Piece-Goods Row Handling for Precise Pallet Layer Formation
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Solution Overview
Problem
Existing methods for handling unit loads face challenges in precise positioning and efficient layering of items due to speed differences, frictional resistance, and mechanical stress, leading to inaccuracies and increased cycle times in palletizing processes.
Innovation Solution
A method and device for handling unit loads in successive rows using manipulators to grip and reposition items with minimal back pressure, allowing for asynchronous picking and rotational movements to achieve precise alignment and orientation without compromising speed or reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual items are transferred between conveyor belts using speed differences, then item transfer is achieved, but positioning precision deteriorates due to frictional resistance and mechanical stress
Solution Approach 1:
The patent replaces the mechanical speed-difference transfer system with an optical detection and control system. Optical sensors detect item positions and trigger controlled transfer mechanisms, eliminating reliance on friction-based speed differences. This substitution maintains transfer reliability while significantly improving positioning precision by enabling precise control of transfer timing and location.
Solution Approach 2:
The patent implements feedback control through optical sensors that continuously monitor item positions on conveyor belts. The system uses this feedback information to dynamically adjust transfer timing and control the release of items, ensuring precise positioning while maintaining reliable transfer. The feedback loop compensates for variations in item movement, resolving the contradiction between transfer reliability and positioning precision.
2Adaptability or versatility
If multiple conveyor belts are used for spacing and rotating packaged goods, then layer formation capability is improved, but device complexity increases
Solution Approach 1:
The patent makes single conveyor belt perform multiple functions by integrating spacing, positioning, and rotation capabilities into one system. The conveyor belt works in coordination with manipulators that can both position and rotate items, eliminating the need for separate specialized conveyors for each function. This multi-functionality approach maintains layer formation versatility while reducing overall device complexity.
Solution Approach 2:
The patent combines the functions of multiple conveyor belts into a single integrated system. Instead of having separate conveyors for spacing, positioning, and rotation, the system merges these functions into one conveyor belt working in coordination with manipulators. This consolidation reduces the number of components and simplifies the overall device structure while preserving all necessary layer formation capabilities.
3Productivity
If abrupt speed and direction changes are applied to conveyor belts, then item grouping is achieved, but mechanical stress on items increases
Solution Approach 1:
The patent applies dynamic control to the conveyor belt system, allowing smooth and gradual changes in speed and direction rather than abrupt transitions. The conveyor belt speed is modulated continuously to achieve item grouping, and direction changes are performed gradually. This dynamic approach maintains grouping efficiency while minimizing mechanical stress and damage to items during the grouping process.
4Manufacturing precision
If optical sensors and control systems are used for item transfer, then positioning accuracy is improved, but system complexity increases
Solution Approach 1:
The patent introduces optical sensors as intermediary detection elements that bridge the physical item and the control system. These sensors provide non-contact detection of item positions, enabling precise positioning control without requiring complex mechanical measurement systems. The optical intermediaries simplify the control architecture by providing clear, binary detection signals that are easy to process and act upon.
Data Source
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AI summary
The invention relates to a method and to a device (10) for handling piece goods (2) moved one after the other in at least one row (1), wherein immediately successive piece goods (2) are transported as a closed formation (F) in a row (1) without clearances or having minimal clearances. In a plurality of temporally successive steps, at least one transported piece good (2) is captured from the closed formation (F) in a clamping and/or frictional and/or interlocked manner, spatially separated from the closed formation (F) by lateral rotation from a linear trajectory (TB) of the closed formation (F) and moved into a defined relative position (P1 and P2) and/or alignment in respect of successive piece goods (2). As a result, a palletizable layer or a pre-grouping for a palletizable layer is formed from the piece goods (2), which are moved to the respective target position (P1 and P2) and/or alignment thereof and/or rotated in the temporally successive steps.