Automated Vertical Loop Conveyor for Article Handling
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Solution Overview
Problem
Industrial facilities face inefficiencies in receiving, storing, and picking articles due to suboptimal temporary storage spaces, manual handling leading to physical fatigue and health risks, and potential errors in order preparation, which increases costs and risks of loss and accidents.
Innovation Solution
A fully automated system utilizing two storage conveyors and elevators forming a vertical loop for efficient article reception, storage, and picking, with a controller that allocates space based on article dimensions and prioritizes urgent items, minimizing human handling and optimizing storage space, and incorporating a secure delivery zone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling is used to transfer articles, then flexibility in handling is maintained, but operator physical fatigue and health risks increase
Solution Approach 1:
The system enables self-service through automated conveyors that transport articles between storage areas and picking stations without human intervention. The conveyor system autonomously moves articles along defined paths, eliminating the need for operators to manually handle and transport heavy or numerous items, thereby reducing physical fatigue and health risks while maintaining operational flexibility through programmable control.
Solution Approach 2:
Manual mechanical handling by operators is replaced with an automated conveyor system. The conveyor mechanism substitutes human physical effort with automated mechanical transport, using belts or rollers to move articles between stations. This substitution eliminates direct human contact with articles during transfer operations, reducing occupational illnesses and physical strain while preserving handling adaptability through controlled system design.
2Quantity of substance
If wire mesh carts and shelves are used for temporary storage, then storage capacity is provided, but significant floor space is consumed
Solution Approach 1:
The storage system transitions from traditional horizontal floor-based storage to a vertical three-dimensional conveyor structure. Articles are transported and stored along elevated conveyor paths and at multi-level picking stations, utilizing vertical space rather than consuming floor area. This dimensional shift allows the facility to maintain or increase storage capacity while dramatically reducing the footprint required for temporary storage operations.
Solution Approach 2:
The conveyor system serves multiple functions simultaneously: it acts as both a storage medium and a transport mechanism. Articles are held on conveyor segments or at designated stopping points along the conveyor path, eliminating the need for separate storage furniture like carts and shelves. This multi-functionality consolidates storage and handling operations into a single space-efficient system that maximizes vertical utilization.
3Productivity
If items are stored in non-orderly manner, then storage speed is increased, but time is wasted searching for particular items
Solution Approach 1:
The system incorporates identification and tracking mechanisms that provide feedback about article location and status. Each article or container is identified through codes or sensors, and the control system continuously monitors their positions along the conveyor path. This feedback enables the system to automatically direct specific articles to appropriate picking stations or storage locations, eliminating manual search time while maintaining high-speed automated handling and sorting operations.
Solution Approach 2:
Articles are pre-sorted and directed to specific conveyor segments or picking stations based on their destination or priority before reaching the final picking point. The system performs preliminary routing and positioning operations along the conveyor path, so that when an article reaches a picking station, it is already in the correct position and orientation. This preliminary action eliminates the need for operators to search for items, as their locations are predetermined and automatically managed by the control system.
4Productivity
If automated conveyor system is implemented, then labor costs are reduced, but device complexity increases
Solution Approach 1:
The automated system is divided into discrete functional modules: loading stations, conveyor segments, picking stations, and unloading points. Each module operates semi-independently with defined entry and exit points, allowing for easier maintenance, troubleshooting, and scalability. This segmentation reduces overall system complexity by breaking down the automated conveyor into manageable units that can be controlled and monitored individually while collectively providing comprehensive automation for labor reduction.
Data Source
Figure 1
AI summary
The present invention relates to a method for receiving, storing and picking articles comprising the following steps in order: - receiving articles (1) at a receiving station (2), - transferring a first article (1) to an upstream elevator (4), then to a first horizontal conveyor (6) on which at least a second article (1) is previously stored, said first conveyor (6) being capable of transferring articles (1) from said upstream elevator (4) to a downstream elevator (7), - transferring said at least a second article (1) to said downstream elevator (7), then to a second horizontal conveyor (9) located above or below said first conveyor (6) and capable of transferring articles (1) from said downstream elevator (7) to said upstream elevator (4), - transferring said first article (1) to said downstream elevator (7), then to a picking station (10).The present invention also relates to a system for implementing the method according to the invention.