Pallet Assembly with Overhead Conveyor and Automated Sorting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing pallet systems lack efficient and accurate sorting and stacking mechanisms for graded pallets, leading to inefficiencies in pallet handling and management.

Innovation Solution

A pallet assembly incorporating an overhead conveyor system with a loading assembly, release assemblies, and stacking assemblies, utilizing motors, sensors, and adjustable floors to sort and stack pallets based on their physical properties and grades, enabling precise sorting and stacking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual sorting and stacking methods are used, then operational simplicity is maintained, but productivity and sorting accuracy deteriorate

Engineering Contradiction:

Improvesorting and stacking speedVSAvoidsystem structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system is divided into distinct functional modules: overhead conveyor system for transport, loading assembly for pallet intake, release assemblies for selective pallet dropping, and stacking assemblies for automated stacking. Each module operates independently but coordinates through control systems, enabling high productivity while managing complexity through modular design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Manual sorting and stacking operations are replaced by an automated control system that uses sensors to detect pallet grades and communicates with motors to operate release assemblies and stacking mechanisms. This substitution of manual mechanical operations with automated electromechanical systems resolves the contradiction by dramatically increasing productivity while the control system manages the inherent complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If automated sorting mechanisms are implemented, then sorting accuracy improves, but device complexity increases

Engineering Contradiction:

Improvepallet grading accuracyVSAvoidcontrol system

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Sensors are positioned along the overhead conveyor system to detect pallet physical properties and grades as pallets are transported. The sensor data is fed back to the control system, which processes the information and sends commands to the appropriate release assemblies and stacking assemblies. This closed-loop feedback mechanism ensures high sorting accuracy while the control system manages the complexity of coordinating multiple actuators

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control system acts as an intermediary between the sensor detection system and the mechanical execution systems (release assemblies and stacking assemblies). It translates sensor measurements into coordinated motor commands, managing the complexity of the automated system while maintaining high sorting precision through centralized intelligent control

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If overhead conveyor systems are used, then handling efficiency improves, but initial investment and system complexity increase

Engineering Contradiction:

Improvepallet handling efficiencyVSAvoidoverhead conveyor structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The overhead conveyor system serves multiple functions: it transports pallets through the sorting area, positions pallets for release at different stacking locations, and integrates sensor systems for grade detection. This multi-functionality justifies the initial investment and structural complexity by consolidating transport, positioning, and measurement functions into a single integrated system that dramatically improves handling efficiency

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system transitions from ground-level pallet handling to three-dimensional overhead transport. Pallets are conveyed above the stacking area, allowing simultaneous access to multiple stacking locations and enabling vertical space utilization. This dimensional change resolves the contradiction by improving handling efficiency through better space utilization and parallel operations, while the overhead structure, though complex, enables these efficiency gains

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20260021975A1Pallet assembly and method of use

Publication Date: 2026.01.22 KAMPS PALLETS INC

AI summary

A pallet assembly including an overhead conveyor system having a conveyor platform and a push rail, a loading assembly, a stacking assembly, and a release assembly. The loading assembly provides a pallet to the overhead conveyor system. The stacking assembly is located below the conveyor platform and includes a first chute, a first movable floor, and a first height adjustment mechanism. The release assembly, which is coupled to a portion of the conveyor platform, includes a portion selectively configured to release a pallet into a first chute.