Tray-Handling Station with Tilting Sliding Surface
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Solution Overview
Problem
In order-picking systems, manually handling large trays with heavy or oversized piece goods is physically exhausting and often violates ergonomic guidelines, as existing automation focuses on automated loading and unloading processes, leaving manual handling of trays and forming of stacks incomplete.
Innovation Solution
A tray-handling station with an ergonomically designed sliding-surface unit and tilting device that allows order-picking personnel to move piece goods from trays to a discharging area without lifting, using a conveyor system that tilts trays and utilizes a sliding surface for stepless handling, reducing physical strain and adhering to ergonomic standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated loading and unloading processes are implemented, then productivity and automation degree are improved, but device complexity and cost increase significantly
Solution Approach 1:
The system enables self-service operation where the order-picking person independently performs tray loading and unloading using the sliding-surface unit and tilting device, without requiring automated robotic systems or complex mechanical handlers. The ergonomic design allows manual operation to serve itself, eliminating the need for expensive automation infrastructure while maintaining operational efficiency
2Device complexity
If manual handling of large trays with heavy piece goods is performed, then device complexity is reduced, but the physical effort required increases and ergonomic guidelines are violated
Solution Approach 1:
The sliding-surface unit creates a gravity-based equipotential working plane where piece goods can be moved horizontally without vertical lifting. The tilting device adjusts the tray angle to align with the sliding surface, enabling seamless gravity-assisted transfer of heavy items from tray to discharge area, eliminating strenuous lifting motions while maintaining simple mechanical structure
Solution Approach 2:
The sliding-surface unit acts as an intermediary element between the tray and the discharge area. Instead of directly lifting heavy piece goods from the tray to the discharge point, the tilting device and sliding surface provide a intermediate gravity-based transfer path, reducing the physical effort required by the order-picking person while keeping the overall device structure simple
3Ease of operation
If the working area is enlarged to accommodate manual tray handling, then ease of operation is improved, but the space required increases
Solution Approach 1:
The tilting device introduces a vertical dimension to the tray handling process by adjusting the tray angle. This dimensional change allows piece goods to be transferred along a gravity-based inclined plane rather than requiring extensive horizontal working space. The sliding-surface unit leverages the vertical-to-horizontal dimension transition to enable ergonomic handling within a compact footprint
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
The solution significantly reduces physical effort required for handling large trays, enhances ergonomics by eliminating the need for lifting, and increases picking performance by minimizing cycle time through efficient tray handling and piece good transfer.
Implementation Method 1
a tilting device is preferably provided, which tilts the to-be-handled tray or the to-be-removed piece good relative to a substantially horizontally orientated main-conveying plane such that the order-picking person can push and/or pull the to-be-removed piece good over a sliding surface
Data Source
AI summary
A tray-handling station for manually loading or unloading piece goods on or from a tray, comprising a tray-conveyor system including a handling position for buffering at least one tray; a working area including at least partially a packing station, or a piece-good conveyor system; and a sliding-surface unit defining a handling plane together with the to-be-handled tray, the handling plane being arranged adjacent to the tray-conveyor system and the packing station, or the piece-good conveyor system; wherein the working area includes the handling position, at least partially, and is dimensioned such that a person moves, during removal of one of the piece goods from the tray located at the handling position, which serves as removal position, the piece good from the tray to a discharging area, which is located within the working area and which, at least partially, overlaps the packing station, or the piece-good-conveyor system, only by moving his/her upper body without a lift.