Turntable System with Validation Sensors for Pallet Wrapping
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Solution Overview
Problem
The delivery of products from distribution centers to stores is plagued by errors and inefficiencies, particularly in building pallets with various beverage container permutations, leading to significant operating costs due to missing or mis-picked products, and the process of wrapping pallets with stretch wrap is time-consuming and occupies valuable space.
Innovation Solution
A turntable system with cameras and weight sensors for pallet validation and wrapping, allowing for efficient identification of SKUs on pallets, automatic validation, and streamlined wrapping processes, including the use of multiple turntables and a support bridge for efficient pallet handling and wrapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If stretch wrap is wrapped around a loaded pallet using a rotating turntable, then the items are kept stacked stably, but the process takes time and occupies valuable warehouse space
Solution Approach 1:
The system performs validation, identification, and preparation of pallets before they reach the wrapping station. Multiple turntables are pre-positioned in sequence, allowing continuous operation without waiting for single-turntable completion. This preliminary preparation and sequential arrangement reduces overall wrapping time while maintaining stability.
Solution Approach 2:
The wrapping process is divided into multiple sequential stages using multiple turntables (first turntable for initial wrapping, second turntable for additional wrapping). This segmentation allows parallel processing of different pallets at different stages, reducing total time occupation while each turntable maintains stack stability through controlled rotation and wrapping.
2Device complexity
If a single turntable is used for pallet wrapping and validation, then the equipment is simple, but the warehouse space occupied is valuable and processing throughput is limited
Solution Approach 1:
Multiple turntables are merged into a sequential processing line with a bridge connecting them, creating a compact multi-functional system. The bridge serves as both a support structure and a transfer mechanism, combining transportation and positioning functions. This merging allows high-throughput processing in a condensed space arrangement rather than scattered individual turntables.
Solution Approach 2:
Each turntable serves multiple functions: validation platform, imaging station, weighing platform, and wrapping station. The same physical infrastructure (turntable, bridge, support surface) handles multiple operational tasks sequentially, reducing the need for separate dedicated equipment and minimizing total space requirements while maintaining system capability.
3Productivity
If manual pallet building is performed without validation, then the process is quick and simple, but errors and inefficiencies occur leading to additional operating costs
Solution Approach 1:
The system incorporates cameras and weight sensors that continuously monitor and validate pallet contents during the building process. Image recognition technology identifies SKUs and verifies correct product placement, while weight sensors confirm expected load weights. This real-time feedback allows immediate correction of errors without significantly slowing down the pallet building process, maintaining productivity while improving reliability.
Solution Approach 2:
Validation of pallet contents is performed during the building process itself rather than as a separate post-building step. The imaging and weighing systems are integrated into the pallet construction workflow, identifying and verifying products as they are placed on the pallet. This preliminary validation prevents errors from propagating and eliminates the need for separate verification steps, maintaining speed while ensuring accuracy.
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 system significantly reduces errors in pallet loading, increases efficiency in pallet validation and wrapping, and optimizes warehouse space by automating the process, thereby minimizing operating costs and improving delivery accuracy.
Implementation Method 1
The turntable may include a weight sensor
Implementation Method 2
A first camera may be directed toward the first turntable and a second camera may be directed to the second turntable
Data Source
AI summary
Several embodiments of turntable systems for loaded pallets are disclosed. In some embodiments, a first ramp leads up to the turntable and a second ramp leads down from the turntable on the opposite side. In other embodiments, at least two turntables are positioned adjacent one another, optionally with a bridge surface connecting them so that a pallet lift can be driven from one turntable to the other to place one pallet on one turntable and another pallet on the other turntable according to a method disclosed herein. A validation system without a turntable includes a plurality of cameras about a periphery of a platform weight sensor.