Shipping Bay Level Control Unit for Reliable Container Sorting
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Solution Overview
Problem
Existing shipping bay systems face challenges in achieving reliable and efficient sorting operations with complex and costly design efforts, particularly in assigning containers to individual customers, and require extensive components for reliable operation.
Innovation Solution
The introduction of a shipping bay design featuring a container feed section connected to a stationary elevator and track-guided level control units that are displaceable at right angles to the ramps, replacing the complex roller conveyor mechanism with simpler, lightweight level control units, and eliminating the need for sensors and reflectors by integrating control instruments into the level control units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stationary roller conveyor mechanism is used in each bay level, then container conveying is reliable, but the design complexity and cost increase significantly
Solution Approach 1:
The patent replaces stationary roller conveyors with mobile level control units that can move along rails to different positions. These units are lightweight and displaceable, transforming the system from static to dynamic, thereby reducing structural complexity while maintaining conveying functionality through automated positioning and container transfer mechanisms
Solution Approach 2:
The patent extracts the conveying function from the fixed roller conveyor structure and consolidates it into mobile level control units. By removing the complex stationary mechanism and replacing it with simpler, movable units equipped with load pickup means, the system achieves the same container handling capability with reduced design complexity
2Adaptability or versatility
If a pivotable slope conveyor is used for vertical transportation, then containers can be conveyed to any desired bay level, but the design complexity and cost increase
Solution Approach 1:
The patent segments the vertical transportation function into separate components: a stationary elevator handles vertical movement to bay levels, while mobile level control units handle horizontal positioning and container transfer. This division eliminates the need for a complex pivotable slope conveyor that would need to perform both vertical and horizontal functions simultaneously
Solution Approach 2:
The patent introduces buffer sections as intermediary zones between the elevator and the ramps. Containers are first conveyed vertically by the simple elevator to the buffer section, then the mobile level control unit picks up containers from the buffer and transports them to the appropriate ramp. This intermediary approach simplifies the overall system by separating vertical and horizontal transportation functions
3Reliability
If sensors and reflectors are installed for each ramp to check filling level, then container sorting is reliable, but the cost and device complexity increase
Solution Approach 1:
The patent integrates the detection function into the mobile level control unit itself. The level control unit, which already performs container pickup and transport functions, is equipped with control instruments that can detect ramp filling levels. This multi-functional design eliminates the need for separate sensors and reflectors at each ramp, reducing system complexity while maintaining detection reliability
Solution Approach 2:
The mobile level control unit performs self-detection of ramp filling levels using its integrated control instruments. The unit autonomously determines whether a ramp is full before attempting to place a container, eliminating the need for external sensing systems at each ramp location
4Measurement precision
If many short ramps are used for fine sorting criteria, then sorting precision improves, but the number of components and maintenance effort increase
Solution Approach 1:
The patent uses mobile level control units that can dynamically position themselves at different ramp locations. Instead of having fixed, dedicated conveying mechanisms for each ramp, the same mobile unit serves multiple ramps sequentially. This dynamic approach allows the system to handle many short ramps for fine sorting without proportionally increasing the number of components, as the level control units are shared resources
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 solution simplifies the design, reduces costs, increases operational reliability, and allows for finer sorting criteria with shorter, steeper ramps, reducing maintenance efforts and eliminating the need for additional ejectors, while maintaining efficient container handling and sorting capabilities.
Implementation Method 1
The level control unit has a load pickup or carrying means in the form of drivable rollers, whose axes extend in the direction of travel of the level control unit and at right angles to the ramps
Implementation Method 2
The level control unit has a load pickup or carrying means in the form of drivable rollers
Implementation Method 3
a container feed section is connected to an elevator of the shipping bay, which releases a fed container into a selected bay level
Implementation Method 4
a pivoting unit, which is assigned to a plurality of ramps arranged next to each other and which can be pivoted upward to release in the upwardly pivoted state containers onto a selected sloped ramp of a selected bay level based on the container's own weight
Data Source
AI summary
A shipping bay arrangement (1), preferably in an order-picking installation, for accepting and delivering containers (2), with ramps (3) which are arranged next to one another and one above the other, the outlets (A) of which can be reached manually by an operator and on the filling side of which, feeding and filling devices are arranged, wherein the ramps arranged next to one another respectively form a rack level (I, II, III, IV, V) of the shipping rack. A container feeding section (4) leads to a lift (5) of the shipping rack. The lift (5) transports a fed container (2) to a selected rack level, wherein a dedicated rail-guided level conveyor device (6) is provided at each rack level, and receives the fed container (2). The level conveyor device (6) can be made to move transversely in relation to the inlets (E) of the ramps (3) for transporting the fed container (2) to a selected ramp, and for filling the selected ramp with the fed container. A buffer section (7) may be provided at each rack level, and downstream of the lift. At the exit of the buffer section, the level serving device (6) of each rack level can be positioned for taking over a fed container.