Manipulator Layer Formation for Piece Goods Handling
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Solution Overview
Problem
Existing methods for handling and grouping piece goods for layer formation are inefficient, leading to high mechanical loads and errors, and require additional cycles for assembly, which can be detrimental to the goods and increase processing time.
Innovation Solution
A method and device that convey piece goods in closed or clocked formations to a grouping module, where a manipulator rotates and shifts them into a defined layered arrangement, eliminating the need for additional cycle formation modules and reducing mechanical stress, by briefly delaying the transport device and horizontal conveyor to create space for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual items are transferred from a metering belt to a conveyor belt using speed difference and optical sensors, then item transfer is achieved, but the process requires additional control complexity and time
Solution Approach 1:
The patent extracts the control function from complex optical sensor systems and speed difference mechanisms, replacing them with a simplified gravity-based transfer mechanism where items naturally flow from the metering belt to the conveyor belt without active control intervention
Solution Approach 2:
The system allows items to self-transfer between belts using gravity and their own momentum, eliminating the need for external control systems to manage the transfer process
2Manufacturing precision
If the layering belt is moved in synchronized steps with the conveyor belt to transfer items, then item positioning is improved, but the mechanical stress on items increases due to abrupt speed and direction changes
Solution Approach 1:
The patent implements a periodic feeding rhythm where items are presented to the layering belt at regular intervals, allowing the system to maintain precise positioning while avoiding continuous abrupt movements that would generate excessive mechanical stress
Solution Approach 2:
The system dynamically adjusts the layering belt movement to match the natural flow rhythm of items from the conveyor, creating smooth transitions that maintain positioning precision while minimizing mechanical stress through coordinated motion patterns
3Manufacturing precision
If multiple cycles are used to assemble a shift of items, then complete layer formation is achieved, but the processing time increases and throughput decreases
Solution Approach 1:
The patent establishes a continuous feeding process where items are constantly supplied to the layering belt in a rhythmic sequence, eliminating idle cycles and maintaining continuous productive action that completes layer formation in a single operational sequence rather than multiple discrete cycles
Solution Approach 2:
The metering belt performs preliminary grouping and sequencing of items before they reach the layering belt, preparing the exact sequence needed for complete layer formation in advance, which allows the layering process to complete in one continuous operation without requiring multiple assembly cycles
4Manufacturing precision
If a roller conveyor is used to feed items linearly with mechanical positioning by stop points, then item alignment is improved, but the device complexity and mechanical stress increase
Solution Approach 1:
The patent removes the complex mechanical positioning system with stop points and active alignment mechanisms, replacing them with a simplified gravity-fed approach where items naturally align through their own weight and the geometry of the feeding path
Solution Approach 2:
The system replaces active mechanical positioning mechanisms with passive gravity-based alignment, where the natural flow of items and the design of the feeding path work together to achieve proper alignment without complex mechanical intervention
Data Source
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AI summary
The invention relates to a method and a device for handling piece goods (2) in the context of the grouping and/or layer formation thereof. Piece goods (2) are conveyed in a single row or in multiple rows by means of at least one transport device (3) in a transport direction (TR), in a formation without holes or in a formation with holes between each piece good (2), to a grouping module (20) with a horizontal conveyor device (6) and a manipulator (5). In the grouping module (20), the piece goods (2) are seized by the manipulator (5) from the closed or interstitial formation, individually or in groups of two or more piece goods (2), one after the other, and are inserted into a defined layer arrangement by rotating and/or moving and/or lifting. After each time at least one piece good is seized by the manipulator (5) and before the moving, rotating and/or positioning of the piece good for producing a respective layer arrangement, the piece goods (2) seized by the manipulator (5) are distanced from the subsequent piece goods (2) of the formation (F) by at least temporarily delaying the at least one transport device (3) upstream of the grouping module (20).