Pallet De-layering Gripper with Void Filling Stabilizer
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Solution Overview
Problem
Existing packaging systems struggle to efficiently reconfigure palletized products from a uniform assortment to a diverse assortment as per retailer demands, particularly when products are stacked in layers with voids that complicate gripping and handling.
Innovation Solution
A pallet de-layering system equipped with a gripper mechanism that includes expandable void filling members to stabilize layers during clamping, allowing for the removal and reconfiguration of product cases, combined with a metering system to achieve the desired product assortment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a gripper mechanism is used to clamp and remove layers from palletized products, then productivity is improved by enabling automated de-layering and reconfiguration, but reliability deteriorates because voids between product cases cause layer instability and make secure gripping difficult
Solution Approach 1:
A void filling member is introduced as an intermediary element between the gripper mechanism and the product cases. This member extends into the void spaces between cases, providing additional contact points and stabilization, thereby enabling reliable gripping and stable layer removal without compromising productivity
Solution Approach 2:
The solution addresses the two-dimensional gripping problem by adding a vertical dimension with the void filling member that extends downward into the void spaces. This dimensional extension allows the gripper to anchor into previously inaccessible spaces, improving layer stability during the de-layering operation
2Adaptability or versatility
If product cases are arranged in layers with voids between them, then adaptability is improved by allowing flexible packaging configurations, but device complexity increases because additional void filling members are required to stabilize the layers during handling
Solution Approach 1:
The void filling members are designed with dynamic characteristics, being movable relative to the gripper mechanism frame. They can extend into and retract from void spaces as needed during the de-layering operation, allowing the system to adapt to different packaging configurations without requiring a completely different gripper design for each case
Data Source
AI summary
A packaging system for handling palletized product arranged in multiple layers of product cases, a pallet de-layering system includes a gripper mechanism. The gripper mechanism is configured to clamp a layer of the multiple layers by applying a clamping force to one or more product cases of the layer such that the layer can be removed from an adjacent layer of product cases to a different location. The layer includes a void between adjacent product cases. The gripper mechanism includes a void filling member carried by the gripper mechanism. The void filling member is sized and located to be positioned within the void to limit movement of the adjacent product cases into the void during a clamping operation.