Trolley Sidewall Spreading Mechanism for Mixed-Case Stacking
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Solution Overview
Problem
Current automatic palletizing systems face challenges in efficiently stacking packages of varying sizes and shapes without manual intervention, as they struggle with stability, packing density, and optimized unloading sequences, especially when dealing with mixed-case palletizing where packages have different characteristics.
Innovation Solution
A device with a spreading mechanism for trolley sidewalls and a modular pusher/sliding plate system, combined with an intermediate plate and film wrapping for stabilization, allows for flexible and efficient stacking of packages on trolleys or pallets, enabling simultaneous positioning and stacking of multiple packages with high throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If packages of different sizes and shapes are stacked manually to optimize stability and unloading sequence, then stacking quality and reliability are improved, but productivity and automation level deteriorate
Solution Approach 1:
The device segments the stacking process into distinct functional zones: a positioning conveyor for precise package placement, a stacking location for controlled stacking operations, and separate pusher mechanisms for different directional movements. This segmentation allows automated high-speed operation while maintaining stacking quality through specialized handling in each zone.
Solution Approach 2:
The positioning conveyor acts as an intermediary between package input and the stacking location, pre-positioning packages with precise control over their spatial arrangement. This intermediary device enables the main stacking mechanism to operate at high speed without compromising placement accuracy or stack stability.
2Measurement precision
If displacement on the packing table is used for positioning packages, then positioning capability is improved, but processing time increases and throughput deteriorates
Solution Approach 1:
Packages are pre-positioned on the positioning conveyor before reaching the stacking location, with their final coordinates determined in advance. This preliminary positioning action allows the stacking operation itself to be executed rapidly without time-consuming adjustments during the actual stacking process.
Solution Approach 2:
Instead of moving packages slowly across a packing table for positioning, the system inverts the approach by using a fast-moving positioning conveyor that delivers pre-positioned packages to the stacking location. The positioning function is separated from the stacking function, allowing each to optimize for its primary purpose.
3Manufacturing precision
If sequential processing of single packages is used, then positioning accuracy is improved, but productivity deteriorates due to limited throughput
Solution Approach 1:
The device merges multiple package handling operations into parallel processes: the positioning conveyor operates continuously to prepare multiple packages simultaneously, while the stacking location processes them in sequence at high speed. The pusher mechanisms are designed to handle packages in rapid succession, combining precise positioning capability with high-rate processing.
Solution Approach 2:
The system uses dynamic control where the positioning conveyor speed and package spacing are continuously adjusted to match the stacking rate. The pusher mechanisms employ dynamic positioning and timing control to maintain placement accuracy while operating at high speeds, adapting to varying package characteristics in real-time.
4Strength
If trolley sidewalls are closed during stacking, then structural integrity is improved, but accessibility and stacking flexibility deteriorate
Solution Approach 1:
The trolley sidewalls are designed to be dynamically adjustable - closed during transportation to maintain structural integrity and stability, and open during stacking operations to provide full accessibility. This dynamic configuration allows the same structure to serve both protective and accessible functions at different operational stages.
Solution Approach 2:
The sidewalls are opened in advance before stacking begins, preparing the trolley for accessible loading. After stacking is complete, the sidewalls are closed as a preliminary action before transportation, ensuring structural integrity is established before the trolley enters the transportation phase.
Data Source
AI summary
A device and method for automatically stacking packages on a roll container in a predetermined spatial arrangement for forming a stack, comprising at least one feed conveyor which arranges the individual packages in a predetermined order; a lifting and lowering unit for lifting and lowering of the roll container in the Y-direction; at least one sliding plate and one pusher in order to transport the packages in the Z-direction to the predetermined position in the stack; moveable journals being provided in order to separate the lateral walls of the roll container. In a particular embodiment the journals are arranged on rotating disks.