Segmented Pallet Loading Carriage for Flush Contours
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Solution Overview
Problem
Existing methods for loading pallets with articles often result in suboptimal utilization of pallet space, leading to gaps and uneven outer contours, and require complex or space-intensive systems to achieve flush layers.
Innovation Solution
A one-piece loading system with a movable support plane featuring driven rollers that can create defined gaps and smooth outer contours by controlling the movement of articles during the loading process, allowing for efficient placement of layers with or without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a layer pusher is used to close gaps in pack layers, then the outer contour of the pack layer becomes flush, but the device complexity increases and space requirements increase
Solution Approach 1:
The loading carriage is divided into a first carriage body and a second carriage body that can move independently. The first carriage body transports the pack layer, while the second carriage body acts as a pusher to close gaps and form a flush outer contour. This segmentation allows the pushing function to be separated from the transport function, achieving flush contours without requiring a completely complex integrated system.
Solution Approach 2:
The second carriage body serves as an intermediary element between the first carriage body and the pack layer. It temporarily holds and pushes the pack layer to close gaps and form the desired outer contour, then releases it. This intermediary mechanism simplifies the overall system by providing a dedicated gap-closing function without requiring complex integrated controls.
2Shape
If divided loading carriages or divided roller shutters are used to create flush layers, then the outer contour becomes flush, but the system requires overhead container inserts and large space
Solution Approach 1:
The loading carriage is segmented into two independently movable carriage bodies that operate at the same level. The first carriage body transports the pack layer while the second carriage body pushes it to form a flush contour. This segmentation eliminates the need for overhead container inserts and reduces the vertical space requirement compared to traditional divided roller shutter systems.
Solution Approach 2:
Instead of using vertical overhead structures to achieve flush contours, the invention uses horizontal movement of two carriage bodies at the same level. The second carriage body moves horizontally along with the first to push the pack layer into position, transforming the problem from a vertical space-consuming approach to a horizontal space-efficient approach.
3Productivity
If conventional loading systems are used, then loading can be performed, but gaps occur within layers and pallet space utilization is suboptimal
Solution Approach 1:
The control unit monitors the position of the first and second carriage bodies and coordinates their movements to ensure proper alignment and gap closure. The system provides feedback control to maintain synchronized operation of the two carriage bodies, ensuring that the pack layer is formed with uniform gaps and flush outer contours while optimizing pallet space utilization.
Solution Approach 2:
The system dynamically adjusts the positions and speeds of the first and second carriage bodies during the loading process. The carriage bodies can move independently at different speeds and positions to adapt to the specific requirements of each pack layer, enabling optimal space utilization and uniform layer formation without rigid constraints.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach increases loading performance by up to 40% compared to previous systems, enabling reliable formation of layers with flush outer contours and defined gaps, enhancing stability and efficiency in palletizing processes.
Implementation Method 1
support elements (16) that can be driven and/or move the articles, piece goods or containers (12, 13) in a defined direction
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The method involves driving a movable support surface (14) in a defined direction in a partial manner, where articles, packaged goods or containers are deposited on a layer. A pushing element (20) is arranged at the longitudinal side of the support surface for forming a stop for the articles, packaged goods or containers. The articles, packaged goods or containers are transported to overfeed in the direction of a target position on a pallet. An independent claim is also included for an apparatus for handling of articles, packaged goods and or containers, and for layer formation during loading of pallets or when stacking the articles, packaged goods and or containers.