Palletizing System with Segmented Conveying for Multi-Pallet Loading
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Solution Overview
Problem
Palletizing systems face inefficiencies when loading different types of workpieces onto separate pallets, as the waiting time increases due to the need for all workpieces of one type to be prepared before loading can commence, leading to stagnation and reduced operational efficiency.
Innovation Solution
A palletizing system that includes a conveying device, a sorting device, and a loading operation unit, where workpieces are sorted and conveyed based on specific sequences for each pallet, with a control unit managing the flow to maximize robot efficiency by selecting and arranging workpieces according to their respective loading sequences, allowing simultaneous arrangement and loading of workpieces for multiple pallets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If workpieces of different types to be loaded onto different pallets are let to flow together, then the sorting operation can be simplified, but workpieces for one pallet stagnate until loading operation to another pallet is completed, producing waiting time and reducing efficiency
Solution Approach 1:
The patent divides the workpiece flow into separate channels using multiple conveying devices. Each conveying device is assigned to specific pallets, creating segmented flow paths that prevent mixing of workpieces destined for different pallets. This segmentation eliminates stagnation while maintaining sorting simplicity.
Solution Approach 2:
The patent applies preliminary action by pre-arranging workpieces in the correct loading sequence on the conveying devices before the loading operation begins. The control unit determines the arrangement sequence in advance based on pallet information, so workpieces are already positioned correctly when the robot begins loading, eliminating waiting time.
2Productivity
If workpieces are arranged in loading sequence on a single conveying device, then loading operation efficiency is improved, but the system cannot handle multiple pallets concurrently, reducing overall productivity
Solution Approach 1:
The patent merges multiple conveying devices into a coordinated system under centralized control. Each conveying device handles specific pallets independently, but the control unit synchronizes their operations. This merging allows the system to maintain the efficiency benefits of sequenced arrangement while gaining the versatility to handle multiple pallets concurrently.
Solution Approach 2:
The conveying devices are designed with multi-functionality to handle different types of workpieces and serve different pallets. The control unit provides universal coordination that adapts the arrangement sequences based on which pallets are present, allowing the same conveying devices to efficiently serve multiple pallet types.
3Ease of operation
If a robot loads workpieces onto multiple pallets sequentially, then the loading operation can be completed, but the robot experiences waiting time when no workpieces are available, reducing operational efficiency
Solution Approach 1:
The patent ensures continuity of useful action by having multiple conveying devices continuously supply workpieces to the robot. While the robot loads one pallet, other conveying devices continue to arrange and supply workpieces for subsequent pallets, eliminating idle waiting time and maintaining continuous productive operation.
Data Source
AI summary
A plurality of workpieces include a plurality of first workpieces of a first workpiece group to be loaded onto a first loaded member according to a first loading sequence and a plurality of second workpieces of a second workpiece group to be loaded onto a second loaded member according to a second loading sequence. On a conveying device, workpieces are arranged at ransom with respect to respective arrangement sequences of the first workpiece group and the second workpiece group and the classifications of the first workpiece group and the second workpiece group. On a conveying device, workpieces of the first workpiece group are sequentially arranged based on the first loading sequence and workpieces of the second workpiece group are sequentially arranged based on the second loading sequence. At the same time, the workpieces of the first workpiece group and the second workpiece group are arranged together.