Sack Stacking Recesses via Segmentation
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Solution Overview
Problem
Existing methods for stacking filled sacks often require special lifting devices due to the absence of recesses for forklifts, leading to high costs and inaccuracies, and are not adaptable to all sack formats, compromising stability and efficiency.
Innovation Solution
A transport device and system that integrates filled special sacks of varying formats into the stacking process, allowing for the creation of alternative stacking patterns with recesses suitable for forklifts, using a conveyor unit, delivery unit, and intermediate storage to automate the stacking process and reduce dependency on specific sack formats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If palletless stacking is used to eliminate pallets, then cost is reduced, but special lifting devices are required which increases complexity
Solution Approach 1:
The bottom layer of the bag stack is segmented into individual bags arranged with gaps between them, creating recesses that function as lifting interfaces. This segmentation allows standard forklifts to engage and lift the stack without requiring special lifting devices, resolving the contradiction between cost reduction and device complexity
Solution Approach 2:
The bag stack itself provides the lifting function through its own structure - the gaps in the bottom layer create recesses that enable direct engagement by standard forklifts. The stack serves its own lifting needs without external special equipment, eliminating the need for complex lifting devices while maintaining cost-effectiveness
2Ease of operation
If recesses are created in the bottom layer for forklift engagement, then handling is improved, but automation becomes very complex and inaccuracies arise
Solution Approach 1:
The recesses are created during the stacking process itself by arranging bags in the bottom layer with intentional gaps, rather than creating recesses after stacking. This preliminary arrangement of bags during automated stacking ensures accurate recess formation without requiring complex post-processing or manual intervention, improving both handling and automation compatibility
Solution Approach 2:
The stacking system adjusts bag placement parameters to create consistent gaps in the bottom layer. By controlling the positioning parameters of bags during automated stacking, the system forms accurate recesses that enable forklift engagement while maintaining full automation without complex additional mechanisms
3Ease of operation
If large recesses are formed to accommodate forklifts, then forklift engagement is enabled, but stability against tipping is reduced
Solution Approach 1:
The bag arrangement applies different qualities to different parts of the stack: the bottom layer has gaps creating recesses for forklift engagement, while the upper layers maintain continuous, tight packing for stability. This local differentiation allows the bottom layer to provide handling access while the overall stack structure maintains tipping resistance through proper weight distribution and compact upper layers
Data Source
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AI summary
The invention relates to a transport device (10) for conveying filled sacks (1, 2), having a conveyor unit (13) which can form at least part of a conveying path (3) for conveying filled standard sacks (1) from a feed station (101) to a stacking region (105). The invention also relates to a system (100) for stacking filled sacks (1, 2) and a method for stacking filled sacks (1, 2).