Vertical Roller Conveyor Pallet Access System
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Solution Overview
Problem
Conventional pallet picking systems require extensive space and resources due to long order-picking routes and inefficient use of storage and retrieval machines, as pickers must navigate through multiple aisles to access pallets, leading to suboptimal space utilization and increased costs.
Innovation Solution
The system employs a network of perpendicular roller conveyors connected to a delivery shelf, allowing pickers to access pallets from both sides and omit unnecessary aisles, with separators and a gradient to manage pallet movement and empty pallet removal, optimizing path length and reducing access depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional racks with static pallets are used, then storage capacity is provided, but the picker has to cover long distances and the system requires a lot of space
Solution Approach 1:
The patent transitions from longitudinal pallet arrangement to vertical roller conveyors connected perpendicularly to a delivery shelf. Pickers access pallets from both sides of the vertical conveyors, converting a one-dimensional longitudinal access path into a two-dimensional access pattern that significantly shortens travel distance while maintaining storage capacity
Solution Approach 2:
The system replaces static pallet racks with dynamic roller conveyors that can move pallets automatically. The gradient of 1° to 6° enables gravity-assisted pallet movement, and brake rollers provide controlled stopping. This dynamic system allows pallets to be replenished automatically without requiring pickers to traverse entire aisles
2Extent of automation
If automatic high-bay warehouse with storage and retrieval machines is used, then pallet replenishment is automated, but only a fraction of parking spaces can be used and expensive machines are required
Solution Approach 1:
The roller conveyors with gradient enable pallets to move automatically using gravity. When a pallet is removed from a picking position, the gradient causes the next pallet to roll forward automatically, eliminating the need for complex automated storage and retrieval machines while achieving continuous pallet replenishment
Solution Approach 2:
The patent changes the physical parameter of the conveyor system by introducing a gradient of 1° to 6°. This gradient parameter enables gravity-driven pallet movement, transforming the system from requiring powered mechanical retrieval to using passive gravitational force for automatic pallet replenishment
3Ease of operation
If longitudinal access to pallets is used, then pickers can access all pallets, but the access depth is approximately 1.2 m which is inefficient
Solution Approach 1:
The patent changes the access geometry from longitudinal (front-to-back) to lateral (side-to-side) by positioning vertical roller conveyors perpendicular to the delivery shelf. This dimensional change reduces the required access depth from approximately 1.2 m to approximately 0.8 m while maintaining full picker access to all pallets
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
This configuration significantly shortens the picker's path, enhances space efficiency, and allows for lateral access, reducing the need for extensive storage and retrieval machinery while ensuring safe pallet movement and replenishment.
Implementation Method 1
the roller conveyors have a gradient of 1° to 6°, preferably about 2°, which is greater than usual. In combination with brake rollers, it is ensured that both heavy (full) and light (empty) pallets can safely roll one space forward.
Implementation Method 2
In combination with brake rollers, it is ensured that both heavy (full) and light (empty) pallets can safely roll one space forward.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The device has a commissioning front (3) with roller conveyors (2, 2', 2'', 2''', 2IV, 2V) arranged at a supply shelf (1). The roller conveyors are vertically attached to the supply shelf. The roller conveyors have a set-up station (7) for 4 pallets separated from each other by separators. The roller conveyors exhibit a gradient of 2 degree. The set-up station exhibits a separate mechanical unlocking device. A locking mechanism is attached to the separators. The set-up station is arranged at a front side of gears (6) between the roller conveyors. An independent claim is also included for a method for commissioning of articles of palettes.