Buffer Carts With Articulating Floors for Palletization
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Solution Overview
Problem
The process of palletization in fulfillment centers is time-consuming and poses a risk of injury to operators due to the manual handling of non-uniform packages and the long distances they need to travel, which complicates the sorting and shipping processes.
Innovation Solution
The implementation of buffer carts with articulating floors that automatically position packages for easy retrieval, reduce the distance operators need to travel, and include sensors to trigger palletization when a threshold is reached, thereby reducing manual effort and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling of packages is used for palletization, then operators can directly sort and load packages, but operators face injury risks and long travel distances
Solution Approach 1:
The patent introduces buffer carts as intermediary devices between the conveyor system and palletization area. These carts automatically receive, store, and present packages to operators, eliminating the need for operators to manually handle packages during transport and reducing injury risks from direct manual handling of non-uniform packages
Solution Approach 2:
The buffer carts are equipped with articulating floors that automatically position packages for easy retrieval without operator intervention. The system self-adjusts package positioning and triggers palletization automatically when thresholds are reached, reducing manual effort and operator exposure to harmful factors
2Quantity of substance
If deep carts are used for storage, then storage capacity increases, but users face difficulty accessing items at the bottom
Solution Approach 1:
The patent employs articulating floors that dynamically adjust their position and angle based on package accumulation levels. As packages are added to the buffer cart, the articulating floor automatically elevates and repositions them within the optimal zone, ensuring that items remain easily accessible regardless of the cart's fill level or depth
Solution Approach 2:
The system performs preliminary actions by automatically positioning packages in the optimal retrieval zone before operators need to access them. The articulating floor proactively adjusts package positions as they are deposited, preventing items from becoming difficult to reach even as storage capacity is utilized
3Productivity
If automated articulating floors are implemented, then package positioning improves and retrieval efficiency increases, but device complexity increases
Solution Approach 1:
The patent divides the buffer cart into modular segments, including separate first and second floor portions that can articulate independently. This segmentation allows the complex articulating mechanism to be broken down into manageable components, each performing a specific function, thereby improving productivity while making the overall system more maintainable and less daunting in its complexity
Data Source
AI summary
Systems, methods, and computer-readable media are disclosed for buffer carts having articulating floors. In one embodiment, an example cart may include a front wall, and a first floor portion coupled to the front wall. The first floor portion may include a slot along a lateral side of the first floor portion. The cart may include a second floor portion, where the second floor portion is coupled to the first floor portion. The cart may include a scissor mechanism coupled to the second floor portion, and a drive system coupled to the scissor mechanism and configured to drive the scissor mechanism in a vertical direction, wherein movement of the scissor mechanism includes relative motion between the first floor portion and the second floor portion via the slot.