DE102013110045A1 - Method and system for multilayer stacking of a base - Google Patents

Abstract

Method and system for automatic multi-layer stacking of a carrier (P), in particular a pallet, with packages (W) of different dimensions in a predetermined spatial arrangement to form a stack, comprising the steps:
- Computer-aided determination of the order and spatial position of the packages (W) on the carrier (P);
- Fetching the isolated packages (W) in a required order by means of conveyor (2);
- Transport of the packages to be shipped (W) from the conveyor (2) to the pre-calculated spatial positions on the support (P) or the forming stack (S) on the support (P) by handling means;
wherein in the pre-calculation of the order and spatial position of the packages (W) on the carrier (P) is checked for at least two successive packages (W1, W2) in succession, stackable on each other and in common to the predicted spatial positions on the carrier (P) or the forming stack (S) on the carrier (P) by handling means are transportable.

Description

The invention relates to a method and a system for automatic stacking of packages on a base in a predetermined spatial arrangement for forming a stack according to claim 1.

The automatic stacking of a base or a carrier, in particular a pallet or a trolley, with packages for forming a stack for later shipping, so the "palletizing" is known per se. In this case, however, packages of uniform size or extent by robots, grippers, etc. are stored on mathematically determined places.

The process of automatically loading a load carrier with packages of different characteristics to form a stack, on the other hand, is the so-called automatic mixed-case palletizing.

In today's distribution logistics, ever greater demands are placed on order picking. It is therefore necessary to develop picking systems that process jobs automatically without manual intervention.

Thousands of different products (or packages) of different characteristics (size, shape, weight, dimensions, surfaces, strength, compressibility, etc.) must be picked automatically with such systems.

Here, different aspects must be taken into account, which enormously increase the complexity compared to the "simple" manual stacking of simple regular geometries. Thus, a subsequent package can be stacked or deposited well on a previous package only if it has a flat or even surface, which should also be aligned approximately horizontally, and if the package carry the weight of the deposited on him further packages without damage can.

Furthermore, the stack formed should have a certain stability, u. a. so that it does not fall over during transport. A wrapping with foil helps, but can not alone stabilize a faulty stack.

In addition, on the customer side, optimization of the stacks due to the desired unloading order is increasingly desired.

The stacking of different packages or goods of different size or extent is therefore usually still done by hand, since the requirements for the stability of the stack, the packing density within the stack and the order of loading and the associated discharge order and not least the stackability of the goods are extremely high and are not yet met only partially by the known methods and devices.

From the EP 1 462 394 B1 is a device for automatically loading a load carrier with a load stack forming packing units, so a device for palletizing known. In the apparatus, the packing units are stored on trays and occasionally fed and deposited by them on a packing table. There, the packing unit is moved on the table by a pusher along the broad side of the pallet to be loaded, until the loading coordinates in the X direction are reached. Subsequently, another pusher and a loading tongue simultaneously push the packing unit in the direction of the loading depth over the pallet until the loading coordinates in the Z direction are reached. The loading tongue then retracts, with the pusher stopping and serving as a scraper, so that the packing unit is deposited on the pallet at the desired point "freely falling". In this case, the forming stack is supported by a loading aid on the other three sides. So it is stacked "against the wall". Moving on the packing table, however, is time consuming and has disadvantages in forming the packing pattern due to limited accessibility. It is also imperative that the loading tongue and the scraper / pusher move simultaneously in the X direction. Also, only one packing unit can always be "processed" sequentially.

From the WO 2010/059923 A1 For example, an automatic robot-based stacking apparatus is known in which an intermediate plate is used to form the first layer of a stack and simultaneously change pallets.

In contrast, the object of the present invention is to provide a method and apparatus for automatically stacking a carrier with packages of varying degrees in a predetermined spatial arrangement that flexibly permits high throughput mixed-case stacking.

This object is achieved by the method set forth in claim 1 and the system specified in claim 4. Advantageous embodiments will become apparent from the dependent claims and the description.

According to the invention, it has been recognized that the throughput in automatic stacking can be increased if the number of itself slow Ablagervorgange of packages on the carrier or the forming stack can be reduced. This is achieved by stacking packages in a faster process where possible. Thus, two slow steps of stacking two individual packages are replaced by a rapid step of pre-stacking the two packages and a slow step of stacking the pre-stack thus formed, thus saving time overall.

In the pre-calculation of the order and spatial position of the packages on the carrier is to computationally checked whether they are stackable and jointly transported to the predicted spatial positions on the carrier or the stack forming on the carrier by handling means as a pre-stack.

