AMR Unit Load Lifter with Vertical Fork and Counterbalance
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Solution Overview
Problem
Conventional fork-type pallet movers and autonomous mobile robots (AMRs) are bulky, heavy, and require large maneuvering spaces, making them inefficient and costly for use in tight warehouse environments, and they lack the ability to efficiently lift and move unit loads without external assistance.
Innovation Solution
A compact and lightweight unit load lifter system mounted on an autonomous mobile robot, featuring a vertical axis fork assembly with counterbalance arms and rollers, which allows for zero-turn radius operation and independent lifting of unit loads without external help, utilizing a combination of rack gear, pinion gear, and linear motion guides for precise movement and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional fork-type pallet movers or forklift trucks are used, then lifting and moving capability is achieved, but the vehicle becomes bulky, heavy, and requires large maneuvering spaces
Solution Approach 1:
The vehicle is divided into separate functional modules: a compact base vehicle and an attachable fork assembly with counterweight mechanism. This segmentation allows the base vehicle to remain lightweight and maneuverable, while the fork assembly provides the necessary lifting capability only when needed.
Solution Approach 2:
The counterweight mechanism is positioned vertically above the base vehicle rather than horizontally extending behind it. This vertical arrangement in the third dimension eliminates the need for long horizontal counterbalance structures, reducing the vehicle's footprint and maneuvering space requirements.
2Extent of automation
If conventional fork-type AGVs or AMRs are used, then automated unit load movement is achieved, but the vehicle is bulkier in size and significantly heavier requiring more power
Solution Approach 1:
The automated lifting function is segmented into a separate attachable fork assembly rather than being integrated into the base vehicle. This allows the base vehicle to maintain minimal weight for automated navigation, while the fork assembly with its own counterweight mechanism handles lifting operations independently.
Solution Approach 2:
A counterweight mechanism is integrated into the fork assembly to balance the weight of the forks and unit loads. This counterbalance system reduces the power required by the drive mechanism to lift and lower loads, thereby reducing overall energy consumption during automated operations.
3Stability of the object's composition
If conventional vehicles with longer wheelbase are used, then stability is improved, but maneuvering space requirement increases and tight space parking becomes impossible
Solution Approach 1:
The counterweight and fork assembly are arranged vertically above the base vehicle rather than extending horizontally. This vertical configuration maintains the center of gravity within a compact footprint, enabling zero-turn-radius maneuvering and tight space parking while preserving vehicle stability through proper vertical balance.
Solution Approach 2:
The fork assembly is designed with movable components including extendable forks and adjustable counterweight positioning. This dynamic configuration allows the vehicle to adapt its weight distribution and fork position based on load requirements, maintaining stability across various operating conditions without requiring a fixed long wheelbase.
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
Enables efficient and stable lifting and transportation of unit loads in tight spaces with reduced operational costs and power requirements, allowing for autonomous operation and precise positioning without the need for external counterweights or manual intervention.
Implementation Method 1
a pinion gear and a motor mounted on the vertical axis fork assembly coupled with a rack gear for creating a desired horizontal motion
Implementation Method 2
an actuating end of a linear actuator to drive the at least one fork up and down
Implementation Method 3
a vertical axis fork assembly with a plurality of rollers, wherein the plurality of rollers are mounted on a roller mounting plate
Implementation Method 4
a plurality of linear motion guide blocks sandwiched between a sliding plate and a plurality of linear motion rails, wherein the sliding plate is configured to slide vertically and linearly up and down
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A unit load lifter with counterbalance arm mountable on an autonomous mobile robot (AMR) to load and unload unit load from one position to another position autonomously. The unit load lifter includes a horizontal slide unit and a vertical axis fork assembly. The horizontal slide unit include base plate of the unit load lifter is mounted on the AMR. A plurality of fixed guides is integrated with the base plate to house the vertical axis fork assembly by a plurality of rollers on a roller mounting plate. The vertical axis fork assembly include an actuating end of a linear actuator is connected to the sliding plate to drive the at least one fork up and down.