ES2787948A1 - MACHINE FOR THE SEMI-AUTOMATIC PREPARATION OF FULL LAYERS IN FLEXIBLE ENVIRONMENTS OF HIGH CONSUMPTION WAREHOUSES (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

Machine for the semi-automatic preparation of complete layers in flexible environments of large consumption warehouses. It is a machine specially designed for the semi-automatic preparation of orders on pallets in full layers. To do this, starting from the structuring of a side-loading truck, it has been foreseen that it includes two masts with pallet lifting means, a source mast (3) and a destination mast (5), among which a system for handling complete layers (8) is established that allows the layers to be transferred in a unitary manner from the origin pallet to the destination pallet. The machine also has a pallet supply platform (9), thus reducing the number of movements, the complexity of placing the boxes and the number of errors in preparing each order. (Machine-translation by Google Translate, not legally binding)

Description

D E S C R I P T I O N

Machine for the semi-automatic preparation of complete layers in flexible environments of a large consumer warehouses

TECHNICAL SECTOR

The present invention refers to a machine for the semi-automatic preparation of complete layers in flexible environments of mass consumption warehouses, that is, for the composition of pallets based on boxes of the same type at least for each of the layers that are used. stacked on the pallet, in order to reduce the number of movements, the complexity of placing the boxes and the number of errors in preparation of each order.

The object of the invention is to provide a machine that allows this process to be carried out semi-automatically, to date carried out manually.

BACKGROUND OF THE INVENTION

In order picking there are currently two types of merchandise handling in general: full pallets and loose boxes.

When a recipient (for example, a hypermarket) requests merchandise from a specific manufacturer, it indicates the codes of the desired references and the required quantity of each of them. This quantity is usually a multiple of full boxes but not always of full pallets.

Thus, each requested reference breaks down its preparation into complete pallets, moved by specific machinery, and into loose boxes.

The preparation of these loose boxes usually involves manual handling of each box. An operator moves through each position in the warehouse, manually picking up the indicated quantities of each reference and placing them on another initially empty pallet that is dragged with another specialized machine.

Since between each collection the operator must move to the position where each reference is located, this task is more laborious and less productive the fewer boxes must be collected from each reference. In addition, the composition of the final pallet is complicated by the differences in the size of the box of each reference, so the operator must place the boxes according to the final stability of the composite pallet and the fragility of each reference.

On the other hand, normally all the references leave the factory on pallets made up of different uniform layers. That is, since all the boxes of a reference will have the same dimensions, the mono-reference pallets will have their boxes arranged in layers with the same boxes for each layer.

With all this, sometimes it is requested that the final recipient orders some references in multiples of complete layers, trying to reduce the number of displacements, the complexity of placing the boxes and the number of preparation errors since it is more easy to verify the collection of full layers.

However, this 'full layer' preparation is still done manually in most warehouses. This is so because a traditional automation collides with the flexibility that is usually required in most sectors, especially in multi-client logistics operators.

EXPLANATION OF THE INVENTION

The machine for the semi-automatic preparation of full layers in flexible environments of high-consumption warehouses that is recommended solves in a fully satisfactory way the above-mentioned problems, allowing the process to be carried out semi-automatically.

To do this, starting from the structuring of a side-loading truck, it has been foreseen that it will be integrated with a system for handling complete layers, an additional mast for lifting pallets, and a platform for empty pallets with means of lateral displacement.

The machine has adequate dimensions to be used in conventional storage facilities, allowing to take advantage of the height of said warehouses, making the stock in height compatible with the preparation of complete layers.

More specifically, the machine will be guided by hand in a manner analogous to a conventional side loader to the position where the original pallet resides. This pallet could be located in the first or second height.

The operator proceeds to pick up said pallet and retract it to the machine, as it is done with conventional machinery.

The machine control system has a sensor bar to detect the exact height of the pallet and pressure sensors in the layer handling system. With this information, it positions the original pallet at the parameterized pick-up height and proceeds to activate said system for handling complete layers, materialized in a robot for handling the layers from the top, through vacuum suction cups.

In accordance with another of the characteristics of the invention, the layer handling system will have means of rotation on its own support arm, so that it can be positioned on the vertical for collection and delivery.

