PURPOSE OF MIXING PRODUCTS ON PALLETS

The invention provides a system and a method for automatic selection of articles from an assortment for the purpose of mixing products on pallets in order to prepare a MIX-type pallet, i.e. a pallet with an arbitrary product assortment packed in a collective pack, including storing/transporting trays with a system of pushers for raising a product from a storing/transporting trays.

The development of logistic systems aims at higher and higher level of automatizations in order to save costs and time and enhance profitability of such systems. Thus it is known to use automated, computer-controlled machines mounted in cabinets, e.g. for storage on and picking from the installation of warehouse racks. In such a case the crucial operation for the capacity of the whole system is order picking, i.e. picking goods for the ordered supply, e.g. a set of pallets with orders including diverse assortments of goods for different branches of supermarket networks, individual recipients.

Numerous documents describe individual elements for storing and/or picking orders at a corresponding installation. For example, WO 2005077789 A1 provides an automatic warehouse and automatic truck for introducing products into said automatic warehouse. The specification discloses an elevator positioned at the front of the warehouse for moving trucks with goods from one warehouse level to another and a central computer system to control the warehouse trucks.

Comprehensive logistic systems for products and/or product units are presently of special importance. Development is aimed at greater automatizations in order to relieve workers from tedious and unhealthy tasks to save costs and to increase cost effectiveness of the systems. Some product units of identical or unidentified type are usually introduced into logistics systems by means of transporting units of any kind. In logistic systems said transporting units are stored, disassembled, sorted and suitably to the client's requirements assembled again in order to form new transporting units.

A logistics system of this kind is described e.g. in DE 10313576 B4. There, product units are stored in and removed from a high-bay warehouse. Said handling is carried out by means of automated and computer-controlled vehicles for storing and picking. High-bay warehouse is a conventional pallet-based warehouse to which a tray storage system is connected by means of an automated conveyor technology. Product units are picked separately on trays in the tray storage system. Each tray is this loaded with a unitary packaging. Said unitary packaging units are then also handled individually, and for this purpose considerable time is necessary as well as vast provision of devices and large space.

On the other hand, WO 2007134841 A1 describes a plant for picking orders with a high-bay warehouse, at least one tray storage system, at least one packing station and at least one dispatch station. In this case, packing units that, in particular, form a complete layer of a pallet, are depalletized, layer by layer, onto a suitably sized tray. Said tray along with the entire layer of the pallet is then conveyed to a tray storage system. Suitably to the order, respective trays are then picked and they are mounted onto new transport units from the individual product units. This means that a considerably large unit is to be conveyed and stored and for this purpose considerable space is required. Moreover, in numerous product tray stations, where the latter are not completely emptied, they have to be handled and conveyed there and back, and this involves a considerable effort. In order to increase the probability of the tray to be completely emptied, several orders to be completed are combined (a batch) and this causes that product units have to be sorted later in time according to the individual orders according to a complex technology and sequence.

A solution for the above described problems is an "automatic selecting system" that makes manually performed operation automatized and provides enhancement of the process and increase in the productivity thereof. A method and installation of this kind are provided in which product units may be handled and processed further in a fast, automated, space-saving and cost-effective manner.

A system for automatic selection for logistics operations for the purpose of mixing products on pallets according to the invention comprises a control system, a storing rack module, transporting/storage trays with holes for pushers as well as a depalletization module and a palletization module.

The depalletization module with a mono product comprises an entire product layer selecting system and a storage system for empty pallets from depalletization. Depalletization module, via a storing/transporting tray transport system, is connected to the rack module. At the inlet and outlet of the storing rack module there are positioned vertical cargo elevators for transporting up and down selected products on the transporting/storing trays with holes for pushers. The storing rack module, via the transporting/storing tray transport system, is connected to the palletization module. The palletization module comprises a single product selecting system, connected to a vision system and the entire product layer selecting system as all as a preparation station for MIX pallets. A control system for automatic selection for the purpose of mixing products on the pallets is connected to depalletization module, storing/transporting trays transport system, storing rack module, palletization module.

Preferably, said storing rack module comprises a first storing rack and a second storing rack.

Preferably, said storing rack module comprises a main frame and a driving arrangement for transporting/storing trays.

Preferably, storing rack module comprises a plurality of levels at which in series transporting/storing trays are stored.

Preferably, said vertical cargo elevators comprise at the inlet two loading elevators at the depalletization module side and two unloading transporting elevators positioned at the palletization module side.

Preferably, the storing rack module operates in FIFO mode.

Preferably, said entire product layer selecting system is constituted by a mechanical/vacuum gripper.

Preferably, said single product selecting system comprises a pushing head positioned beneath the transporting/storing tray moving above it and a vision system connected to a set of pushers to raise the product from the transporting/storing tray through the holes.

Preferably, said pushing head is provided with pushers to push a single product or more products out at one time.

Preferably, the pushing head comprises a system for independent control of the pushers.

Preferably, the single product selecting system comprises a mechanical robotized picking arrangement.

Preferably, the aforementioned mechanical robotized picking arrangement is constituted by a mechanical gripper provided with a fork system to deliver the individual products onto a MIX pallet.

