Palletizing Head With Removable Support for Precise High-Speed Layer Transfer
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Solution Overview
Problem
Existing palletizing systems face challenges in achieving high unit load throughput while minimizing component wear and maintaining precise positioning of individual items during transfer, often requiring reduced speeds to avoid instability and imprecision.
Innovation Solution
A palletizing head with a removable support surface that stabilizes and positions items during transfer using inertial movements, allowing for coordinated positioning with the palletizing head's movement, reducing the need for high drive power and minimizing waiting times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If transfer speed is increased to improve throughput, then productivity increases, but positioning precision deteriorates due to inertia causing items to overshoot or shift position
Solution Approach 1:
The support surface is removed in advance before the palletizing head reaches the discharge position, allowing items to be released proactively rather than forcing them at high speed. This preliminary action enables high transfer speeds while maintaining positioning accuracy through inertial release rather than mechanical pushing.
Solution Approach 2:
The patent replaces the mechanical push beam system with an inertial release mechanism. Instead of using mechanical force to push items at high speed (which causes positioning errors), the system uses controlled removal of the support surface to let inertia naturally position items, substituting active mechanical pushing with passive inertial positioning.
2Ease of operation
If push beam is used to transfer layers, then items can be moved to discharge position, but component wear increases due to high drive power requirements and mechanical stress
Solution Approach 1:
The system uses the inherent inertia of the items being transferred to accomplish the positioning task, rather than relying on an external push beam mechanism. The items essentially position themselves through their own momentum when the support is removed, eliminating the need for high-power drive mechanisms and reducing component wear.
Solution Approach 2:
The patent extracts and eliminates the push beam component from the system by replacing it with a support surface removal mechanism. This extraction of the mechanical pushing element directly reduces component wear and simplifies the drive system while maintaining transfer capability.
3Manufacturing precision
If transfer speed is reduced to maintain positioning precision, then positioning accuracy improves, but throughput decreases
Solution Approach 1:
The support surface is periodically removed at precise moments during the transfer cycle, creating a rhythmic pattern of release that synchronizes with the palletizing head's motion. This periodic action allows the system to operate at high speeds while maintaining precision through timing-critical release rather than continuous mechanical control.
4Loss of time
If high drive power is applied to position items quickly, then transfer time decreases, but mechanical stress and component wear increase
Solution Approach 1:
The patent converts the potentially harmful effect of high-speed inertial forces into a beneficial positioning mechanism. Rather than fighting inertia with high-drive-power mechanical pushing (which causes wear), the system removes support to let inertia work in favor of rapid, accurate positioning, converting what would be a harmful force into a useful tool.
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
Enhances throughput and reduces component wear by utilizing inertial movements for precise positioning, enabling faster transfer speeds and continuous operation without significant mechanical stress.
Implementation Method 1
stabilizes and positions items during transfer using inertial movements
Data Source
Figure 1
AI summary
A palletizing head (1) and a method for palletizing layers of individual items using a palletizing head (1) are disclosed. The palletizing head (1) has a support level (2) for each layer of individual items to be picked up and transferred from a receiving station to a destination. This support level (2) can be removed from under the layer of individual items at the destination. The placement direction (A) of the layer of individual items at the destination is oriented approximately perpendicular to a loading direction (B) at the receiving station. The layer of individual items can be stabilized and positioned within the palletizing head (1) both when picked up at the receiving station and when placed at the destination, in coordination with a positioning movement of the palletizing head (1) between the receiving station and the destination.The process involves picking up individual loads at a receiving station and transferring them onto a support level (2) of the palletizing head (1). The palletizing head (1) then deposits the loads at a destination by removing the support level (2) from beneath the loads within the palletizing head (1) at the destination. The discharge direction (A) of the loads at the destination is approximately perpendicular to the loading direction (B) of the loads at the receiving station. The loads are initially positioned within and relative to the palletizing head (1). As the palletizing head (1) moves to the destination, the loads are further advanced on the support level (2) in the loading direction (B). Upon reaching the destination, the support level (2) is removed from beneath the loads to be deposited.