Thus, the machine includes two pallet lifting masts, one to manipulate the pallets of origin for the collection of the layers of the products, and the other to manipulate the destination pallet or collection of the order, so that the handling system of layers can work on both areas depending on their angular position.

More specifically, it is the lifting masts that control the vertical height of the load to the pick-up or delivery position, in correspondence with the layer handling system, by slightly pressing the merchandise on the absorption suction cups of said system.

The horizontal arm that allows the rotation of the layer collection system is made up of two robotic sections to carry out said rotation with the least horizontal separation both towards the inside of the machine and towards the outside, to achieve the use of the machine in conventional aisles with standard retractable pallet pickup masts and to allow the pickup mast to be deployed vertically without colliding with such equipment.

From this structuring, it is possible to lift the pallets of the original products to the layer manipulator, which is in charge of moving said layers to the pallet located on the destination mast, previously raised by said mast to the operation area handling system, automatically adjusting the height of the pallets through the machine's sensorization system.

In accordance with another of the characteristics of the invention, in order to achieve greater autonomy, the machine has a limited supply of empty pallets that have previously been placed on it by a traditional front machine in a repository arranged for this purpose, specifically a platform. storage of empty pallets with means of horizontal movement.

Each time the preparation of a new composite pallet begins, the operator can activate the sequence of movements that moves an empty pallet from its pallet to the mast of the destination pallet.

Thus, the sliding platform allows the repository to be placed in the vertical pick-up of the sucker.

The platform is laterally movable through three telescopic guides, counting on side walls to allow the exact positioning of the empty pallets against the corner formed by both walls, being partially open at the bottom, to allow passage through the means of elevation of the origin mast, allowing the stack of pallets to be raised to the layer manipulator, which will be in charge of picking up the upper pallet and moving it to the destination mast, leaving it ready to carry out a new order, so that the mast The origin will go down again until the remaining pallets are stacked on the tray, the latter moving again to its position initial, leaving the original mast free to operate with it.

From this structuring, the following advantages are derived:

• The machinery allows the collection of complete layers without physical manipulation by the operator and without the need for specific facilities for this. Therefore, it allows great flexibility both in the number of references involved in the operation and in the number of layers prepared. Thanks to this, it can be applied in situations of great variability in the volume of activity or when the average volume does not make it possible to make profitable fixed facilities dedicated to such handling.

• In addition, the possibility of working in the standard aisles of traditional warehouses makes it possible to make the most of their capacity, allowing the removal of pallets with merchandise from various location heights or simply using them to replenish the usual picking.

• This same machine can also be used both to replenish your own picking (if you do not want to carry out picking from high locations) as well as for complete re-palletizing of single reference pallets.

• The functionality of reusing pallets emptied during preparation and their storage on the machine itself, allows you to take advantage of your working capacity for almost the entire day, increasing your total productivity.

• Likewise, the possibility of depositing the final, ready-made pallets in the warehouse aisle, without altering their preparation rhythm, makes it possible to take advantage of the machine's work cycle even more if it is accompanied by a frontal machine. Furthermore, the placement of the pallets on the ground allows the passage of other machinery through the aisle and therefore reduces the urgency of their removal.

• Therefore, this full-layer harvester allows not only to improve the direct productivity of the preparation, but also drastically reduces the overexertion made by the operators and therefore improves the prevention of occupational risks of the operation.

• Likewise, optimizing the preparation of layers in flexible environments will reduce costs to customers and, therefore, alter the size of the orders of the final recipient, increasing the number of complete layers with respect to the entire preparation of loose boxes. This will not only improve the costs associated with today's heavy-duty logistics, but will also reduce setup errors and transport breakdowns due to loose boxes being placed on mixed pallets.

• By reducing the difference in the logistics cost for each box shipped between the preparation of full pallets and full layers, it is also possible that in some cases there is a reduction of full pallets in benefit of the preparation of full layers, allowing a better adequacy of their stocks.

In short, this device will positively alter the logistics of mass consumption.

DESCRIPTION OF THE DRAWINGS

To complement the description that is going to be made below and in order to help a better understanding of the characteristics of the invention, according to a preferred example of a practical embodiment thereof, a set of drawings is attached as an integral part of said description. where, for illustrative and non-limiting purposes, the following has been represented:

Figure 1.- Shows a schematic plan view of a machine for the semi-automatic preparation of complete layers in flexible environments of mass consumption warehouses carried out in accordance with the object of the present invention, in which on the destination mast The corresponding receiving pallet of the order layers appears ready.

