Multi-Storey Pallet Racks for High-Throughput Machining Cells
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Solution Overview
Problem
Machining centers with large pallets require extensive space for storage and transportation, leading to inefficient use of space and reduced machining throughput due to long transport routes and high space demands.
Innovation Solution
A cell design with multi-storey pallet racks and a rack storage and retrieval device with lifting function, allowing for direct and efficient storage and transport of pallets between horizontal machining centers, minimizing space requirements and optimizing pallet flow paths for high throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large number of pallets is stored next to one another in conventional pallet stations, then the number of available pallets increases, but the space required for storage and transport increases significantly
Solution Approach 1:
The patent transitions from horizontal storage arrangement to vertical multi-storey rack storage. Pallets are stacked vertically on multiple levels rather than being placed side-by-side horizontally, effectively utilizing the vertical dimension to increase storage capacity within the same footprint area.
Solution Approach 2:
The pallets are nested vertically within the multi-storey rack structure, with each storey containing a pallet. This nested arrangement allows multiple pallets to occupy the same horizontal space by stacking them in the vertical direction, similar to nested dolls occupying the same space at different scales.
2Adaptability or versatility
If pallets are moved translationally between storage, setup and loading positions over long distances, then all pallets can be accessed, but the transport time increases and machining throughput decreases
Solution Approach 1:
The patent introduces vertical movement capability through lifting devices that can transport pallets between different storeys of the rack. This vertical dimension of transport, combined with transverse movement along the rack, creates a two-dimensional access system that reduces the linear travel distance compared to conventional single-level translational transport.
Solution Approach 2:
The lifting device acts as an intermediary mechanism between the horizontal transport system and the vertical rack storage. It enables efficient transfer of pallets between different levels without requiring long horizontal transport routes, thereby reducing overall transport time while maintaining full accessibility to all stored pallets.
3Area of stationary object
If horizontal machining centers are placed close together to reduce cell space, then space requirements decrease, but pallet transport and manipulation becomes more complex
Solution Approach 1:
The lifting device is designed as a multi-functional unit that can serve multiple horizontal machining centers simultaneously. It can transport pallets to and from different racks associated with different centers, perform vertical positioning, and interface with the machining centers' loading positions. This universal design reduces the need for separate dedicated transport mechanisms for each center, thereby managing complexity while enabling close spacing.
Solution Approach 2:
The patent combines the storage rack, lifting mechanism, and transverse transport function into an integrated pallet handling system that serves multiple machining centers. By merging these functions into a shared infrastructure rather than providing separate systems for each center, the overall system complexity is reduced despite the close proximity of multiple centers.
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
This solution enables the efficient storage and transport of a large number of pallets with minimal space, reducing transport distances and increasing machining throughput while maintaining optimal cell utilization.
Implementation Method 1
a rack storage and retrieval device with lifting function that can be moved transversely to the conveying direction of the pallets
Data Source
AI summary
In a cell with linked horizontal machining centers, each with two swivel arms for manipulating and changing pallets, which can be conveyed to and from a support in a conveying direction, each horizontal machining center is assigned at least one multi-storey pallet rack which is offset in the conveying direction relative to the front side and in which a pallet through-path is provided, and at least one rack storage and retrieval device with a lifting function transverse to the conveying direction is moveable at least between the pallet racks.