Multi-Tier Pallet Rack for Synchronized Battery Module Handling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current transportation machines in manufacturing industries, particularly in lithium battery formation processes, are inefficient as they can only perform single-line transportation, limiting production efficiency and requiring multiple operations for multiple batches, which increases time and labor costs.
Innovation Solution
A motion synchronized multi-tier pallet rack system comprising a fixation rack, movable frames, and actuators, allowing for simultaneous transportation and pick-and-place operations across multiple tiers, optimized by telescopic arms, gear assemblies, and position detectors, controlled by a controller to enhance efficiency and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single line transportation is used, then the transportation machine can perform simple operations, but the production efficiency is limited and multiple operations are required for multiple batches
Solution Approach 1:
The transportation system is segmented into multiple independent tiers, each capable of transporting pallets simultaneously. The multi-tier structure divides the transportation function across different levels, allowing parallel operations without increasing the complexity of individual transportation paths.
Solution Approach 2:
The system transitions from single-line (1D) transportation to multi-tier (3D) transportation by adding vertical dimension. Multiple pallets are transported simultaneously at different heights, converting a sequential single-line process into parallel multi-level operations, thereby dramatically improving productivity without proportionally increasing system complexity.
2Productivity
If a pallet rack performs pick-and-place operation for a single pallet, then the operation is simple, but the transportation performance is inefficient
Solution Approach 1:
Multiple pick-and-place operations are merged into a single synchronized action. The system simultaneously extends telescopic arms from multiple movable frames to pick up pallets from different positions and places them onto a single conveyor, combining multiple operations into one coordinated action that improves transportation performance while maintaining operational simplicity through centralized control.
Solution Approach 2:
The system achieves continuous useful action by having multiple telescopic arms operate simultaneously across different tiers. While one arm is picking up a pallet, another arm is already positioned for the next pickup, eliminating idle time and ensuring continuous productive operation across all tiers.
3Loss of time
If multiple batches of products are transported through multiple separate operations, then each operation can be performed carefully, but time and labor costs increase
Solution Approach 1:
The transportation system is divided into multiple independent but synchronized tiers, allowing different batches of products to be transported simultaneously rather than sequentially. Each tier operates independently but coordinates through the control system, reducing total transportation time without requiring overly complex inter-tier interactions.
Solution Approach 2:
The system changes the operational parameter from sequential single-pallet handling to parallel multi-pallet handling. By modifying the configuration to include multiple movable frames with telescopic arms at different heights, the system transforms the time-consuming sequential process into a time-efficient parallel process, reducing transportation time proportionally to the number of tiers.
Data Source
AI summary
A motion synchronized multi-tier pallet rack and a battery formation apparatus are provided. The pallet rack includes a fixation rack, two movable frames, and two actuators. The movable frames are coupled to two corresponding sides of the fixation rack and each includes telescopic arms, a motor, and a drive rod. The actuators are disposed on other the two corresponding sides of the fixation rack to drive the movable frames to move toward or away from each other. The telescopic arms are kinematically connected to the motor through the drive rod to extend from or retract into the movable frame. The battery formation apparatus includes a motion synchronized multi-tier pallet rack, a conveyor module, a formation cabinet, and a controller. The conveyor module carries a battery module. The controller controls the pallet rack to obtain the battery module from the conveyor module and place the battery module in the formation cabinet.