According to the invention, in the prediction of the order and spatial position of the packages on the carrier for at least two consecutive packages in the sequence can be checked whether these stackable on each other and the precalculated spatial positions on the carrier or the forming stack on the carrier through Handling means are transportable as pre-stack.

However, the invention goes one step further and optimizes the possibility of using pre-stacking in stack calculation in order to use as many as possible.

• – Oberflächenbeschaffenheit
• – Tragfähigkeit des unteren Packstücks
• – Grundfläche des Packstücks
• – Gesamthöhe des Stapels

As criteria for the examination are for example in question:

• - surface texture
• - Load capacity of the lower package
• - Base of the package
• - Total height of the stack

It can usefully be checked prior to the transport of the respective package to the respective predicted spatial position on the carrier or the forming stack on the carrier in a pre-stacking, whether the current package is to be stored on the subsequent package for pre-stacking. In other words, it is checked in a pre-stacking unit belonging to the stacking unit whether the package currently arriving has a positive result of the pre-stackability with the subsequent package.

If so, the first package in the pre-stack unit is lifted, the succeeding second package positioned below the raised first package, and the first package lowered onto the second package to form a pre-stack. In other words, the first package is lifted by the conveyor and the second package is conveyed to the same location, whereupon the first package is lowered to form the pre-stack. Repeat this process for more packages until a maximum stack height is reached. Subsequently, the packages may be taken together, i. the pre-stack are transported in the stacking unit to the predicted spatial positions on the carrier or the forming stack on the carrier in the manner of a proven manner.

The system according to the invention is thus provided with a computer, wherein the computer is designed programmatically to check in the prediction of the order and spatial position of the packages on the carrier for at least two successive packages in the sequence, whether these stackable on each other and jointly to the precalculated spatial positions on the carrier or the forming stack on the carrier by the handling means are transportable. It is thus also already checked in the calculation of the position and the order of the packages, if pre-stacking are bildbar.

The calculator thus calculates a virtual stack based on a job and the related products, which determines the position of the products in the stack and thus determines the subsequent order of stacking. During the pre-calculation by the computer always a maximization (optimization) of the number of pre-stack and the Vorstapelhöhe is aimed. In other words, the calculated virtual stack is already optimized to form as many pre-stacks in the stack as possible to reduce the actual stacking cycles in favor of the pre-stacks.

To form the pre-stacks, the system preferably includes a pre-stacking unit upstream of the main stacker. In spite of this, the pre-stacking unit can nevertheless be spatially integrated into the stacking device and possibly even directly upstream of the actual stacking.

It is preferred if the pre-stacking unit has a lifting and lowering mechanism for raising and lowering a package such that a subsequent package can be positioned underneath the lifted preceding package (see above).

The lifting and lowering mechanism may have a liftable and lowerable fork to lift the respective package from the conveyor, eg roller conveyor. But also suction units and other gripping units are possible - such as out DE102007046919B4 known gripper, the one Lifting and settling or more packages on the underlying package allows.

The fork of the lifting and lowering mechanism is preferably also transversely displaceable to the lifting or lowering direction, so that they can be "pushed under" or "pulled out" under the package. Thus, the package does not slip when retracting the fork and thus the pre-stack "tilts", it makes sense if the lifting and lowering has a respect to the transverse to the lifting or lowering direction movable fork fixed retention plate.

Overall, it is possible to perform the stacking of the carrier flexible and high performance. In particular, a wide range of different packages can be stacked continuously.

It can therefore be stacked fully automatic, in addition to the course, also manageable uniform little demanding packages packages with different dimensions successively on the carrier at high speed.

The packages are a wide variety of goods, packaged goods, packaged goods, such as boxes, boxes, boxes, containers, goods on trays, packaging units, such as. Multiple film packaging of plastic bottles, etc., as well as individual items of all kinds in question.

As a support are intermediate plates or carriers, such as pallets and trolleys, or similar documents for general cargo and their packaging in question.

Further details of the invention will become apparent from the following description of exemplary embodiments with reference to the drawing, in which

1 shows a schematic perspective view of an apparatus for automatic multi-layer stacking of pallets at the beginning of the formation of the first layer;

2 an enlarged schematic side view of the device 1 in the area of the endless conveyor;

3 a 2 corresponding view from another angle;

4 a 2 corresponding view from another angle;

5 a 2 corresponding view from above;

6 a 2 corresponding view after completion of the first layer;

7 a 1 corresponding view after the completion of further layers;

8th a 3 corresponding view including the pre-stacking unit; and

9 a detailed view of the pre-stacking 8th such as

10 a flow chart of the process of pre-stacking.

