Independent Pusher and Plate Mechanism for Mixed-Case Pallet Stacking
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Solution Overview
Problem
Current automatic stacking systems struggle with efficiently stacking packages of varying sizes and dimensions onto supports like pallets without manual intervention, as they often require complex and time-consuming processes, limited accessibility, and can only handle one package at a time, leading to instability and inefficiency in mixed-case palletization.
Innovation Solution
A device featuring a supply conveyor, lifting and lowering unit, and a displacement system with a positioning conveyor, pushing plates, and pushers that allow for independent movement in the Z direction, enabling packages to be positioned and stacked simultaneously or with minimal time-offset, facilitating flexible and high-throughput mixed-case stacking by using a modular pusher-pushing plates unit and optional film wrapping for stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single pusher and loading tongue are used to stack packages, then the device structure is simple, but only one package can be processed at a time and the stacking speed is limited
Solution Approach 1:
The single pusher is divided into multiple independent pushers (first pusher, second pusher, third pusher, fourth pusher) that can operate simultaneously. Each pusher is responsible for pushing packages to specific positions, enabling parallel processing of multiple packages and significantly increasing stacking productivity without requiring a completely new system design.
Solution Approach 2:
The loading tongue is combined with multiple pushing plates (first, second, third, fourth pushing plates) that can move independently. This merging allows the system to handle multiple packages simultaneously while maintaining a unified structural approach, balancing complexity increase with productivity gains.
2Ease of operation
If packages are displaced along the broad side of the pallet using a pusher, then the stacking process is simplified, but the displacement is time-consuming and accessibility is limited
Solution Approach 1:
The displacement function is segmented into multiple parallel pushers that can operate simultaneously at different positions along the pallet. This segmentation reduces the total displacement time by processing multiple packages in parallel while maintaining the simplicity of the pusher mechanism itself.
Solution Approach 2:
The system transitions from sequential displacement along a single path to parallel displacement across multiple dimensions. The pushers operate simultaneously at different locations, effectively utilizing spatial distribution to reduce overall processing time while keeping each individual pusher operation simple.
3Productivity
If the loading tongue and stripper pusher travel simultaneously in the X direction, then the stacking process is efficient, but the coordination complexity increases
Solution Approach 1:
The simultaneous travel function is segmented across multiple independent pushers and pushing plates. Each component can be controlled independently to travel to its designated position, allowing parallel operations without requiring complex coordination between all components simultaneously.
Solution Approach 2:
Each pusher and pushing plate has its own specific function and movement trajectory tailored to its local position. This local quality approach allows simultaneous operation of multiple components without requiring centralized coordination, as each component operates autonomously according to its predetermined role.
4Adaptability or versatility
If packages of different sizes are stacked automatically, then mixed-case palletization is achieved, but the requirements for stack stability and packing density greatly increase complexity
Solution Approach 1:
The stacking system is segmented into multiple independent pushers that can handle packages of different sizes at different positions. This segmentation allows the system to accommodate varied package dimensions without requiring a single complex coordination mechanism, as each pusher can be optimized for its specific local requirements.
Solution Approach 2:
The system employs dynamic positioning and independent movement of multiple pushers to adapt to packages of different sizes. The pushers can adjust their positions and movements based on the specific package dimensions being handled, providing flexibility for mixed-case stacking without requiring rigid predetermined configurations.
Data Source
AI summary
Device for automatic stacking of packages on a support in a predetermined spatial arrangement for formation of a stack, having at least one supply conveyor which provides the separated packages (W) in a predetermined succession, a lifting and lowering unit for lifting and lowering a support disposed in a stacking site in the Y direction and a displacement device which adjoin an output end of the supply conveyor and which receive packages (W) from the supply conveyor (2) and transport them to the predetermined position in the stack (S). The displacement device includes a positioning conveyor adjoining the output end of the supply conveyor and being disposed horizontally and longitudinally with respect to one side of the stacking site in order to position the packages (W) in the X direction, and at least one pushing plate and a pusher (14) in order to transport the packages (W) from the positioning conveyor in the Z direction to the predetermined position in the stack (S). The at least one pushing plate is formed as a flat strip-like plate, formed to be able to move horizontally and along the side of the stacking site and transverse thereto, in order to receive the packages (W) as the packages (W) are being pushed by the pusher off the positioning conveyor at the X direction position and to lay them in the Z direction on the support or in the stack (S). The pusher is formed as an arrangement of a plurality of individual pushers disposed horizontally and along the side of the stacking site, which push the packages (W) off the positioning conveyor in the direction of the stack (S), wherein the individual pushers can each move independently of the at least one pushing plate in the Z direction in order to retain the package (W) when the pushing plate is being withdrawn.