Manual Multi-Layer Stacking With AMR Delivery for Mixed-Size Loads
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Solution Overview
Problem
Existing automatic stacking systems for load carriers with objects of varying dimensions are costly, complex, and require structured interfaces, making them inefficient and ergonomically challenging for manual mixed-case palletizing.
Innovation Solution
A manual and manual-assisted process using autonomous mobile robots (AMR) and automated guided vehicles (AGV) for flexible object delivery and load carrier handling, combined with an ergonomic workstation design that includes hopper-like devices and reduced-friction conveyors, allowing for precise, high-throughput stacking without structured infrastructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automatic mixed-case palletizing systems are used to handle objects with different dimensions, then stacking precision and throughput are improved, but device complexity and cost increase significantly
Solution Approach 1:
The system allows operators to perform manual stacking tasks autonomously without requiring complex automated infrastructure. The AMR/AGV delivers objects directly to the operator, who then places them on the load carrier according to the predetermined spatial arrangement, eliminating the need for sophisticated automated placement mechanisms
Solution Approach 2:
The patent extracts the object delivery function from the automated system and assigns it to the AMR/AGV, while the complex placement decision-making and execution are separated out to the human operator. This division allows the system to achieve high precision without requiring a fully automated complex structure
2Extent of automation
If structured interfaces and implementations are used for automated stacking, then automation extent is improved, but ease of operation and flexibility deteriorate
Solution Approach 1:
The system dynamically adapts to different stacking scenarios by allowing operators to manually adjust object placement based on real-time conditions while the AMR/AGV provides flexible delivery. This dynamic human-in-the-loop approach enables both automation benefits and operational flexibility
Solution Approach 2:
The operator acts as an intermediary between the automated AMR/AGV delivery system and the final object placement. This intermediary role allows the system to maintain high automation for delivery while preserving flexibility and judgment for the placement decisions
3Ease of operation
If manual stacking is performed without ergonomic support, then ease of operation is improved, but operator safety and wellbeing deteriorate
Solution Approach 1:
The patent replaces manual object delivery mechanics with the automated AMR/AGV system, which handles the transport of objects to the operator. This substitution reduces the physical burden on operators while they retain control over the placement process
Solution Approach 2:
The system positions the load carrier at an optimal height within the hopper-like device, reducing the need for operators to lift or reach excessively. This height optimization creates an equipotential working condition that reduces physical strain while maintaining manual operation benefits
4Productivity
If fully automated systems are implemented for mixed-case palletizing, then productivity is improved, but device complexity and infrastructure requirements worsen
Solution Approach 1:
The patent segments the palletizing process into two distinct functions: automated object delivery performed by the AMR/AGV, and manual object placement performed by the operator. This segmentation allows each component to be optimized independently, achieving high throughput without requiring a fully automated complex system
Solution Approach 2:
The AMR/AGV serves multiple functions including object collection, transport, and precise positioning at the workstation. This multi-functionality increases productivity while avoiding the need for separate specialized equipment for each task, thereby reducing overall infrastructure 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
Enables efficient, accurate, and ergonomic multi-layer stacking of objects with different dimensions on load carriers, improving operator safety and productivity while eliminating the need for complex infrastructure.
Implementation Method 1
delivering the objects to a workstation according to a sequence based on the spatial arrangement in a supply level; supplying objects to a working level in said workstation
Implementation Method 2
hopper like devices and reduced-friction conveyors
Implementation Method 3
reduced-friction conveyors, allowing for precise, high-throughput stacking
Data Source
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AI summary
(P) in a predetermined spatial arrangement, in particular on a pallet or roller cart, with said objects (W) having different dimensions, comprising the following steps: - computer-aided determination of the spatial arrangement of the objects to be packed (W) on the load carrier (P) according to an order listing said objects; - delivering the objects (W) to a workstation according to a sequence based on the spatial arrangement in a supply level (L1); - supplying objects (W) to a working level (L2) in said workstation; - presenting objects (W) to the operator at the working level (L2); - manually moving the objects (W) onto a support which is in the working level (L2) and is connected to a manual stacking station in the working level (L2) and - presenting the load carrier (P) in said manual stacking station which defines a work surface and forms a support for the stack (S) being formed on the load carrier (P) on four sides as it is packed with said objects (W); - manually placing each object at a position according to said predetermined spatial arrangement in the stack (S) being formed on the load carrier (P) in said manual packing station; wherein in that said objects (W) are automatically delivered by means of an autonomous mobile robot (AMR) and/or an automated guided vehicle (AGV).