In the figures one is as a whole with 1 designated device for automatic multi-layer stacking of pallets P shown with packages W of different dimensions in a predetermined spatial arrangement. It is therefore a device for "mixed-case" palletizing. Of course, with the device 1 also only similar packages W are palletized.

The device 1 includes a roller conveyor 2 as a feed conveyor, which provides the separated packages W in a computer-aided predetermined order from a warehouse, not shown, so that they can be placed at the precalculated position in the stack S.

At the end of the roller conveyor 2 is a pusher 3 trained converter arranged, which converts the packages W by 90 degrees and delivers to the subsequent positioning conveyor. In this case, the packages W are also aligned at an angle, so far as possible due to their external shape, on the positioning conveyor 4 are aligned.

The positioning conveyor 4 is designed as an endless conveyor in the form of a circulating conveyor belt. Through him, the packages W are positioned in the X direction promoting to take this coordinate of the later position in the stack.

To exactly maintain the positioning or while the conveyor belt is running 4 perform is a stopper 5 (see. 4 ) is provided, which is driven in the X direction relative to the conveyor belt movable to "stop" the respective package. Depending on the type of system, the use of a stopper for positioning the package is not absolutely necessary and can be dispensed with. The drive takes place via a toothed belt (not shown), which is attached to the linear axis 5B is arranged and in the stopper 5 is mounted.

The positioning conveyor or the conveyor belt 4 is horizontal (on the same level) and along one side of the place 6 arranged for stacking. Usually, the carrier P to be loaded (pallet) will be arranged here (cf. 6 and 7 ).

However, as will become apparent, this is not the case with the formation of the first layer of a stack.

At the level of the upper run 7 of the endless conveyor 4 above the carrier P to be loaded is an intermediate plate 8th in the place 6 intended. The intermediate plate 8th is divided in the middle and every part 8A , B to the side (in the X direction) slidably designed such that the first layer of a stack on the intermediate plate 8th is formed while the completely loaded carrier P of the previous stacking operation is exchanged for a new empty carrier P. Thus, the batching process can be continued without interruption. When the first layer is formed and the new carrier P is present, the parts become 8A , B moved to the side (cf. 6 ) and the first layer is transferred to the underlying support P on which is subsequently further stacked (see. 7 ).

For feeding empty pallets or discharging stacked pallets is a corresponding roller conveyor 9 below the stacking place 6 intended.

From the roller conveyor, the respective pallet P of a lifting and lowering unit 10 taken to raise and lower the carrier P in the Y direction and up to the stacking place 6 hazards. The lifting and lowering unit 10 is also responsible for the level adjustment in stacking per se, so if necessary when stacking a package W performs a stroke or a lowering and also performs the adjustment of the compensation of the layers at the beginning of a new layer.

From the conveyor belt 4 Thus, the respective package W is laterally in the place to the desired position in the stack 6 on the intermediate plate 8th (First layer) or the pallet P (other layers) deported in the Z direction.

For this displacement of the packages W to the predetermined position in the stack S, the apparatus comprises a sliding plate battery 11 and a pusher battery 12 , ie in each case a plurality of side by side horizontally and along the side of the stacking place 6 or the pallet P arranged individual sliding plates 13 and single pushers 14 ,

The sliding plates 13 grab between the upper strand 7 and the bottom strand 20 through the endless conveyor and take over the pusher 14 From the conveyor belt deported package W. Then push the pusher and the sliding plate together to the desired position and the sliding plate 13 is withdrawn while the pusher 14 to stop the package W stops. Thus, the package W is positioned. The sliding plates 13 run flat at the front (cf. 2 ) so that positioning can be as accurate as possible.

The sliding plates 13 are each as horizontal and along the side of the stacking place 6 and formed transversely thereto designed flat strip-shaped plate, which in the direction of the stacking place 6 run thinner.

The sliding plates 13 are on the opposite side of the carrier of the endless conveyor 4 suspended and arranged parallel and side by side. They are each on a Z-direction aligned linear axis 16 slidably back and forth movable. The drive is per axle via an electric motor 16E and a toothed belt (not shown), which is arranged on the linear axis and in which the carriage or the sliding plate 13 is mounted.

The sliding plate battery 11 thus forms an optional broadening of the endless conveyor 4 in the stacking place 6 into it.

