Overhead Gantry Robot With Dual Grippers for Layered Pallet Stacking
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Solution Overview
Problem
Existing overhead handling systems for pallets face inefficiencies in handling and stacking operations, particularly in multi-layer configurations, and lack flexibility in accommodating different pallet sizes and materials.
Innovation Solution
An overhead loading and unloading system utilizing a linear gantry robot with a dual gripper mechanism, capable of handling pallets and protective sheets, which includes forks and a vacuum gripper, enabling multi-layer stacking and adaptable handling of various pallet sizes and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional overhead handling systems are used for pallets, then the system structure is relatively simple, but the handling efficiency and precision for multi-layer stacking operations deteriorates
Solution Approach 1:
The system segments the handling functions by equipping the robot arm with interchangeable gripper modules - a fork gripper for pallets and a vacuum gripper for protective sheets. This modular segmentation allows specialized handling for different objects, improving efficiency without requiring entirely separate systems for each task.
Solution Approach 2:
The robot arm serves multiple functions: transporting pallets horizontally, stacking them vertically in multiple layers, and placing protective sheets between layers. This multi-functionality consolidates what would traditionally require separate machines into one integrated system, improving productivity while managing complexity through centralized control.
2Adaptability or versatility
If fixed gripper design is used, then the device structure is simple, but the adaptability to different pallet sizes and materials deteriorates
Solution Approach 1:
The fork gripper features adjustable fork spacing that can be dynamically modified to accommodate different pallet widths. The vacuum gripper can also adjust its suction area configuration. These dynamic adjustments allow the same gripper mechanism to handle various pallet sizes without requiring multiple fixed-size grippers, improving adaptability while keeping the base structure relatively simple.
Solution Approach 2:
The system replaces traditional mechanical clamping or gripping mechanisms with a vacuum-based gripper for handling protective sheets. This substitution provides more adaptable and gentler handling for different sheet sizes and materials, improving versatility while using a relatively simple vacuum system rather than complex mechanical adjustment mechanisms.
3Reliability
If manual handling operations are performed, then the equipment cost is low, but the operational safety and precision deteriorates
Solution Approach 1:
The robot arm with automated grippers performs all handling operations independently - picking up pallets, transporting them, stacking them in multiple layers, and placing protective sheets. This self-service automation eliminates the need for manual intervention in hazardous overhead operations, significantly improving safety while the relatively straightforward robot control system manages the complexity.
4Productivity
If single-layer pallet stacking is used, then the handling process is simple, but the space utilization and productivity deteriorates
Solution Approach 1:
The system transitions from single-layer horizontal stacking to multi-layer vertical stacking, utilizing the vertical dimension to increase storage density. The robot arm can lift pallets and place them on top of existing stacks, creating multiple layers. This dimensional change dramatically improves space utilization and productivity without requiring a larger facility footprint, while the robot's vertical movement capability manages the added operational complexity.
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 provides efficient, precise, and safe handling of pallets and protective sheets, minimizing collision risks and reducing operational costs by optimizing transport distances and accommodating different pallet sizes with adjustable forks and vacuum gripper functionality.
Implementation Method 1
The gripper is provided with forks for handling the pallets and a vacuum gripper for handling the protective sheets
Data Source
AI summary
An overhead loading and unloading system (1) and method for handling pallets (2). The system comprises a pickup station (3), a loading station (4), a storage station (5) for storing protective sheets (S), and an automatically controlled linear gantry robot (6). The gantry robot comprises a robot arm (12) provided with a gripper (13) comprising forks (23) for handling the pallets and a vacuum gripper (24) for handling the protective sheets. The robot arm transports the pallets on the forks from the pickup station to the loading station and stacks the pallets in several layers (L). The robot arm implements the vacuum gripper for placing the protective sheets between the stacked layers.