Mixed Pallet Assembly with Layer Handling and Compact Warehouse Flow

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Solution Overview

Problem

Existing methods for assembling mixed pallets in warehouses are inefficient, time-consuming, and expose human operators to danger, while semi-automated or automated techniques require large floor space and are slow due to the use of single-pallet carrying AGVs.

Innovation Solution

Automated warehouse facilities with conveyor systems, layer handling devices, and item retrieval devices that operate in delayering and palletizing modes to assemble mixed pallets efficiently, using vacuum and clamping systems to handle layers and items, and centering detection mechanisms to accommodate non-centered pallets.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual assembly of mixed pallets is used, then flexibility in handling different item types is maintained, but labor safety deteriorates and assembly efficiency decreases

Engineering Contradiction:

Improveflexibility in handling different item typesVSAvoidlabor safety

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system enables automated self-service pallet assembly where the robotic system autonomously retrieves layers, positions them on pallets, and secures them without human intervention. The control system automatically manages the entire process from order receipt to pallet completion, eliminating manual labor while maintaining adaptability through programmable instructions.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical assembly operations are replaced with an automated robotic system that uses robotic arms for layer retrieval and positioning, automated conveyors for transport, and automated fastening mechanisms. This substitution eliminates human exposure to hazards while maintaining the ability to handle diverse item types through programmable control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Extent of automation

If automated guided vehicles are used for pallet transport, then labor requirements are reduced, but floor space requirements increase and assembly speed decreases

Engineering Contradiction:

Improveautomation of pallet assemblyVSAvoidfloor space

Core Design Contradiction:

Extent of automationVSArea of stationary object

Solution Approach 1:

The system merges multiple functions into a compact integrated assembly station: layer storage, robotic retrieval, pallet positioning, layer placement, and fastening all occur in one localized area. This eliminates the need for separate AGV transport routes and large floor spaces, as the entire automated assembly process is consolidated in a single footprint.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system transitions from horizontal floor-space-based AGV transport to vertical layer-stack-based storage and retrieval. Layers are stored vertically in stacks and retrieved by robotic arms, eliminating the need for horizontal transport pathways and reducing floor space requirements while maintaining automated operation.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Extent of automation

If semi-automated techniques are used, then some automation benefits are achieved, but assembly speed remains slow due to single-pallet handling

Engineering Contradiction:

Improveautomation levelVSAvoidassembly speed

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

Multiple layers are pre-positioned on conveyors in the desired assembly sequence before the pallet assembly begins. The control system pre-plans the entire assembly sequence and prepares layers in advance, allowing the robotic system to continuously retrieve and place layers without waiting for previous operations to complete, thereby increasing assembly speed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system maintains continuous operational flow by having multiple layers ready on conveyors simultaneously. While the robotic arm places one layer, the system continuously prepares and positions the next layer, eliminating idle time and maintaining uninterrupted assembly action. The conveyor system continuously feeds layers to the assembly point without interruption.

Inventive Principle:

Principle #20Continuity of useful action

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 enables rapid and efficient assembly of mixed pallets, reducing human exposure to hazards and optimizing space usage by automating the process of pallet layer separation, storage, and assembly.

Implementation Method 1

utilizing a vacuum system to grab and remove a layer from a pallet

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

an air pump system to place the layer onto a conveyor

Methodology Applied

Scientific EffectAir pressure: Pressure Increase

Data Source

PatentEP4370454B1Automated warehouse systems, assemblies, apparatuses, and methods for assembling mixed pallets and facilitating order picking

Publication Date: 2025.12.24 NEWTEQ HLDG BV

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AI summary

This disclosure is directed to automated warehouse facilities that are configured to assemble mixed pallets. The warehouse facilities can include one or more layer handling devices that are configured to remove layers from pallets in a delayering operational mode, and to add layers to pallets in a palletizing operation mode. The warehouse facilities also may include one or more item retrieval devices that are configured to retrieve individual items from storage racks. The warehouse facilities can include other automated devices as well.