction to achieve final precise placement. This preliminary action at high speed is followed by a secondary precision-adjustment phase, allowing the system to maintain both speed and accuracy.
4Manufacturing precision
If multiple layer deposit cycles are required, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
Multiple layer deposit operations are merged into a single compaction operation. The oversized layer assembly platform accumulates multiple layers or partial layers, and a single compaction action transforms the entire accumulated configuration into the final precise pallet load, eliminating multiple separate deposit cycles and reducing operational time.
Solution Approach 2:
The compaction mechanism maintains continuous useful action by processing multiple layers in a single operational cycle. Instead of interrupting the process for multiple deposit and repositioning cycles, the system continuously builds up layers on the oversized platform and then performs a single continuous compaction to achieve the final configuration, maximizing productive time.
Data Source
AI summary
The present invention relates to compact palletizers that include a stretch-wrap operation as the pallet is built. A four-sided compaction mechanism compresses the rough-built load to the final pallet size and then the entire layer is released to the pallet. Individual items or group of items are picked and placed onto a layer support device in a loose orientation. The loose orientation enables a much faster palletizing operation because the robotic arm that pick-and-places the item, the items, or the row of items, can travel much faster as it does not have to precisely locate the item, items, or row of items. During the time that a layer is being loosely constructed on the layer support device concurrent wrapping can occur.