Palletizer Safety Device Distinguishing Pallets from Intruders
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Solution Overview
Problem
Existing safety devices for palletizers fail to differentiate between pallets and users, leading to potential unauthorized access during pallet removal, which can result in injuries, and require complete deactivation of safety mechanisms, compromising safety and efficiency.
Innovation Solution
A detection device with first and second detection elements is arranged on the conveyor unit to distinguish between pallet removal and unauthorized access, triggering safety functions only when necessary, such as switching off the palletizer, and is designed to adapt to different pallet widths, ensuring secure operation while allowing smooth pallet transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If detection sensors are completely switched off when the pallet exits, then the pallet can pass through without triggering false alarms, but unauthorized access by users cannot be detected
Solution Approach 1:
The patent applies dynamics by making the detection device adaptive - it adjusts its detection behavior based on whether a pallet is present. The device switches between different detection modes: when a pallet is detected, it allows pallet passage; when no pallet is present, it activates unauthorized access detection. This dynamic adaptation resolves the contradiction between allowing pallet passage and detecting unauthorized access.
Solution Approach 2:
The patent changes the detection parameters dynamically. The detection device monitors specific parameters (pallet presence, object characteristics) and adjusts its detection sensitivity and target accordingly. By changing detection parameters based on the situation, it can distinguish between pallets and unauthorized objects, resolving the contradiction between false alarm prevention and security detection.
2Productivity
If safety mechanisms are deactivated to allow pallet removal, then operational efficiency is improved, but safety during pallet transport is compromised
Solution Approach 1:
The safety device dynamically adjusts its safety level based on the operational phase. During pallet transport, it maintains high safety monitoring; during pallet removal when the area is clear, it reduces monitoring intensity. This dynamic safety adjustment ensures both productivity and reliability without constant full safety intervention.
Solution Approach 2:
The system performs preliminary detection to determine whether a pallet is present before adjusting safety measures. By detecting pallet presence in advance, it can proactively adjust safety mechanisms - maintaining full safety during transport but allowing efficient removal when the area is clear, thus resolving the contradiction between safety and productivity.
3Object-affected harmful factors
If detection sensors monitor the exit area continuously, then unauthorized access can be detected, but pallet passage is obstructed by false alarms
Solution Approach 1:
The detection device applies different detection qualities to different situations. It uses pallet-specific detection characteristics (size, shape, material properties) to distinguish pallets from unauthorized objects. By applying localized detection quality focused on pallet identification, it can allow smooth pallet passage while still detecting unauthorized access attempts that differ in their characteristics.
Solution Approach 2:
The system uses feedback from continuous monitoring to adjust its responses. When the detection device identifies an object matching pallet characteristics, it provides feedback to allow passage; when it detects objects with unauthorized characteristics, it triggers alerts. This feedback mechanism enables continuous monitoring without false alarms blocking legitimate pallet passage.
Data Source
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AI summary
The invention relates to a safety device for a palletizer (1), comprising a detection device (110) that can be arranged on a conveying unit (3) of the palletizer (1), which serves to transport a plate unit (4). The invention further relates to a system with a palletizer (1) and a safety device (10), as well as a method for increasing the safety of a conveying unit (3) of a palletizer (1).