Piece Goods Handling Device for Layer Formation
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Solution Overview
Problem
Existing methods for handling and grouping piece goods, such as beverage containers, face challenges in achieving high throughput and reliability due to discontinuous conveying and mechanical stress, which can lead to product damage.
Innovation Solution
A method and device that utilize a transport device to convey piece goods in closed or clocked formations to a grouping module, where a manipulator detects and repositions them into defined layer arrangements, allowing for efficient layer formation and palletizing with minimal gaps, using a combination of clamping and non-positive gripping to manage the pieces and correct any deviations from the desired pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If piece goods are conveyed individually from distribution belt to conveyor belt using speed differences and optical sensors, then individual piece goods can be transferred precisely, but the conveying process becomes discontinuous causing high mechanical stress on the piece goods
Solution Approach 1:
The patent implements continuous conveying by maintaining synchronized movement between the distribution belt and layer forming belt, eliminating the discontinuous stop-and-go motion of traditional individual transfer methods. Multiple piece goods are conveyed together in a continuous stream rather than being transferred one by one with interruptions, thereby reducing mechanical stress while maintaining positioning accuracy through control unit coordination.
Solution Approach 2:
The patent segments the conveying process into synchronized zones where different belts move at coordinated speeds. The distribution belt and layer forming belt are divided into functional sections that operate in synchronization, allowing precise positioning of multiple piece goods simultaneously while maintaining continuous motion, thus reducing mechanical stress compared to individual transfer methods.
2Productivity
If multiple cycles are used to assemble layers with abrupt changes in speed and direction, then layer formation can be achieved, but correspondingly high mechanical stress is caused on the piece goods
Solution Approach 1:
The patent reduces the number of conveying cycles by implementing continuous synchronized movement between belts. Instead of multiple discontinuous cycles with abrupt speed and direction changes, the system uses coordinated continuous conveying where piece goods are positioned and layered in a more streamlined process, maintaining productivity while significantly reducing mechanical stress on the goods.
Solution Approach 2:
The patent employs dynamic speed adjustment where the distribution belt and layer forming belt operate at different synchronized speeds during different phases of the process. The control unit coordinates speed variations smoothly rather than using abrupt changes, allowing efficient layer formation while minimizing mechanical stress through controlled dynamic movement.
3Manufacturing precision
If piece goods are rotated and mechanically arranged using stop points on roller conveyor, then required positions can be achieved, but the process becomes complex and causes mechanical stress
Solution Approach 1:
The patent replaces complex mechanical arranging systems with synchronized belt conveyance and control unit coordination. Instead of using stop points, mechanical rotators, and complex positioning mechanisms, the system achieves precise positioning through coordinated belt movement and timing, significantly reducing device complexity while maintaining or improving positioning accuracy.
Solution Approach 2:
The synchronized belt system serves multiple functions simultaneously: conveying, positioning, rotating (through differential speed zones), and arranging piece goods. This multi-functional approach eliminates the need for separate specialized mechanisms for each function, reducing overall system complexity while achieving the required positioning precision.
4Reliability
If traditional grouping tables with multiple cycles are used to form layers, then palletizable layers can be created, but throughput is reduced compared to continuous conveying methods
Solution Approach 1:
The patent implements continuous conveying throughout the layer formation process, eliminating the intermittent operation of traditional grouping tables. Piece goods are conveyed continuously from the distribution belt through the layer forming zone to the finished layer, maintaining constant motion and eliminating cycle-based interruptions. This increases throughput while the control unit ensures reliable layer formation through coordinated synchronized movement.
Data Source
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AI summary
The invention relates to a method and to a device for handling piece goods (2) in the context of the grouping thereof and/or the forming of layers with same. The method provides a conveying of the piece goods (2) to a grouping module (20) by means of a transport device (3). The piece goods (2) are seized individually or in groups of two or more piece goods (2), and successively by a manipulator (5) moving within a seizing region (4) within the grouping module (20), and same are brought into a defined layer arrangement (12) via rotation and/or shifting and/or lifting. In addition, at least one of the handling steps, of seizing, rotating, shifting and/or lifting at least one of the piece goods (2), carried out successively after one another to form a defined layer arrangement (12) within the grouping module (20), provides the raising and transferring the respective at least one of the piece goods (2) over at least another of the piece goods (2) located in the seizing region (4). Subsequently, the piece goods (2) brought into the layer arrangement (12) are conveyed onwards in the transport direction (TR) to further handling, stacking and/or palletising modules, downstream of the grouping module (20).