Directed Palletization Using LED Visual Guidance
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Solution Overview
Problem
Manual palletization in logistics networks is time-consuming, cumbersome, and prone to operator error, leading to increased ergonomic stress and inefficiencies in sorting and routing of packages.
Innovation Solution
A directed palletization system using lights and sensors to guide operators, reducing the need for manual scanning and movement by illuminating LEDs to indicate the correct scanner and destination for each package, thereby streamlining the palletization process and improving operator workload and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual palletization is used, then operators can handle packages flexibly, but the process becomes time-consuming and prone to operator error
Solution Approach 1:
The patent replaces manual mechanical operations with an optical guidance system. LED lights provide visual cues to operators, substituting human decision-making with optical signaling. This reduces operator error while maintaining manual dexterity, directly addressing the contradiction between speed and accuracy in palletization.
Solution Approach 2:
The patent introduces LED lights as an intermediary between the control system and the operator. The lights serve as a visual mediator that translates package destination data into intuitive spatial guidance, enabling faster and more accurate package placement without requiring operators to manually scan or search for destinations.
2Productivity
If manual scanning and movement are required, then package tracking is possible, but operator workload increases and throughput decreases
Solution Approach 1:
The system enables packages to effectively guide themselves to their destination through the optical guidance system. The LED lights provide self-service navigation cues that reduce the need for operator intervention in tracking and movement decisions, thereby increasing throughput while decreasing operator workload.
Solution Approach 2:
The patent extracts the scanning and tracking functions from the operator's task portfolio and transfers them to the optical guidance system. By removing these cognitive and manual tasks from operator responsibilities, the system increases ease of operation while maintaining package tracking capability through the LED indicators.
3Reliability
If visual guidance is provided, then operator accuracy improves, but system complexity increases
Solution Approach 1:
The patent applies local quality by providing targeted visual guidance only at specific locations where packages need direction. Rather than a comprehensive complex control system, LED lights are strategically placed to provide localized accuracy enhancement, improving sorting precision while minimizing overall system complexity.
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 reduces manual effort and time spent on palletization, decreases the likelihood of mis-picked packages, and enhances the efficiency of package sorting and routing by providing clear visual guidance and intelligent assignment of packages to operators based on load balancing metrics.
Implementation Method 1
cause a first light emitting diode (LED) to emit light having a first color and cause a second LED to emit light having a second color
Data Source
AI summary
Systems, methods, and computer-readable media are disclosed for directed palletization using lights. In one embodiment, an example system may include a conveyor configured to support packages, a first set of LEDs disposed along a first side of the conveyor, the first set of LEDs having a first LED, a second set of LEDs disposed adjacent to the first set of LEDs, the second set of LEDs having a second LED, and a first sensor configured to identify packages. The system may include a second sensor disposed on the first side of the conveyor, and a third sensor disposed on the first side of the conveyor. A first color of the first LED may indicate the first package is to be scanned at the second sensor, and a second color of the second LED may indicate the second package is to be scanned at the third sensor.