Autonomous Carriages for Order Processing
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Solution Overview
Problem
Existing automatic order processing systems face inefficiencies due to high construction costs, increased maintenance needs, and reduced flexibility, as well as potential machine stoppages from ejector malfunctions, especially when handling diverse products with varying frequencies.
Innovation Solution
The system employs autonomous carriages with a rack/pinion mechanism and brushless motors, allowing independent movement and coordination along the machine length, with a central control unit managing carriage allocation and operation to adapt to changing product demands and handle malfunctions, eliminating the need for fixed modules and extensive cabling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed ejectors are used for each storage unit, then product extraction is reliable, but construction costs increase and maintenance becomes more difficult
Solution Approach 1:
A single carriage-mounted ejector serves multiple storage units sequentially, replacing the need for dedicated fixed ejectors at each storage unit location. The ejector performs the same function (product extraction) across different positions, reducing the total number of ejector elements while maintaining extraction reliability through controlled positioning.
Solution Approach 2:
The ejector is mounted on a movable carriage that travels along the tunnel structure, transitioning from a static fixed-position system to a dynamic mobile system. This allows one ejector to service multiple storage units by positioning itself at required locations, reducing the overall number of ejectors needed.
2Productivity
If multiple moving ejectors are used, then order preparation time is reduced, but machine operation becomes more complex and positioning difficult
Solution Approach 1:
The system divides the ejection function into multiple independent carriages, each capable of autonomous operation. This segmentation allows parallel processing of multiple storage units, improving order preparation speed while the modular nature simplifies control compared to a single complex positioning system.
Solution Approach 2:
Each carriage is equipped with its own motor and control systems, enabling autonomous navigation and positioning to required locations. This self-service capability reduces the complexity of centralized control and simplifies operation, as each unit independently manages its own positioning and ejection timing.
3Reliability
If independent driving belts are used for each module, then module independence is achieved, but machine length increases and positioning accuracy decreases
Solution Approach 1:
Multiple carriages share a common driving belt infrastructure rather than each having separate belts. This merging of the transmission system reduces the overall machine length while maintaining module independence through the autonomous control capabilities of each carriage. The shared belt system eliminates redundant driving mechanisms.
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
This configuration reduces construction costs, maintains high production rates, minimizes downtime from ejector failures, and allows for flexible machine expansion and adaptation to changing product demands, while ensuring accurate and efficient order processing.
Implementation Method 1
The rack (10) is oriented in a direction according to the extension of the machine and engages with a pinion (11) connected to a brushless motor (12) mounted on the carriage
Implementation Method 2
a pinion (11) connected to a brushless motor (12) mounted on the carriage
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A machine for automated processing of orders with products (30) piled up in storage units (2), arranged in rows, includes the use of motorized carriages (7), moving autonomously and coordinated one with another, and having ejector means (4) . The carriages are moved in a coordinated way, until they are placed below the storage units containing selected products, by a control unit (20) , which cooperates with a central control unit (50) . Then, the ejector means are operated to pick up, from the storage units, the products forming the order prepared each time.