Automated Sorting Robot for Variable Stacking Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The delivery and sorting of goods, particularly non-palletized items like car tires, face challenges in automated unloading and quality control due to variable stacking patterns during transport, leading to inefficient manual processes prone to errors and requiring significant workforce, which complicates quick discharge and storage.
Innovation Solution
A system involving EDP-based recording of delivery notes, optoelectric scanning for parameter determination, and programmable algorithms for charge carrier allocation, combined with conveyor and sorting robots for automated sorting and palletization, minimizes human intervention and reduces errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual processes are used for unloading and sorting goods, then flexibility and adaptability to different goods are maintained, but productivity is low and workforce requirements are high
Solution Approach 1:
The system enables self-service through automated identification and sorting. Scan units automatically read identification data from goods, the control unit automatically determines sorting destinations, and conveyor routing units automatically transport goods to correct locations without human intervention
Solution Approach 2:
Manual mechanical sorting operations are replaced by an automated system combining optical scanning (scan units), computational logic (control unit with algorithms), and automated conveyor mechanisms. This substitutes human physical labor with automated mechanical and electronic systems
2Loss of time
If automated systems are introduced for unloading and sorting, then productivity increases and service time decreases, but device complexity increases
Solution Approach 1:
The system achieves universality through a modular architecture where scan units, conveyor routing units, and the control unit can handle multiple types of goods with different identification methods (barcodes, RFID, optical recognition). The same basic infrastructure serves various sorting requirements without needing completely separate systems
Solution Approach 2:
The control unit acts as an intermediary that bridges the scan units and conveyor routing units. It receives identification data, processes sorting logic through algorithms, and generates routing commands, thereby coordinating the complex interactions between different system components
3Measurement precision
If manual recording and sorting of goods is performed, then adaptability to different goods types is maintained, but measurement precision and recording accuracy decrease due to human errors
Solution Approach 1:
Manual visual inspection and recording are replaced by automated scan units that optically read identification data and transmit it to the control unit. This eliminates human reading errors and ensures consistent, accurate data capture across all goods
Solution Approach 2:
The system implements feedback through the control unit comparing scanned identification data against the delivery note and goods receipt. This verification process ensures recording accuracy by detecting and correcting discrepancies automatically
4Productivity
If goods are delivered in variable stacking patterns, then loading efficiency is maintained, but automated discharge becomes difficult due to unpredictable positions
Solution Approach 1:
Each good performs self-identification by presenting its identification data (barcode, RFID tag, or optical features) to the scan unit. This eliminates the need for the system to determine physical position or orientation, as goods automatically provide their identification information regardless of stacking pattern
Solution Approach 2:
The system changes the detection parameter from physical position (which varies with stacking patterns) to identification data (which remains constant). By scanning identification markers rather than relying on positional information, the system can handle any stacking configuration
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 system enables fully automated and efficient sorting and storage of goods, reducing workforce needs, minimizing service times, and ensuring accurate tracking and quality control, adaptable for various goods and supply chain transparency.
Implementation Method 1
Transfer the goods on the first conveyor routing unit to at least one first scan unit, wherein the specific parameters of the respective goods are recorded by the at least one first scan unit
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for sorting loose goods of different dimensions, comprising the following method steps: A) EDP-assisted recognition of the delivery label and determining the target goods input value; B) allocating a sufficient number of load carriers according to the target goods input value; C) providing a first conveyor section unit with goods from the amount of delivered goods; D) transporting the goods on the first conveyor section unit to at least one first scanning unit; E) detecting the specific parameters of the respective goods using the at least one first scanning unit; F) transmitting the specific parameter of the respective goods to a distributer station via the at least one first scanning unit; G) forwarding the scanned goods to a distributer station on a further conveyor section unit; H) allocating the respective goods to one of the conveyor sections connected to a distributer station using the distributer station and according to the specific parameter of the respective goods and the load carrier determined from same using an algorithm; I) transmitting the further processing data for the respective goods from the distributer station to an appropriate sorting robot; K) the appropriate sorting robot retrieving the goods from the connected conveyor section unit; L) the appropriate sorting robot palletising the goods into the allocated load carrier; M) aligning the target goods input value with the actual goods input value. The invention also relates to a corresponding device.