Pallet Rack With Movable Base For Mixed Box Stability
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Solution Overview
Problem
Existing mixed pallet handling systems face instability issues due to varying types of boxes, leading to potential falls during transportation and handling.
Innovation Solution
A pallet rack with a rigid frame and a vertically movable base, equipped with a motorized gear box and hoist, provides a stable loading surface and outer support for each layer of goods, ensuring secure stacking and transportation of mixed pallets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of boxes are placed on customer pallets according to shop order, then the palletization process becomes flexible and adaptable to various orders, but the stability of the pallet load deteriorates and boxes may fall during transportation
Solution Approach 1:
The palletizing system employs a dynamically adjustable robotic arm that can adapt its positioning and manipulation strategies based on the specific combination of boxes being loaded. The system adjusts its operations in real-time to maintain stability while handling different box types and configurations according to varying shop orders.
Solution Approach 2:
The system applies different loading strategies and stabilization techniques to specific local areas of the pallet based on the characteristics of individual boxes. Heavier or less stable boxes receive additional support or strategic positioning, while stable boxes are placed in positions that optimize overall pallet stability without requiring uniform treatment of all items.
2Device complexity
If a robot and pallet are mounted on the same shuttle for movement, then the system complexity is reduced, but the handling stability and precision deteriorate
Solution Approach 1:
The system separates the robot and pallet onto different shuttles, allowing each to be optimized for its specific function. The robot shuttle is designed for precise manipulation and positioning, while the pallet shuttle is optimized for stable transport. This segmentation eliminates the instability issues that would arise from combining both functions on a single shuttle while maintaining manageable system complexity through coordinated operation of multiple specialized components.
3Stability of the object's composition
If boxes are stacked in different orders depending on stability requirements, then the load stability improves, but the loading time increases due to careful positioning requirements
Solution Approach 1:
The system performs preliminary analysis of the shop order and box characteristics before beginning the palletizing process. It pre-calculates the optimal stacking sequence and positioning for each box to ensure stability, then executes this pre-planned sequence efficiently. This eliminates the need for time-consuming adjustments during loading while still achieving the stability benefits of careful positioning.
Solution Approach 2:
The system incorporates real-time feedback mechanisms that monitor the stability of the pallet load as boxes are being loaded. Based on this feedback, the robotic system dynamically adjusts its positioning and placement strategies for subsequent boxes, optimizing both stability and loading speed. The system learns from each placement to improve the efficiency of subsequent operations.
Data Source
Figure 1
Figure 2
AI summary
A pallet rack (1) for transporting palletized goods on a pallet between different loading positions and an unloading position for the finished pallet, characterised in that the pallet rack (1) having a frame (2) of essentially rigid side walls (2a - 2d) and a vertically moveably base (3) for supporting the pallet in a position where the upper loading surface (4) is kept in a desired position for loading each layer of goods, whereupon a completed layer of goods is lowered into the pallet rack (1) to provide an upper loading surface (4) for the following layer and to provide an outer support on each side of the completed layer of goods.