Centralized Palletization Using Shuttle Robots and Buffer Batching
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Solution Overview
Problem
The existing palletization systems for objects from production lines are poorly automated, leading to high costs and inefficiencies due to the need for extensive infrastructure and idle palletizing stations, especially when production lines have varying throughput.
Innovation Solution
A process utilizing shuttle robots controlled by a command unit to pool palletizing stations across multiple production lines, where objects are transferred and stacked onto accumulation trolleys, then moved to a buffer storage area for batch grouping and palletization, reducing the necessity for fixed conveyors and allowing flexible re-direction of resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If dedicated palletizing stations are assigned to each production line, then automation level is improved, but device complexity and infrastructure requirements increase significantly
Solution Approach 1:
The patent merges multiple dedicated palletizing stations into a single shared palletizing station that serves multiple production lines. The system uses mobile accumulation carriages that can be dynamically assigned to different production lines, allowing one palletizing station to handle objects from several lines sequentially, thereby reducing overall infrastructure complexity while maintaining automation.
Solution Approach 2:
The shared palletizing station is designed with universal functionality to handle objects from multiple production lines. The control system dynamically assigns mobile accumulation carriages between different production lines based on real-time needs, enabling the single station to perform the functions previously requiring multiple dedicated stations.
2Productivity
If multiple dedicated palletizing stations are deployed, then productivity is improved, but floor area requirements increase prohibitively
Solution Approach 1:
The system transitions from a spatial distribution model (multiple stations placed throughout the facility) to a temporal distribution model (single station serving multiple lines at different times). Mobile accumulation carriages act as intermediaries, allowing the single palletizing station to serve multiple production lines sequentially, thereby maintaining productivity while dramatically reducing floor space requirements.
Solution Approach 2:
Mobile accumulation carriages serve as intermediaries between production lines and the shared palletizing station. These carriages temporarily store objects from multiple production lines and transport them to the palletizing station when ready, enabling the single station to handle throughput equivalent to multiple dedicated stations without requiring multiple station locations.
3Area of stationary object
If pooled palletizing station is used, then floor area is reduced, but loss of time increases due to object transport distances
Solution Approach 1:
The system performs preliminary accumulation of objects on mobile carriages at or near the production lines before transport to the palletizing station. This preliminary grouping and accumulation reduces the frequency and volume of transport operations needed, thereby minimizing the time loss associated with moving objects over longer distances while still achieving space savings from the pooled station approach.
Data Source
Figure 1A~1E
Figure 2
AI summary
Use is made of shuttle robots (107) able to move trucks (106, 106') under the control of a command/control unit (190) in order to handle objects between a collection point (110) and a palletization station (151) distant from the collection point, the said shuttle robots being autonomous in their movements and able to couple to and uncouple from the trucks, the command/control unit operates the shuttle robots so as to move the objects on the truck from the collection point to a buffer storage zone (141) where the objects on the truck are grouped together into batches of objects to be palletized, and the command/control unit operates the shuttle robots in such a way as to pick up the batched objects on the trucks from the buffer storage zone and move them in sequence to the palletization station.