The pushers 14 are horizontal and along the side of the stacking place 6 and the carrier P along the endless conveyor 4 and formed in alignment with each other and independently movable. They are arranged on the opposite side of the carrier of the endless conveyor or are there in the rest position to the conveyor belt 4 to extend the removal of packages.

The pushers are as the sliding plates over the entire length of the stacking place 6 or the pallet P and arranged on a clamped above the endless conveyor frame 17 attached. There they are each aligned on a Z-direction linear axis 18 slidably back and forth movable. The drive is per axle via an electric motor 18E and via a toothed belt (not shown), which is arranged on the linear axis and in which the carriage or the pusher 14 are hung.

Both the stopper 5 as well as the pushers 14 extend from the respective linear axis down to a height just above the surface of the conveyor belt 4 and have at the local end on an enlarged foot area to handle the packages W better and safer.

Below the stacking place 6 is a unit 19 provided for wrapping the formed stack S with a film.

The wrapping is done layer by layer when stacking or after stacking a layer. The carrier P with the already formed layers of the stack S is from the lifting and lowering unit 10 , gradually, lowered downwards and so drives through the ring-shaped unit 19 for wrapping.

When the entire stack S has been completed, the stack S on the pallet P is moved downwards and over the roller conveyor 9 removed.

At the same time, the intermediate plate 8th closed and continued on this to form the next batch of the next order.

Parallel to this, as already described above, a new empty pallet P is "loaded".

Overall, therefore, the order and spatial position of the packages W on the pallet P for the establishment of a stack S based on the underlying job for automatic stacking of packages W on a pallet P in a predetermined spatial arrangement for forming a stack S computer-aided determined.

Then, the packages W in a predetermined order required by means of the feed conveyor 2 isolated from a warehouse etc. without aids (trays, etc.). The packages W to be loaded are subsequently delivered by the infeed conveyor 2 through the converter 3 on the endless conveyor 4 implemented.

By means of this, the stopper 5 and the pusher battery 12 and sliding plate battery 11 is the respective package W to the predetermined spatial position on the pallet P (or the stack 6 or intermediate plate 8th ) transported in the forming stack.

Depending on requirements, the pallet P in Y-direction through the corresponding unit 10 lowered or raised.

As in 8th illustrated, includes the device 1 a pre-stacking unit 21 in the area of the roller conveyor 2 before that as a pusher 3 trained converter is arranged to increase the throughput in the automatic stacking packages W, if possible, for stacking each other before they are implemented and stacked analogously to the packages W as described above.

In the pre-calculation of the spatial position of the packages on the carrier in the subsequent stack to be formed and thus their order of delivery to the device 1 (see above) is also computationally checked or optimized whether it is possible to form pre-stack. For this purpose, it is also calculated, for example, for at least two successive packages W1, W2 in succession, whether they can be transported stacked on top of one another and pre-stacked to the predicted spatial positions on the carrier P or the forming stack S on the carrier P.

If the system or the computer recognizes such a possibility, later the respective first or preceding package W1 in the pre-stacking unit 21 lifted, the subsequent second package W2 below the raised first package by means of the roller conveyor 2 positioned and the first package W1 lowered onto the second package W2 to form a Vorstapels V.

This pre-stack V is transported analogously to the above procedure for individual packages W to the precalculated spatial positions on the carrier P or the forming stack S on the carrier.

The pre-stacking unit 21 has a lifting and lowering mechanism 22 for raising and lowering (cf. 9 , Arrow 28 ) of a package W with a liftable and lowerable fork 23 on to the respective package from the roller conveyor 2 withdraw.

The fork 23 the lifting and lowering mechanism 22 is also displaceable transversely to the lifting or lowering direction, so that they can be "pushed in" under the package W or "pulled out" can be. So she grabs her teeth 26 between the rollers of the conveyor 2 , For this purpose, the tines can be perpendicular to the conveying direction of the conveyor 2 to be driven back and forth (cf. 9 , Arrow 27 ).

So that the package W1, which is up, when retracting the fork 23 or their tines does not slip, has the lifting and lowering mechanism 22 one opposite the fork 23 fixed slotted retaining plate 24 on. The slots 25 run vertically, leaving the tines 26 the fork 23 These can pass through (in the back and forth movement) and also vertically raised or lowered to relocate the package W1.

Now runs a package W on the roller conveyor 2 on (step I), the method described below proceeds (cf. 10 ).

