Stacker Crane Selective Panel Withdrawal
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Solution Overview
Problem
Current production systems for painted panels face inefficiencies due to long lead times, material waste, and high costs associated with frequent paint changes and manual handling, particularly when dealing with customized orders and varying panel dimensions and finishes.
Innovation Solution
An automated system utilizing a vertical oven with a stacker crane and multiple forks that allows for the selective withdrawal of painted panels according to customer orders, enabling random sequence and pull logic, reducing the need for human intervention and optimizing product changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If panels are grouped by painting batch and withdrawn manually, then production follows batch-and-queue logic, but lead times become long and productivity is reduced
Solution Approach 1:
The patent replaces manual mechanical handling with an automated stacker crane system equipped with multiple forks that can selectively withdraw panels based on customer orders. The system uses automated control units to manage the withdrawal process, substituting human labor with mechanical automation to improve productivity while maintaining operational simplicity.
Solution Approach 2:
The stacker crane system dynamically adapts its operation by selectively activating specific forks based on the dimensions and positions of panels required for customer orders. The system can adjust the number and position of active forks in real-time, enabling flexible and efficient panel withdrawal without fixed batch constraints.
2Adaptability or versatility
If painting machines frequently change colors to accommodate customized orders, then product customization is improved, but material waste and set-up costs increase
Solution Approach 1:
The system performs preliminary grouping of panels by painting batch before the drying process. By organizing panels into batches based on their painting characteristics in advance, the system enables more efficient paint change scheduling, reducing the frequency of color changes and associated material waste while still accommodating customized orders.
Solution Approach 2:
The patent segments the production process into distinct phases: painting batches are grouped separately, then the automated withdrawal system selectively combines panels from different batches according to customer orders. This segmentation allows painting operations to optimize for batch efficiency while final order assembly achieves customization, reducing overall material waste.
3Device complexity
If vertical ovens use FIFO logic for drying, then drying process is simplified, but random sequence withdrawal for order preparation becomes impossible
Solution Approach 1:
The system segments the drying and withdrawal functions. The vertical oven maintains simple FIFO drying control for process simplicity, while the stacker crane system independently manages the selective withdrawal of dried panels. This separation allows the drying process to remain simple while the withdrawal process achieves full flexibility for random sequence order preparation.
Solution Approach 2:
The stacker crane acts as an intermediary between the FIFO drying process and the final order assembly. It receives dried panels in FIFO sequence from the oven, then uses its selective fork activation capability to reorganize and withdraw panels in the random sequence required by customer orders, decoupling the two processes.
4Quantity of substance
If multiple panels are stored per rack position, then storage capacity is optimized, but selective withdrawal of single panels becomes complex
Solution Approach 1:
The stacker crane system dynamically activates only the specific forks needed to access and withdraw the required panel. When a panel is stored among multiple panels at the same rack position, the control unit calculates which forks need to be activated based on the target panel's position and dimensions, enabling selective withdrawal without complex manual intervention.
Solution Approach 2:
The multiple forks are segmented and independently controllable, with each fork responsible for specific panel positions. This segmentation allows the system to activate only the necessary subset of forks for each withdrawal operation, simplifying the selection mechanism while maintaining high storage capacity.
Data Source
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AI summary
Vertical oven (1) for drying and temporarily storing painted panels (2, 2', 2", 2"'), said oven comprising racks (6) made of fixed laths (7) for supporting said panels (2) placed on at least two facing columns, further comprising: - A system for uploading/downloading said panels (2) in/from said vertical oven (1) through at least a roller conveyor (3); - A stacker crane (4) comprising two multiple forks (8', 8") each comprising a plurality of single forks (8), wherein the first multiple fork (8') withdraws the panels placed on a first side of said oven (1) while the second multiple fork (8") withdraws the panels placed on the opposed side of the oven; - wherein on said racks (6) said panels (2", 2"') can be placed side by side or alone (2') according to the width of said panels; - A control unit (11) suitable for controlling the uploading/downloading of the panels and/or said stacker crane, said control unit executing a control software comprising the instructions for controlling said uploading/downloading system of panels and/or said stacker crane; characterized in that there is provided an independent actuator (9) for each single fork (8) forming said multiple forks (8', 8"), which independent actuators are separately controlled by said control unit; said control unit comprising instructions for the independent control of said each actuator (9) of the single forks (8) of said multiple forks (8', 8"); optionally comprising at least one sensor (17) of a system for detecting the dimensions of said panels (2), which is connected to said control unit; said software comprising instructions configuring the control unit in a suitable way for determining: - The number of the single forks (8) to be actuated, correspondingly to the length of the panel (2p) to be withdrawn; - The length of the stroke of said forks (8) correspondingly to the width of the panel (2', 2", 2"') to be withdrawn.