Loading Carrier Stacking Rows for High-Speed Unit Placement
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Solution Overview
Problem
Existing methods for loading a load carrier with loading units are time-consuming and inefficient due to the sequential placement of units, which limits throughput and loading performance.
Innovation Solution
The method involves forming stacking rows based on the dimensions of loading units, with units being sorted and placed in a single loading cycle using a positioning conveyor, allowing for simultaneous delivery and placement of multiple units in a single level, and utilizing an allocation conveyor to maintain continuous supply and increase loading speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If loading units are conveyed individually and placed one after another on the load carrier, then the loading configuration can be optimized for stability and volume utilization, but the loading process becomes very time-consuming and loading performance is limited
Solution Approach 1:
The loading process is segmented into distinct phases: a fast conveyance phase where stacking rows are transported quickly to loading positions, and a controlled placement phase where units are positioned for stability. This segmentation allows different parts of the system to optimize for different objectives simultaneously.
Solution Approach 2:
Loading units are pre-grouped into stacking rows based on their dimensions and compatibility before conveyance. This preliminary organization enables faster conveyance and automatic sorting, as units within each row are already configured to work together, reducing on-the-fly adjustment time.
2Manufacturing precision
If loading units are conveyed individually to loading positions, then precise positioning can be achieved, but the number of adjustment movements increases and loading speed decreases
Solution Approach 1:
Multiple loading units are merged into stacking rows that are conveyed and positioned together as a group. The positioning conveyor conveys entire stacking rows to loading positions in a single operation, then places them simultaneously or in rapid succession, reducing the total number of adjustment movements compared to individual unit positioning.
Solution Approach 2:
The automatic sorting device automatically sorts and organizes loading units into dimension classes and stacking rows without manual intervention. This self-organizing capability ensures that units are pre-configured for optimal stacking, enabling faster conveyance and placement while maintaining precise positioning requirements.
3Manufacturing precision
If the positioning conveyor is moved back after each loading unit placement, then individual units can be accurately positioned, but the loading cycle time increases
Solution Approach 1:
The positioning conveyor conveys multiple loading units or entire stacking rows to loading positions in a single forward movement, eliminating the need to return after each individual placement. The conveyor moves forward, positions multiple units, and then returns once, significantly reducing cycle time while maintaining positioning accuracy through the grouped placement approach.
Data Source
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AI summary
The invention relates to a method for loading a load carrier (2) with loading units (4) forming a loading stack, in which a computer registers an order-picking job and determines a spatial loading configuration of the loading units (4) for the loading stack and in which at least some of these loading units (4) are conveyed in groups by means of a positioning and conveying device (16) to the loading positions (95) determined by the loading configuration. After the order-picking job has been registered, dimensions of at least some of the loading units (4) are compared with one another by the computer. On the basis of their dimensions, the loading units (4) are allocated to dimension classes and, in accordance with the dimension classes and the loading configuration, they are sorted into a loading sequence and conveyed in groups as stack rows (91) to the loading positions (95) by means of the positioning and conveying device (16).