Figure 2.- Shows a view similar to that of figure 1, but in which the robotic arm of the layer manipulator is shown in different positions, for example when loading a pallet previously deposited on the original mast to through the sliding platform of the machine, for its final implantation on the destination mast.

Figures 3, 4 and 5.- They show elevational views of different operating sequences that are carried out in the process of preparing an order by layers.

Figure 6.- Shows a view similar to that of the previous figures, but in this case corresponding to the process of feeding pallets by means of the tilting platform with which the machine is provided.

Figures 7, 8 and 9.- Finally, they show two views in plan, elevation and profile of the pallet supply platform, in a variant embodiment in which the platform has a lower height than the platform shown in the figures. 1 to 6.

PREFERRED EMBODIMENT OF THE INVENTION

In view of the figures outlined, it can be seen how the machine for the semi-automatic preparation of complete layers in flexible environments of large consumption warehouses is constituted from a side-loading truck (1), with its corresponding cabin (2 ) of control, and in which lifting means for pallets are established, specifically a lifting mast that we will call the origin mast (3), that is, destined to receive the pallets carrying the original products that are to be extracted by layers towards a receiving or destination pallet (4), with the particularity that laterally to the origin mast (3) an additional pallet lifting mast is established, which we will call destination mast (5), having foreseen that between these two masts is established a column (6) with a robotic arm (7-7 ') carrying a layer handling system (8) materialized in a layer handling robot from above, through vacuum suction cups, the aforementioned chassis having a platform (9) for supplying pallets, partially open at the bottom, and horizontally movable on the lifting means of the original mast (3).

The machine will be steered by hand in the same way as a conventional side loader to the position where the original pallet resides. This pallet could be located in the first or second height, so that the operator proceeds to pick up said pallet through the lifting means of the original mast (3).

At that moment, the operator must indicate that the pallet has been picked up and the number of layers indicated by the warehouse management system. This information transfer could be automated by communicating said warehouse management system with the machine's control system, although it is not strictly necessary.

The machine's control system has a sensor bar to detect the exact height of the pallet and pressure sensors in the layer handling system (8).

With this information, it positions the original pallet at the parameterized pick-up height and proceeds to activate said system for handling complete layers (8), as shown in Figure 3, so that said system for handling layers (8) works on an imaginary horizontal plane, moving the layers from one pallet to another through its robotic arm (7-7 '), taking care of the origin (3) and destination (5) masts, by means of their sensorization and control elements to arrange each pallet at the necessary height so that said layer handling system (8) can work correctly.

Based on this structuring, once the handling system has been activated and therefore the first layer is already held by the suction cups and its absorption mechanism, the original mast (3) descends to the ground position or, only a few centimeters if the preparation is of more than one layer of the same origin pallet.

When performing this separation, the sensor bar detects the height of the removed layer and informs the target mast (5) so that it retracts enough so that the boxes do not collide with it.

Then the layer handling system (8) turns and places the layer on the vertical of the destination pallet. The target mast (5) is raised again to the height calculated for the new layer or until collision is detected. In the case of single layer preparation from the source pallet, the handling system can now turn off its absorption system, staying in that position. The target mast (5) also remains in this position (or drops a few millimeters). Thus, the load will be kept pressed between the destination mast (5) and the handling system while the machine moves through the aisles, improving its stability and increasing the safety of the operation.

In the case of preparations of more than one layer per origin pallet, the cycle is repeated as many times as necessary.

Before proceeding to carry out a collection operation, the target mast (5) is lowered slightly a few centimeters to allow the handling system (4) to rotate without friction with the boxes previously placed and not collide with the target mast itself. Once the height of the removed layer is known, it will complete its descent to the necessary height, as previously described.

While these manipulations are being carried out, the control system keeps the machine paralyzed to prevent user interaction from displacing it from its position.

Once the indicated layers have been collected, the operator can again take up the controls of the machine and place the original pallet back in place.

On the other hand, when the destination pallet is complete, the operator can, before moving to the next location, manually lower said pallet and release it for another machine to pick it up and complete the necessary tasks for its final dispatch.

