Beverage Multipack Damage Detection for Stable Palletizing
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Solution Overview
Problem
High-throughput manipulation of beverage containers during palletization often results in damage, leading to unsuitable containers for sale and unstable pallets prone to tilting or breaking, which complicates processing and affects pallet stability.
Innovation Solution
A system and method involving a horizontal conveyor device, manipulators (such as parallel kinematics robots), and sensor systems to detect and separate damaged containers, adjust handling processes, and regulate packaging to prevent future damage, using a control unit to coordinate the movement and inspection of containers to form stable palletizable layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-throughput handling is used to quickly assemble pallets, then productivity is improved, but container damage increases
Solution Approach 1:
The system performs preliminary inspection of containers before they are fully assembled into pallets. Sensors detect damage early in the process, allowing damaged containers to be identified and removed before they compromise the entire pallet structure or reach the end customer.
Solution Approach 2:
The system implements continuous feedback through sensor monitoring during the palletization process. When damage is detected, the control unit receives real-time information and adjusts the handling process accordingly, slowing down or stopping manipulation of potentially damaged containers while maintaining throughput for undamaged ones.
2Productivity
If high-throughput manipulation is used to increase productivity, then pallet assembly efficiency is improved, but damage to containers increases
Solution Approach 1:
The control unit acts as an intermediary between the sensor system and the manipulators. It processes sensor data and coordinates the manipulators to handle containers differently based on their condition, allowing high-throughput operation for good containers while providing protective handling or removal for damaged ones.
Solution Approach 2:
The system segments the container population into damaged and undamaged groups based on sensor detection. This allows differential handling where undamaged containers continue through high-speed palletization while damaged containers are routed to separate processing, maintaining overall productivity while protecting against damage propagation.
3Productivity
If damaged containers are included in pallets to maintain productivity, then throughput is maintained, but pallet stability deteriorates
Solution Approach 1:
The system performs preliminary identification and segregation of damaged containers before final pallet assembly. By detecting damage early and removing problematic containers in advance, the system ensures that only stable, undamaged containers are placed on pallets, maintaining pallet stability without sacrificing overall productivity.
Data Source
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AI summary
The invention relates to a system (1) for transporting and manipulating a plurality of beverage containers combined into multi-packs. The system (1) comprises a conveying device (16), by means of which piece goods can be transported. Furthermore, the system comprises a manipulator, which can handle piece goods as said piece goods are transported, at least one sensor system (22), and an open-loop and/or closed-loop control unit (S), which is connected to the at least one sensor system (22). According to the invention, the open-loop and/or closed-loop control unit (S) is designed to determine and/or detect, by means of the at least one sensor system (22), damage to piece goods caused by the handling and, if damage is determined and/or detected, the open-loop and/or closed-loop control unit (S) can initiate at least one process for ejecting the damaged piece good and/or at least one process aimed at avoiding future damage.