Multi-Container Baggage Loading With Sorting-Cell Robots
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Solution Overview
Problem
Existing systems for loading containers with piece goods, such as ULDs and baggage carts, suffer from inefficiencies due to incomplete batches, waiting times, and reduced throughput, particularly when sorting criteria are mixed, leading to suboptimal utilization of loading robots and increased storage requirements.
Innovation Solution
A method and system that utilizes a sorting cell with a loading robot, multiple container locations, a feeding device, and a control system to assign piece goods to containers based on sorting criteria, allowing for continuous loading and reduced interference between feeding and loading operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a robot serves exactly one ULD from a transfer position, then the loading process is simple and focused, but the robot's throughput is reduced due to waiting times when ULD is replaced and positions require large numbers of cases to be prepared
Solution Approach 1:
The system divides the loading function into two independent segments: a loading robot dedicated to loading containers and a feeding robot dedicated to preparing and transporting baggage batches. This segmentation allows each robot to specialize in its task and operate continuously without waiting for the other, resolving the throughput limitation caused by the single robot having to perform both loading and waiting functions.
Solution Approach 2:
A feeding robot acts as an intermediary between the baggage storage areas and the loading robot. This intermediary prepares baggage batches in advance and delivers them to the loading position, allowing the loading robot to load continuously without waiting for baggage preparation. The intermediary eliminates the waiting time bottleneck that limited the single-robot system's throughput.
2Productivity
If baggage items are distributed among ULDs based on sorting criteria with sufficient items available, then ULDs reach economically viable fill levels, but storage capacity requirements increase and loading peaks occur
Solution Approach 1:
The feeding robot performs preliminary actions by preparing and transporting baggage batches to the loading position in advance of when they are needed for loading. This advance preparation allows the system to maintain lower storage capacity requirements while still achieving high ULD fill levels, as baggage is staged closer to the loading point just before it is needed rather than requiring large centralized storage areas.
3Ease of operation
If ULDs move at low speeds to allow manual or machine loading, then loading can be performed accurately, but changing a ULD takes time and reduces system throughput
Solution Approach 1:
The system segments the container handling function from the loading function. A dedicated container transfer mechanism handles the movement and replacement of containers at optimized speeds, while the loading robot focuses solely on accurate loading. This segmentation allows container changes to occur quickly without compromising loading accuracy, as the transfer mechanism is specifically designed for efficient container handling rather than requiring the loading robot to slow down for each container change.
4Reliability
If only a portion of baggage to be loaded into a ULD is in the airport baggage handling system, then the ULD cannot be fully loaded, but bringing the ULD to the loading cell multiple times reduces loading efficiency
Solution Approach 1:
The feeding robot performs preliminary gathering and transport of baggage batches to the loading position before the ULD arrives or while it is being loaded. This preliminary action ensures that when a ULD is brought to the loading cell, the required baggage items are already prepared and waiting, eliminating the need for multiple trips and ensuring complete loading in a single pass.
Solution Approach 2:
The feeding robot operates continuously to prepare and stage baggage batches, ensuring that the loading robot always has baggage available when a ULD is positioned for loading. This continuous preparation eliminates interruptions and waiting periods, maintaining continuous useful action in the loading process and ensuring that each ULD can be fully loaded without requiring multiple trips to the loading cell.
Data Source
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AI summary
Method for loading at least two containers (2), each with a plurality of piece goods (3), in particular with a plurality of pieces of luggage, wherein each piece goods (3) can be assigned to one of the at least two containers (2) by means of a sorting criterion (13); the method comprising: a) feeding the piece goods (3) on a piece goods conveyor system (9), in particular a baggage conveyor system, in particular an airline baggage conveyor system, to a sorting cell (1); b) picking up the piece goods (3) fed to said sorting cell (1) by means of a loading robot (4); c) loading the piece goods (3) by the loading robot (4) into the container (2) which can be assigned to the respective piece goods (3) by means of the sorting criterion (13).