Variety Packing Conveyor Loops to Reduce Shingling and Jamming
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Solution Overview
Problem
Existing variety packing systems suffer from inefficiencies such as shingling and jamming of articles, large space requirements, and damage to articles due to mass transport on single filing conveyors, leading to operational inefficiencies and increased space needs.
Innovation Solution
A compact variety packing system with a donor case unloading station, first and second pick and place systems, and a conveyance system that includes a loop of conveyors and carriages with a grid structure to manage articles, eliminating single filing conveyors and preventing shingling, while allowing flexible and efficient packing of mixed-case packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mass transport on single filing conveyors is used, then articles can be moved through the system, but shingling and jamming occur leading to article damage
Solution Approach 1:
The conveyor system is segmented into multiple parallel conveyors (first conveyor, second conveyor, third conveyor, fourth conveyor) that work together in a loop, eliminating the single filing conveyor that causes shingling and jamming. Articles are distributed across multiple transport paths rather than forced through a single narrow channel.
Solution Approach 2:
Transfer conveyors (third and fourth conveyors) act as intermediaries that move articles between parallel conveyors in a controlled manner. These intermediary conveyors facilitate smooth transitions and prevent direct contact between articles from different conveyors, eliminating shingling and jamming.
2Productivity
If traditional variety packing systems are used, then packing can be performed, but large space requirements are needed
Solution Approach 1:
Multiple conveyor functions are merged into a compact loop configuration. The first, second, third, and fourth conveyors form an integrated loop system where articles flow continuously through packing operations without requiring large linear space. The parallel conveyors are positioned close together, merging transport paths into a compact arrangement.
Solution Approach 2:
The conveyor system transitions from a linear single-file arrangement to a multi-dimensional loop configuration. Articles can be transported in parallel on multiple conveyors simultaneously, utilizing vertical and lateral spacing to create a compact three-dimensional layout rather than requiring extensive linear floor space.
3Ease of operation
If single filing conveyors are used, then articles can be transported, but space inefficiencies occur
Solution Approach 1:
Each conveyor in the loop system performs multiple functions: the first conveyor transports articles away from the loading zone, the second conveyor unloads articles at the unloading zone, the third conveyor transfers articles between zones, and the fourth conveyor completes the loop. This multi-functional loop design eliminates wasted space and maximizes the utility of each conveyor segment.
Data Source
AI summary
A variety packing system includes a donor case unloading station for receiving donor cases having first and second articles, a variety packing conveyor having a packing zone for forming a variety packing case, a conveyance system arranged as a loop between the donor case unloading station and the variety packing conveyor, the conveyance system including a plurality of carriages configured to move along the conveyance system, each carriage of the plurality of carriages configured to receive the first and second articles, a first pick and place system configured to move the first articles and the second articles from the donor case unloading station to the conveyance system, a second pick and place system configured to move the first articles and the second articles from the conveyance system to the variety packing conveyor, and a control system, where the variety packing case includes at least one of the first and second articles.