Automated Package Stacking with Joint Handling Logic
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current automatic palletizing systems struggle with efficiently stacking packages of different dimensions and characteristics, leading to instability, low throughput, and manual intervention due to the complexity of handling varied sizes, shapes, and weights, while also failing to optimize the unloading sequence.
Innovation Solution
A method that uses computer-aided joint handling of packages to determine if they can be grouped and pre-stacked, allowing for simultaneous handling and placement on a conveyor system, which increases throughput by grouping packages horizontally and vertically, and uses a positioning conveyor with sliding plates and pushers to precisely position packages on a carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If packages are stacked individually using conventional automatic palletizing systems, then the stacking process is simple to control, but the throughput is low and manual intervention is required
Solution Approach 1:
The system performs preliminary computational checks to determine whether consecutive packages can be transported together before actual stacking occurs. The control system pre-calculates spatial positions and verifies stacking feasibility (flat surfaces, weight support capacity) in advance, allowing packages to be grouped and handled together rather than individually, thus increasing throughput without proportionally increasing complexity
Solution Approach 2:
The system uses computational models and digital representations of packages (with their geometric and physical characteristics) to simulate and verify stacking arrangements before physical execution. This virtual pre-checking allows the system to identify groupable packages and optimize stacking sequences without requiring complex real-time coordination during actual stacking
2Reliability
If packages of different dimensions are stacked manually to ensure stability, then the stack stability is maintained, but the automation level is reduced
Solution Approach 1:
The control system continuously monitors package characteristics (dimensions, weight, surface flatness) and uses this feedback to dynamically adjust stacking decisions. The system verifies whether consecutive packages meet stability criteria (flat surfaces, adequate weight support) and automatically determines grouping opportunities, maintaining stack stability while operating autonomously without manual intervention
Solution Approach 2:
The system automatically evaluates package compatibility for joint handling by checking geometric and physical properties against stability requirements. The control algorithm independently determines which packages can be stacked together based on their characteristics, eliminating the need for manual assessment while ensuring stability criteria are met
3Productivity
If consecutive packages are handled together to increase throughput, then the productivity improves, but the handling system complexity increases
Solution Approach 1:
The control system performs preliminary computational verification to identify groups of consecutive packages that can be transported together. By pre-calculating spatial positions and checking stacking feasibility before physical handling, the system enables batch processing of multiple packages without requiring complex real-time coordination mechanisms during the actual stacking operation
Solution Approach 2:
The system uses digital models of packages and their spatial arrangements to simulate joint handling scenarios. This virtual verification allows the control system to identify groupable packages and plan multi-package operations without requiring complex physical coordination systems, as the grouping logic is resolved in the digital domain before execution
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for automatically stacking packages (W) of different sizes in layers on a support (P) in a specified spatial arrangement so as to form a stack, having the steps: - determining the order and spatial position of the packages (W) of different sizes in the stack to be formed on the support (P) in a computer-assisted manner; - placing the individual packages (W) in an order required for this purpose by means of a conveyor system (2); and - transporting the packages (W) to be loaded from the conveyor system (2) to the pre-calculated spatial positions on the support (P) or the stack (S) being formed on the support (P) using handling means of a stacking device for forming the stack; wherein the specified order and the specified spatial position of the packages (W) are used to computationally check whether at least two packages (W1, W2) following each other on a conveyor system path leading to the stacking device can be transported together to the pre-calculated spatial positions on the support (P) or the stack (S) being formed on the support (P) by means of the handling means.