Preferably, the entire layer selecting system comprises a mechanical robotized picking system.

Preferably, the mechanical robotized picking system is constituted by a mechanical-vacuum gripper to deliver the entire product layer onto a MIX pallet being formed.

Preferably, said transporting/storing trays comprise evenly distributed holes on the entire surface of the transporting/storing tray. A method for automatic selection for logistics operations for the purposes of mixing products on the pallets comprises the following steps.

A depalletization module, using an entire product layer selecting system, removes the entire layer of products from a MONO pallet and places the products on a transporting/storing tray. The transporting/storing tray, via a transporting/storing tray transport system and with the use of a transport elevator at the inlet to a storing rack module, is introduced into a storing rack module. A palletization module, upon receipt of a signal from the control system, by means of an outlet transport elevator and the transporting/storing tray transport system, a tray is transported along with a product selected from the storing rack module to the palletization module. Suitably to the current needs, if the amount of products needed is less than the entire layer, the single product selecting system selects a product, and if the amount of products needed is equal to the entire layer, the entire product layer selecting system selects the entire product layer and the selected products are positioned on a MIX pallet being prepared.

Preferably, a single product in the single product selecting system is selected by a set of pushers included in a pusher head positioned beneath the moving storing/transporting tray comprising evenly distributed holes in its entire surface.

Preferably, said pusher head comprises a system of independent control of the pushers.

Preferably, the vision system during arrival of a transporting/storing tray under the head of the pushers records positions of the individual products, and then transmits them to the control system that activates the corresponding set of pushers to push only one selected product out.

Preferably, the aforementioned single product is raised above the surface of other products in the single product selecting system by means of a set of pushers and it is picked by a robotized picking system.

Preferably, in the depalletization module, when all the entire product layers are moved from a pallet with MONO products, the empty pallet is stored in a storage system of empty pallets from depalletization.

Preferably, in the palletization module, an empty pallet is picked from the storage system of empty pallets from palletization.

Advantageous effects of the subject invention are as follows: modular construction enabling easy scalability of the solution; greater productivity of the system thanks to the product picking system, without necessity to line the product up before loading. The proposed system works several times faster over the existing solutions; small amount of occupied space that causes that the system does not require much space in a warehouse bay. With regard to the existing solutions the proposed system occupies about 70% less space; flexibility of the mixing system providing for a possibility to operate on any products of diverse construction (no flat bottom requirement).

The object of the invention in an embodiment is presented in the drawing in which:

Fig. 1 is an overview of the complete system;

Fig. 2 is a structural view of a storing rack module;

Fig. 3 is a general view of one of a plurality of transporting/storing trays with evenly distributed holes on its entire surface;

Fig. 4 is a view of a setup of a transporting/storing tray with the use of a vision system;

Fig. 5 is a view of a first step of selection of a single product by means of pushers;

Fig. 6 is a view of a second step of selection of a single product by means of pushers;

Fig. 7 is a view of a third step of selection of a single product by means of pushers;

Fig. 8 is a view of a fourth step of selection of a single product by means of pushers;

Fig. 9 is a view of a mechanical gripper in a form of a fork for delivering a single product onto a MIX pallet being formed.

The invention providing a system and method for automatic selection for logistics operations for the purposes of mixing products on pallets will be explained closer with reference to embodiments of the solution for each of the aspects of the invention.

A system for automatic selection for logistics operations for the purposes of mixing products on pallets according to an embodiment comprises a control system, a storing rack module, transporting/storing trays with holes for pushers as well as a depalletization module and palletization module.

The control system (SS) is connected to the depalletization module (MD) and the transporting/storing trays transport system (STTMT) and rack module (RM), as well as with the palletization module (MP). On the other hand, the depalletization module (MD) for pallets with a mono product (PP MONO) is connected to an entire product layer selecting system (SWP) comprising a robotized picking system (RP) in a form of a mechanic-vacuum gripper (CHMP) and connected to a storage system for empty pallets from depalletization (MPPzD). The depalletization module (DP) is also connected to the transporting/storing tray transport system (STTMT) to the storing rack (RM) comprising vertical cargo elevators (WT) at the entrance for transporting up and down selected goods on transporting/storing trays (TMT) comprising holes (O) for pushers (W). Additionally, the storing rack module (RM), at the outlet, is connected to the palletization module (MP), via the transport elevators (WT) at the entrance, and via the transporting/storing tray transport system (STTMT). The palletization module (MP) is connected to the single product selecting system (SPP) and the entire product layer selecting system (SWP) as well as a station for preparing MIX-type pallets (PMix). The storing rack module (RM) comprises a storing rack (RM1) and a second storing rack (RM2), each of the storing rack modules (RM) comprising a plurality of levels and having a main frame (RG) and being provided with a driving arrangement (UN). At the inlet of the storing rack module (RM) there are loading transport elevators (WT1Z), (WT2Z) and at the outlet of the storing rack module (RM) there are unloading transport elevators (WT1R), (WT2R). The palletization module (MP) comprises the single product selecting system (SPP) which comprises a pushing head (GW) interacting with an independent pusher control system (STW) and a vision system (SW) connected to a set of pushers (ZW) that raise directly the selected products from the entire layer of products comprised on the tray, without any intermediate devices and with a connected picking system (RP). The picking system (RP) is constituted by a mechanical gripper (CHM) provided with a fork system (W). The transporting/storing tray (TMT) has evenly distributed holes (O) on its entire surface. With the palletization module a storage system for empty pallets for palletization (MPPdP) is arranged.