To achieve greater autonomy, the machine has a limited supply of empty pallets that have previously been placed on it by a traditional front machine in a repository arranged for this purpose, specifically a platform (9) for storage of empty pallets with storage means. horizontal displacement, that shown in detail in figures 6 to 9.

Each time the preparation of a new compound pallet begins, the operator can activate the sequence of movements that moves an empty pallet from its loading platform to the mast of the destination pallet (5), in the same way as he would with a product layer.

Thus, the sliding platform makes it possible to place the repository in the vertical pick-up of the sucker, being partially open at the bottom, to facilitate the passage of the lifting means of the original mast (3).

The platform (9) is laterally movable through three telescopic guides (10), with two vertical orthogonal walls (11-12) as stops to allow the exact positioning of the empty pallets against the corner formed by both walls, including a lower hole (13), to allow the lifting means of the original mast (3) to pass through it.

The height of these walls depends on the number of empty pallets that you decide to store on the machine. The maximum height must allow a correct visualization by the driver operator. To improve such visibility, these walls are configured as frames with maximum edge dimensions of 15 centimeters, but could also be configured as bars or consistent meshes.

When the operator indicates to the machine control system that he needs an empty pallet, the latter, after verifying that: there is no pallet in the destination mast (5) or in the origin mast (3), that the handling system (4) is not occupied, and that there are empty pallets in the repository or platform (8), proceed to: lower the blades of the origin mast (3) to the lowest position, activate the telescopic guides (10) to move the repository to the position of the origin mast (3), raises said mast to the height of action of the layer manipulator (4), activates this manipulator to pick up the empty pallet placed last and deposit it on the previously raised destination mast (5). While this last step is being carried out, the origin mast (3) can lower the remaining empty pallets again, which will return to rest on the platform (9), which can be withdrawn to its initial position by lateral displacement of the same.

On the other hand, during normal setup, an origin pallet may run out of merchandise when its last full layer is removed. This empty pallet can be used by the machine for its own use. Thus, the pallet will be raised to the pick-up position of the sucker which will keep it in that position while the lifting claws are removed. Subsequently, the platform (9) of the pallet repository will move to the vertical of the sucker. The origin mast will raise the repository pallets to the height of the suction unit and the latter will only have to deposit the collected pallet in the highest position of the repository. The origin mast (3) will return to its lower position, depositing the stack of empty pallets on its repository, which will be able to return to its resting position.

If the wooden support that is free from the original pallet is not reusable by the machine, the operator may return it to its original position.

This reuse of the empty pallets generated during preparation drastically reduces the need to replace the empty pallets on the machine itself, further increasing the expected productivity of the operation.

Claims (1)

R E I V I N D I C A C I O N E S 1- .- Machine for the semi-automatic preparation of full layers in flexible environments of large consumption warehouses, in which the products to be prepared are distributed in uniform layers stacked on the corresponding pallets, characterized in that it is made up of a forklift (1) for lateral loading, with its corresponding control cabin (2), and in which an original mast (3) equipped with lifting means for pallets is established, with the particularity that laterally to the original mast (3 ) a destination mast (5) is established with pallet lifting means, having provided that between these two masts a column (6) is established with a layer handling system (8) materialized in a robot with a robotic arm (7- 7 ') that includes means for handling the layers on the top, through vacuum suction cups, the machine chassis having a pallet supply platform (9), partially open at the bottom, and movable h horizontally on the lifting means of the original mast (3), with the particularity that it includes a control system with sensors to detect the height of the pallets on the different masts, as well as load pressure sensors on the lifting system. Layer manipulation (8). 2- .- Machine for the semi-automatic preparation of complete layers in flexible environments of large consumption warehouses, according to claim 1, characterized in that the robotic arm works on a horizontal plane and has two sections (7-7 ') that can be folded over said work plane. 3- .- Machine for the semi-automatic preparation of complete layers in flexible environments of mass consumption warehouses, according to claim 1, characterized in that the platform (9) is laterally movable through telescopic guides (10), with two vertical orthogonal walls (11-12) as stops for the exact positioning of the empty pallets against the corner formed by both walls, including a lower hole (13) for passing through the lifting means of the original mast (3) . 4- .- Machine for the semi-automatic preparation of complete layers in flexible environments of large consumption warehouses, according to claim 1, characterized in that it includes means of communication with the warehouse management system.