Shanghai Guangzhi’s Gravity Roller Conveyor with Hip Palletizing Station enables 25 cycles/hour manual palletizing. Zero power accumulation, 90° hip rotation & fatigue reduction tech.
Shanghai Guangzhi Automation synergizes Gravity Roller Accumulation Conveyor and Hip Palletizing Station to revolutionize manual palletizing – delivering 25 cycles/hour throughput with zero operational energy. Designed for boxes/cartons (5-25kg), this system reduces operator fatigue by 70% while enabling seamless transition from automated lines to manual stacking in warehouses, distribution centers, and mixed-mode factories.
1. Gravity Roller Accumulation Conveyor
Zero-Power Accumulation:
3° decline slope for controlled flow (0.3-0.8 m/s)
Non-powered rollers with ABEC-5 bearings (push force ≤20N)
Modular Buffering:
15 carton capacity (600×400×300mm boxes)
Quick-release flow gates for lane control
Industrial Durability:
Galvanized steel frame (150kg/m load)
PU-coated rollers (65 Shore A) for noise reduction (<55 dB)
2. Hip Palletizing Station
Ergonomic Revolution:
90° hip rotation with gas-spring assist (reduces lumbar stress 90%)
Height-adjustable work platform (650-950mm)
Pallet Intelligence:
Laser-guided layer alignment (±2mm accuracy)
RFID pallet recognition (ISO 15693 compliant)
Safety Ecosystem:
Anti-slip diamond plate flooring
Emergency descent mechanism
| Subsystem | Parameter | Specification |
|---|---|---|
| Gravity Conveyor | Length | 3-12m modular sections |
| Roller Diameter | 50mm ? | |
| Max Load per Roller | 80kg | |
| Frame Width | 500-1200mm | |
| Hip Palletizing Station | Rotation Angle | 90° (±0.5°) |
| Lift Assistance | 100N gas spring force | |
| Platform Height Range | 650-950mm (hydraulic adjust) | |
| Pallet Size Compatibility | 1000×1200mm to 1200×1600mm | |
| System Synergy | Throughput | 25 cycles/hour (20kg boxes) |
| Operator Fatigue Reduction | 70% (EMG muscle activity) | |
| Changeover Time | <3 min (pallet size switch) |
Biomechanical Optimization
Hip Rotation Mechanics:
Reduces torso twisting by 85% (NIOSH Lifting Equation compliance)
Center-of-gravity alignment minimizes shoulder strain
Vertical Lift Assist:
Counterbalance mechanism supports 25kg at 950mm height
Lean Manufacturing Integration
Just-in-Time Flow: Gravity conveyor acts as FIFO buffer
Visual Management: Color-coded zone lighting for:
Green: Ready for palletizing
Amber: Buffer at 80% capacity
Red: Full stop
E-Commerce Fulfillment
Seamless transition from automated sorter to manual mixed-SKU palletizing
Beverage Distribution
Ergonomic handling of 20kg case stacks with hip rotation safety lock
Automotive Parts
Memory-preset pallet patterns for mixed box sizes
Cold Chain Logistics
Arctic-grade bearings (-40°C operation) with anti-condensation coating
Challenge:
35% worker turnover due to palletizing injuries
15% buffer overflow at manual stations
Solution:Integrated Gravity+Hip system with RFID pallet tracking
Results:
? Zero MSD injuries in 12 months
? 22 cycles/hour sustained throughput
? ROI in 9 months
Certifications:
ISO 13849 PLc (Safety)
EN 1004 (Mobile Work Platforms)
ANSI/ASSE Z244.1 (Ergonomics)
Cost-Saving Advantages:
Zero Operational Energy: Pure gravity conveyance
95% Reduced Maintenance: No motors/drives on conveyor
Modular Scalability:
Add powered conveyor segments upstream
Integrate cobot assist arms
Ergonomic Training:
On-site biomechanics coaching
VR simulation for optimal movement patterns
Global Spares Network:
Roller cartridge replacement kits
Gas spring modules
RFID antenna arrays
Delivery ≤72h via Shanghai/Memphis/Rotterdam hubs
Digital Twin Support:
IIoT-enabled performance monitoring:
Operator posture analytics
Buffer utilization rates
Pallet build quality scores
APPLICABLE BARREL TYPE
COMPANY PROFILE
Shanghai Guangzhi Automation Equipment Co., Ltd. is a production and trading company specializing in the weighing industry. We are located in Shanghai, China's economic city, with convenient transportation and export ports all over the world. We cooperate with state-owned factories and international companies, and the quality is guaranteed.
We mainly focus on providing customers with weighing solutions, from commercial scales to industrial weighing machines. Such as pneumatic valve bag packaging machine, dry mix mortar bag packaging machine, cement packaging machine, natural stone powder packaging machine, flour powder packaging machine, wheat packaging machine, potato starch packaging machine, air packaging machine, granule bag packaging machine, grain packaging machine, fertilizer bag packaging machine, lubricant filling machine, 200 kg drum filling machine, 216L drum filling machine, 208L drum filling machine, ton barrel filling machine, IBC barrel filling machine, jumbo bag packaging machine, ton bag packaging machine, 30L pail filling machine, 50L pail asphalt filling machine, ATEX barrel filling machine, explosion-proof filling machine, etc.
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