It is first checked in step II whether the result of the prediction in terms of Pre-stackability of the current package W1 was positive on the subsequent package W2.

If this is not the case, the package W1 according to step III without handling by the pre-stacking unit 21 conveyed and as described above "normal" palletized, so transported to the predicted position in the stack S (step IV).

If a pre-stacking is possible, however, the package W1 in the pre-stacking unit 21 on the conveyor 2 positioned (step V).

Then the tines go 26 the fork 23 and raise the package W1 to a defined height (step VI), which results from the dimensions of the package W1 and W2 and is selected so that the package W1 incl. The tines 26 only slightly higher than necessary to allow subsequent positioning of the package W2.

Then, the second package W2 is so by means of the roller conveyor 2 in the pre-stacking unit 21 positioned (step VII) that it is located directly below the center of the raised package W1.

Thereafter, in step VIII, the tines 26 retracted and the package W1 is doing by the retaining plate 24 held in his position. As soon as the tines are completely retracted, the upper package W1 comes to lie on the lower package W2 and thus forms a prestack V.

The pre-stack V is then palletized (step IX) in the same way, ie transported to the predicted position in the stack S as if it were a single package W.

As pre-stacking is faster than palletizing, time is saved.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• EP 1462394 B1 [0010]
• WO 2010/059923 A1 [0011]
• DE 102007046919 B4 [0025]

Claims (10)

Method for automatic multi-layer stacking of a carrier (P), in particular a pallet, with packages (W) of different dimensions in a predetermined spatial arrangement to form a stack, comprising the steps: - computer-aided determination of the order and spatial position of the packages (W) the carrier (P); - Fetching the isolated packages (W) in a required sequence by means of conveyor technology ( 2 ); Transport of the packages to be loaded (W) from the conveyor system ( 2 ) to the predicted spatial positions on the support (P) or the forming stack (S) on the support (P) by handling means; characterized in that in the prediction of the order and spatial position of the packages (W) on the carrier (P) is checked computationally, whether packages (W1, W2) stacked on each other and together to the predicted spatial positions on the carrier (P) or the forming stack (S) on the carrier (P) by handling means as a pre-stack (V) are transportable. A method according to claim 1, characterized in that computer-aided maximization of the number of Vorstapelmöglichkeiten and Vorstapelhöhe (number of packages) is performed. A method according to claim 1 or 2, characterized in that prior to the transport of the respective package (W1) to the respectively pre-calculated spatial position on the carrier (P) or the forming stack (S) on the carrier (P) in a pre-stacking unit ( 21 ) is checked whether the current package (W1) is to be placed on the subsequent package (W2) for pre-stacking. A method according to claim 3, characterized in that the first package (W1) in the pre-stacking unit ( 21 ), the succeeding second package (W2) is positioned below the lifted first package (W1), and the first package (W1) is lowered onto the second package (W2) to form a pre-stack. A method according to claim 3 or 4, characterized in that the pre-stack (V) from the stacked stacked packages (W1, W2) on the carrier (P) or the forming stack (S) on the support (P) deposited by the handling means becomes. System for automatic multi-layer stacking of a carrier (P), in particular a pallet, with packages (W) of different dimensions in a predetermined spatial arrangement to form a stack, comprising: - a computer for the computer-aided determination of the order and spatial position of the packages (W ) on the support (P); - a conveyor technology ( 2 ) for bringing the separated packages (W) in a required order; A stacking device ( 1 ) with handling means for transporting the packages (W) to be loaded from the conveyor technology ( 2 ) to the predicted spatial positions on the carrier (P) or the forming stack (S) on the carrier (P); characterized in that the computer is program-technically designed to check in the prediction of the order and spatial position of the packages (W) on the carrier (P), whether packages (W1, W2) stackable on each other and together to the precalculated spatial positions the carrier (P) or the forming stack (S) on the carrier (P) by the handling means as a pre-stack (V) are transportable. System according to claim 6, characterized in that the system comprises a pre-stacking unit ( 21 ), the stacking device ( 1 ) is upstream. System according to claim 7, characterized in that the pre-stacking unit ( 21 ) a lifting and lowering mechanism ( 22 ) for raising and lowering a package (W1) such that a subsequent package (W2) can be positioned below the raised preceding package (W1). System according to claim 8, characterized in that the lifting and lowering mechanism a liftable and lowerable fork ( 23 ) having. System according to claim 8 or 9, characterized in that the fork ( 23 ) of the lifting and lowering mechanism is displaceable transversely to the lifting or lowering direction.

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