Transport Layer Distribution for Automated Packaging Storage
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Solution Overview
Problem
Existing storage systems for packing units are inefficient due to the need for large storage spaces, high energy consumption, and underutilization of conveyor systems, as they are designed for the largest packing unit, leading to reduced efficiency and increased costs.
Innovation Solution
Packing units are conveyed as a transport layer, reducing manipulation steps and optimizing the use of conveyor space, eliminating the need for additional loading aids, and utilizing computer-controlled transport trolleys to enhance throughput and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If packing units are conveyed individually through the storage system, then each packing unit can be handled separately, but the conveyor area is underutilized and throughput is reduced
Solution Approach 1:
The patent combines multiple individual packing units into a collective transport layer that moves through the conveyor system as a single unit. This merging approach maximizes conveyor area utilization and throughput while maintaining the ability to separate and handle individual packing units at destination points through sorting mechanisms.
2Adaptability or versatility
If conveyor systems are designed for the largest packing unit, then all packing unit sizes can be accommodated, but small packing units result in large unused conveyor areas
Solution Approach 1:
By merging multiple small packing units into a transport layer, the system fully utilizes the conveyor area designed for larger units. The collective transport layer fills the available conveyor space, eliminating wasted area while maintaining versatility to handle different packing unit sizes through flexible sorting at destination.
Solution Approach 2:
The patent transitions from one-dimensional individual unit conveyance to two-dimensional layer-based transport. This dimensional change allows efficient utilization of conveyor area by packing multiple units side-by-side in a layer configuration, optimizing space usage while maintaining adaptability to different unit sizes.
3Quantity of substance
If a large number of storage spaces are distributed over many storage racks, then packing units can be stored efficiently, but the storage system requires a lot of space and high acquisition costs
Solution Approach 1:
The patent merges multiple storage locations into a consolidated buffer zone where packing units are stored in a compact arrangement. This reduces the total footprint of the storage system while maintaining adequate storage capacity by optimizing the spatial organization of storage racks and reducing the number of distributed storage locations needed.
4Productivity
If packing units are transported as a transport layer, then manipulation steps are reduced and conveyor space is optimized, but individual manipulation of packing units becomes more difficult
Solution Approach 1:
The system merges individual manipulation operations with collective transport. While packing units move collectively as a layer through the conveyor system to maximize throughput, sorting mechanisms at destination points enable efficient separation and individual manipulation when needed, balancing both throughput efficiency and operational flexibility.
Data Source
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AI summary
The method involves conveying the packing units (2,2') to a staging spot (69), where the packing units are formed into rows (97) in the conveying direction (70). The rows are compiled into a transport layer (103) which is received by a transport layer distribution system on a conveying surface and conveyed to a packing unit buffer, in which a material handling system distributes the packing units to storage points. An independent claim is also included for a storage system with an adjusting device.