A method for automatic selection for logistics operations for the purposes of mixing products on pallets, according to an embodiment is carried out in its initial phase by a depalletization module (MD) to which consecutively MONO pallets (PPMONO) are delivered that comprise assortment of one type of product. From the MONO pallets (PPMONO), by means of a robotized picking arrangement (RP) in a form of a mechanic-vacuum gripper (CHMP), products are consecutively picked in entire layers (SWP) and they are delivered onto a transporting/storing tray (TMT) provided by a transporting/storing tray transport system (STTMT). In a further step, the transporting/storing tray (TMT) with the products loaded thereon is conveyed via the transporting/storing tray system (STTMT) to the inlet of the first storing rack module (RM1) and the inlet of the second storing rack module (RM2), where a first loading transport elevator (WT1Z) and a second loading transport elevator (WT2Z), respectively, feed transporting/storing trays with products (TMT) to one of a plurality of levels in serial arrangement (i.e. tray after tray). It is very important for each level of the storing rack (RM) to comprise transporting/storing trays (TMT) with products of the same assortment. On the transporting/storing tray (TMT) numerous products or collective packages are stored. Each level of the storing rack (RM) has a driving arrangement (UN) enabling moving transporting/storing trays (TMT) in a direction from the inlet to the outlet of the storing rack (RM). Additionally, the storing rack (RM) may be expanded by addition of further levels up to the height of the bay and it operates in FIFO mode (first-in-first-out).

A control system of automatic selection for the purposes of forming a MIX pallet, upon receipt of an order for a MIX pallet MIX (PMIX), transmits a signal to a palletization module (MP) which, by means of a first unloading transport elevator (WT1R) and a second unloading transport elevator (WT2R), via a transporting/storing tray transport system (STTMT), picks transporting/storing trays (TMT) with one product assortment from a first rack module (RM1) and from a second rack module (RM2) and conveys the transporting/storing trays (TMT), via the transporting/storing tray transport system (STTMT) to the palletisation module (MP), where, by means of a single product selecting system (SPP) and an entire product layer selecting system (SWP) a single product or entire layer of the product is picked and positioned on the MIX pallet (PMIX) being formed. Products are delivered by means of a robotized picking arrangement (RP). In the entire product layer selecting system (SWP) this is a mechanic- vacuum gripper (CHMP) and in the single product selecting system (SPP) this is effected by means of a set of pushers (ZW) positioned beneath the moving transporting/storing tray with holes (O) and the target product. One relevant and very important element of the single product selecting system (SPP) is the set of pushers (ZW) (Fig. 4-9) included in the pusher head (GW), which pushers push, through the holes (O), a selected single product out above other products, and the selected product is then picked by the mechanic gripper (CHM) in a form of a fork system (W) and delivered into a MIX pallet (PPMIX). A vision system (SW) interacts with the pusher head (GW). When one product is present on a transporting/storing tray (TMT), it may be positioned unaligned and the set of pushers (ZW) would encounter a problem when raising and picking the last product for example, and then the vision system (SW) transfers the information of position of the last product or of positions of the individual products on the transporting/storing tray (TMT) in a manner to activate, during selection, suitable pushers by means of a pusher control system (STW). The aforementioned operation cycle is repeated until all the products are picked and delivered into the MIX pallet (PMIX). During forming consecutive layers the MIX pallet (PMIX) is lowered down (the entire arrangement operates at a height of about 3 metres) and is concurrently wrapped with a stretch film. Upon completion of the operation the MIX pallet (PMIX) is removed and in its place an empty pallet from the storage system of empty pallets for palletization (MPPdP) is positioned.

List of reference signs RM - storing rack module RM1 - first storing rack RM1 - second storing rack UN - driving arrangement TMT - transporting/storing tray WT - cargo elevator WT1 - cargo elevator 1 WT2 - cargo elevator 2 MD - depalletization module MP - palletization module RP - robotized picking arrangement CH - gripper

CHM - mechanical gripper CHMP - mechanical -vacuum gripper SPP - single product selecting system SWP - entire product layer selecting system SW - vision system SS - control system O - hole/holes RG - main frame PP MONO - MONO product pallets

MPPdP - storage system for empty pallets for palletization MPPzD - storage system for empty pallets from depalletization STW - pusher control PMIX-Mix pallet

STTMT - storing/transporting tray transport system WT1Z - loading transport elevator no. 1 WT2Z - loading transport elevator no. 2 WT1R - unloading transport elevator no. 1 WT2R - unloading transport elevator no. 1 ZW - set of pushers STW - pusher control W - fork system