Automated Pallet Loading via Additive Pressure Calculation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for automated pallet loading are complex and inefficient, often resulting in less dense and unstable package stacks due to the difficulty in calculating and implementing classification rules for various packages, leading to potential overloading and damage.
Innovation Solution
A computerized method that virtually constructs package layers and determines the additive pressure on each layer, using maximum allowable pressures from homogeneous stacks to optimize loading patterns, allowing for the iterative selection of reliable and optimal configurations that avoid overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If classification rules are used to assign packages to ranking classes for stable stacking, then package stability is improved, but the calculation complexity and implementation difficulty increase significantly
Solution Approach 1:
The patent changes the approach from classification-based stacking to pressure-based stacking. Instead of assigning packages to ranking classes based on multiple attributes, the system calculates a single critical parameter: the maximum allowable pressure for each package. This simplifies the decision-making process while maintaining stability, as packages are stacked based on whether the cumulative pressure exceeds their pressure tolerance rather than comparing multiple classification attributes.
Solution Approach 2:
The patent replaces the complex rule-based classification system with a physics-based pressure calculation model. Instead of using arbitrary ranking classes and multiple classification rules, the system uses mechanical pressure calculations (force/area) to determine stacking feasibility. This substitution simplifies the system by relying on fundamental physical principles rather than complex computational rules.
2Reliability
If classification rules are applied to prevent overloading, then package damage is reduced, but the packaging density and space utilization decrease
Solution Approach 1:
The patent changes from discrete classification categories to continuous pressure threshold values. Instead of restricting packages to specific ranking classes that may leave space unused, the system allows any package to be placed as long as the cumulative pressure remains below the maximum allowable pressure for the underlying package. This continuous parameter approach maximizes space utilization while maintaining package protection.
Solution Approach 2:
The patent introduces dynamic pressure calculation that adapts to each specific stacking configuration. Rather than static classification rules that apply uniformly, the system dynamically calculates the cumulative pressure at each stacking step and compares it against the specific pressure tolerance of the underlying package. This dynamic approach allows optimal space utilization while preventing damage.
3Ease of manufacture
If maximum allowable pressures are determined from homogeneous stacks, then the determination process is simplified, but the applicability to mixed loading scenarios is reduced
Solution Approach 1:
The patent creates a universal pressure-based stacking methodology that works for both homogeneous and mixed loading scenarios. By using fundamental pressure calculations (force/area) and material properties (compressive strength, contact area) that apply to all packages regardless of type, the system determines maximum allowable pressures that are universally applicable. This single methodology replaces the need for separate classification rules for different package types.
Solution Approach 2:
The patent transforms the pressure determination from a complex multi-parameter classification process into a simple calculation based on fundamental physical parameters: package weight, contact area, and compressive strength. These parameters are intrinsic to each package and can be measured or calculated independently, making the determination process both simple and universally applicable to any package type in mixed loading scenarios.
Data Source
AI summary
In a computerized method, and a computer-readable medium encoded with programming instructions for implementing the method, multiple layers of packages stacked on a load carrier are virtually constructed in a computer and, for each of the layers, an automatic determination is made with regard to the additive pressure that each layer exerts on the respective layers therebelow in the stack. The packages are organized in the multiple layers in the virtual construction dependent on predetermined constraints for the respective additive pressures, and the virtual construction is made available at an output of the computer in a form allowing the actual loading of the load carrier with the packages to be guided.