Palletising Station for Precast Concrete with Forklift Gaps
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Solution Overview
Problem
The existing methods for palletizing precast concrete pieces require numerous wooden pallets, leading to space inefficiencies and increased costs, as well as slowing down the manufacturing and handling processes due to the need for multiple transport stations and fastening devices.
Innovation Solution
A palletizing station with two conveyor lines and gripping elements that allow for the stacking of precast pieces with parallel gaps for forklift access, reducing the need for wooden pallets and minimizing the number of components and space required, while enabling efficient handling and transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wooden pallets are used as a base for stacking precast pieces, then the stacking and transport process is enabled, but the space required for storage and the number of components increase significantly
Solution Approach 1:
The invention extracts and eliminates the wooden pallet from the stacking system by creating gaps in the stacking arrangement itself. The gaps are formed by the selective placement and orientation of precast pieces, removing the need for separate pallet structures while maintaining the functionality of stacking and transport.
Solution Approach 2:
The stacking arrangement is segmented into tiers with deliberate gaps created between certain pieces. These gaps are formed by the modular arrangement of individual precast pieces, allowing forklift prongs to access and lift the stack without requiring a continuous pallet base.
2Ease of operation
If multiple transport stations with fastening devices are used to eliminate wooden pallets, then palletless handling is achieved, but the device complexity and space requirements increase
Solution Approach 1:
The conveyor system performs multiple functions: it transports precast pieces, positions them in specific orientations, and creates the gap structure necessary for forklift access. This single multi-functional system replaces what would otherwise require separate transport stations and fastening devices.
Solution Approach 2:
The invention combines the transport and stacking functions into a single integrated conveyor system. The conveyor both moves the precast pieces and arranges them in the final gap-containing stack configuration, merging multiple operations into one process.
3Ease of operation
If multiple transport stations and fastening devices are deployed, then wooden pallets are eliminated, but the manufacturing and handling process speed decreases
Solution Approach 1:
The conveyor system operates continuously to transport and stack precast pieces without interruption. The automated positioning and gap creation occur during the continuous flow, eliminating the need for stop-start operations that would slow down the process with multiple separate stations.
Solution Approach 2:
The conveyor system pre-positions the precast pieces in the correct orientations and locations to create gaps before the stacking is finalized. This preliminary arrangement of pieces with gaps built-in eliminates the need for subsequent manual intervention or additional fastening operations.
4Volume of moving object
If conventional stacking without gaps is used, then the stack structure is compact, but forklift access and transport are prevented
Solution Approach 1:
The compact stack is segmented by creating gaps between specific pieces within the tiers. These gaps are strategically positioned to allow forklift prong insertion while maintaining overall stack compactness. The segmentation is minimal and precise rather than creating large empty spaces.
Solution Approach 2:
The stack has different local qualities: most of the stack maintains compact arrangement for space efficiency, while specific localized gaps are created at strategic positions to enable forklift access. The gaps are localized features within an otherwise compact stack structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution eliminates the use of wooden pallets, reduces space and maintenance costs, and enhances the efficiency of the palletizing process by allowing direct forklift access and flexible stacking arrangements.
Implementation Method 1
a conveyor mechanism with trays (4) which move forward or move discontinuously in the direction of the arrows (f)
Implementation Method 2
first removal means (5), in order to move a group precast pieces (100) from the first conveyor line (1) towards the second conveyor line (10)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Station for palletising precast concrete pieces (100), comprising a first conveyor line (1) for moving groups precast concrete pieces (100), which includes a second conveyor line (10) connected to the first line by means of a number of first removal means (5) for moving a group of precast pieces from the first conveyor line (1) to the second conveyor line (10), said second conveyor line (10) being arranged above the first conveyor line (1). Said second conveyor line (10) has a stationary rest region (12) provided with propulsion means (i.e. pushers) (14) to move the group of precast pieces (100) from the rest region (12) to a second region (13) which is linearly movable relative to the first region (12), including a number of second removal means (15) arranged on the second conveyor line (10) that move the concrete pieces (100) from the second linearly movable region (13) towards a stacking area.