Pallet Stacking Device with Vertical Guidance for Mixed-Size Packages
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Solution Overview
Problem
Existing pallet stacking devices struggle to efficiently stack packages of different sizes without causing imbalance or significant downtime, especially when loading directly onto a pallet without an intermediate support, leading to inefficiencies and potential loss of packages.
Innovation Solution
A device with a system for continuous loading of packages of varying sizes, utilizing a perforated support for pallet movement, vertical plate guidance for stacking, and robotic arms for precise placement, along with a database for calculating optimal storage order and spatial positions, ensuring stable and efficient stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If packages are stacked directly on the pallet without intermediate support, then loading time is reduced, but package stability and balance are compromised
Solution Approach 1:
The system pre-calculates the optimal stacking arrangement and spatial positions of packages before actual loading begins. The database stores package characteristics and the calculation means determines the stacking plan in advance, allowing direct loading without intermediate support while maintaining stability.
Solution Approach 2:
The system continuously monitors the stacking process and adjusts package placement based on real-time feedback about package positions and pallet load distribution. This ensures stability is maintained during direct loading operations.
2Productivity
If packages of different sizes are stacked, then space utilization is improved, but stacking complexity and imbalance risk increase
Solution Approach 1:
The system changes the parameter of package arrangement by using calculation means to determine optimal spatial positions and stacking orders based on package dimensions, weights, and compatibility. This transforms the complex problem of heterogeneous package stacking into a calculated optimization process.
Solution Approach 2:
The patent replaces manual or simple mechanical stacking with an automated system comprising robotic means, calculation means, and database management. This substitution handles the complexity of different sized packages through intelligent control rather than mechanical complexity.
3Speed
If packages are dropped from height during stacking, then loading speed is increased, but package damage and imbalance occur
Solution Approach 1:
The system pre-determines the optimal drop height and landing position for each package based on its characteristics and the current pallet state. This preliminary calculation ensures packages are dropped from appropriate heights that maintain integrity while achieving loading speed.
Solution Approach 2:
The system prepares cushioning measures in advance by selecting appropriate package orientations and positioning softer packages to cushion harder ones. The calculation means anticipates potential impact issues and arranges packages to minimize damage during the dropping process.
Data Source
Figure 1~2
Figure 1A~2B
Figure 1C
AI summary
The present invention relates to a device (1) and a method for stacking packages (2, 2', ...) of different sizes on a pallet (3), comprising means (10) for supplying an empty pallet, means (5, 6) for loading said empty pallet at a loading station (13) depending on the sizes of the packages, and means (31) for removing the pallet after loading. It comprises a waiting station (11) for the empty pallet that is thus supplied, said waiting station (11) being situated at a first level (9) known as the upper level, horizontal means for pushing the empty pallet from the waiting station (11) to the loading station (13), and means (32) for moving the pallet (3) vertically, comprising an elevator (33) designed to grasp the pallet from below at the loading station (13) and move it vertically downwards during loading between the first level (9) and a final level (29), known as the lower level, for removing the loaded pallet (30).