Product Container Collection Station with Segmented Conveying
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Solution Overview
Problem
Existing product container handling systems are inefficient in replacing product containers quickly, leading to ergonomic challenges for pickers and reduced capacity, as they require synchronous transport and elevate the picker's elbow, increasing the risk of injury and reducing productivity.
Innovation Solution
A station with separate drive means for conveying product containers, using multiple conveyors to supply and discharge containers independently, with ergonomic design features like horizontal conveying paths and sensor-controlled operations to minimize picker strain and maximize space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If synchronous transport of product containers is used, then the conveying system is simpler, but the product container exchange speed is reduced
Solution Approach 1:
The conveying system is divided into independent segments: a first conveyor for supplying product containers and a second conveyor for discharging product containers, each with separate drive means. This segmentation allows asynchronous operation where each conveyor can operate independently at optimal speeds, enabling faster product container exchange without requiring the entire system to synchronize, thus resolving the contradiction between speed and complexity.
2Length of moving object
If the picker elevates the elbow above the shoulder, then the reaching distance is increased, but the physical load and injury risk increase
Solution Approach 1:
The pick position is designed at an optimal height where the picker can access product containers without elevating the elbow above the shoulder. The conveying system positions product containers at this equipotential level, eliminating the need for awkward overhead reaching motions. This maintains adequate reaching distance while keeping the picker's arm in a neutral, ergonomically sound position, thereby reducing physical load and injury risk.
3Productivity
If a single conveyor is used for product container transport, then the device complexity is reduced, but the productivity is limited
Solution Approach 1:
The system uses separate drive means for the first conveyor (supply) and second conveyor (discharge), allowing them to operate independently and asynchronously. This enables continuous operation where the supply conveyor can feed containers while the discharge conveyor removes filled containers without waiting for synchronized cycles, thereby increasing overall station capacity and productivity despite the increased complexity of having separate drive systems.
4Illumination intensity
If the picker works at elevated position, then the visibility is improved, but the ergonomic working conditions deteriorate
Solution Approach 1:
The pick position is positioned at an optimal height that provides both good visibility and ergonomic working conditions. Product containers are conveyed to this equipotential level where the picker can clearly see the products and labels without straining, while simultaneously maintaining a comfortable working posture with the arms at or below shoulder level, thus resolving the contradiction between visibility and ergonomics.
Data Source
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AI summary
The present invention relates to a station (51) for collecting products from product containers, comprising an at least substantially horizontal row of place positions arranged side by side, each for accommodating a collecting container (4), a pick position in said row of place positions for accommodating a product container, a conveying system comprising a first conveyor (52) for conveying product containers along a conveying path, wherein the pick position forms part of said conveying path and said conveying path comprises a first conveying path portion connecting to the pick position and a second conveying path portion connecting to the pick position, and control means for controlling the station, whilst the pick position is included in the row of place positions.