Vertical Grouper System for Compact Container Palletizing
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Solution Overview
Problem
Existing systems for manipulating and palletizing containers require complex transfer mechanisms and significant space, with limited flexibility and high throughput, as they rely on multiple grouping stations and complex movement sequences to achieve stackable arrangements.
Innovation Solution
A grouper system comprising a first and second grouping station, where the second station is vertically positioned above the first, allowing for relative container arrangements through rotation and displacement, with a compact design that includes delta kinematics robots and a palletizer with a transfer unit and loading unit for efficient pallet layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple grouping stations are arranged side by side to achieve high throughput, then productivity increases, but device complexity and space requirements increase significantly
Solution Approach 1:
The patent transitions from a horizontal arrangement of multiple grouping stations to a vertical arrangement where grouping stations are stacked one above another. This dimensional change allows multiple stations to operate simultaneously for high throughput while eliminating the need for complex horizontal transfer mechanisms, as containers can be directly deposited onto pallets from each vertical level.
Solution Approach 2:
The patent combines multiple grouping stations and palletizing functions into a single integrated vertical structure. Instead of separate horizontal stations requiring complex inter-station transfer mechanisms, the vertical configuration merges the grouping and palletizing operations into one compact unit where containers from multiple levels are consolidated and placed onto pallets in a unified process.
2Productivity
If multiple grouping stations are arranged side by side to achieve high throughput, then productivity increases, but the space required increases significantly
Solution Approach 1:
The patent utilizes the vertical dimension to accommodate multiple grouping stations, stacking them one above another instead of arranging them horizontally side by side. This vertical stacking dramatically reduces the floor space required while maintaining the throughput capability of having multiple stations operating simultaneously.
3Manufacturing precision
If portal gripping systems or articulated arm gripping systems are used to arrange containers into stackable layers, then the desired layer pattern is achieved, but multi-phase movement sequences increase handling time and complexity
Solution Approach 1:
The patent segments the container handling process into distinct vertical levels or stages within the vertical configuration. Each grouping station operates at a different vertical level, performing simplified movements to position containers for stacking. This segmentation allows each station to focus on a specific portion of the layer formation process, reducing the complexity of individual movement sequences while maintaining overall precision.
Data Source
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AI summary
A grouper (1) for containers is disclosed. The grouper (1) comprises at least one first grouping station (3) and at least one second grouping station (5) located above the at least one first grouping station (3). It is provided that the grouping stations (3, 5) can each transfer several containers into a relative arrangement corresponding to a pallet layer to be formed from the respective multiple containers by selectively rotating and/or displacing the containers at an angle to their previous direction of movement.