Autonomous Payload Handling Apparatus for Confined Spaces
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Solution Overview
Problem
Conventional payload handling systems, such as manual fork jacks and autonomous forklift vehicles, face challenges in efficiently managing multiple applications like pallet movement, roller cage movements, and custom pallets, especially in facilities with limited space, where there is a need for compact and versatile solutions that can handle various payload sizes and types.
Innovation Solution
An autonomous payload handling apparatus (APHA) with a chassis assembly, fork assemblies, lead screw mechanisms, and sensory systems that enable precise navigation and lifting of payloads, using friction pads, plummer blocks, and vision sensors to adapt to different pallet sizes and shapes, allowing for efficient handling and navigation in confined spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If fork over type robotic vehicles are used, then compactness is improved, but payload handling versatility deteriorates
Solution Approach 1:
The fork assembly is designed with adjustable geometry and interchangeable components that enable a single compact vehicle structure to handle multiple payload types including standard pallets, roller cages, and custom pallet configurations. The lead screw mechanisms allow dynamic adjustment of fork position and angle to accommodate different payload dimensions and handling requirements.
2Ease of operation
If manual fork jacks are used, then operational simplicity is improved, but automation capability deteriorates
Solution Approach 1:
The vehicle incorporates autonomous navigation systems with sensors, processors, and control mechanisms that enable self-directed movement and payload handling operations. The system automatically detects payload positions, calculates optimal fork insertion angles, and executes lifting operations without human intervention, while maintaining ease of operation through automated decision-making.
3Force
If conventional forklift vehicles are used, then lifting capability is improved, but space efficiency deteriorates
Solution Approach 1:
The lifting mechanism is divided into modular components including separate lead screw mechanisms for each fork assembly, allowing independent adjustment and compact arrangement. This segmentation enables the vehicle to maintain full lifting capability while reducing overall vehicle footprint and improving maneuverability in confined facility spaces.
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
The APHA automates payload handling, reducing operator time and effort by enabling precise control and navigation of payloads of varying sizes and shapes, improving efficiency and safety in facilities with limited space, and allowing for continuous operation with cloud or local fleet management.
Implementation Method 1
a first long double left-hand (LH) right-hand (RH) lead screw mechanism and a second long double LH RH lead screw mechanism, wherein the first long double LH RH lead screw mechanism is accommodated within a first fork assembly of the two or more fork assemblies, and wherein the second long double LH RH lead screw mechanism is accommodated within a second fork assembly of the two or more fork assemblies
Implementation Method 2
The APHA comprises a chassis assembly comprising one or more friction pads, wherein each of the one or more friction pads is attached to at least one side of the chassis assembly
Data Source
AI summary
Material handling of packed goods on pallets, roller cages within facilities is in huge volumes and consumes lot of operators' time and efforts. Embodiments of the present disclosure provide an autonomous payload handling apparatus (APHA) that addresses the above material handling process by automating with an intelligent modular robotic platform. The APHA includes fork assemblies that slides alongside of the pallet for better balance over payload and maintains smooth navigation. The fork assemblies equipped with contact/vision sensors that enable APHA to determine whether there is any offset or any contact between surfaces of APHA and/or pallet. The fork assemblies capture sensor data of surrounding object(s) during navigation, size of payload, and pallet, etc. The captured sensor data enables the APHA to correct its offset and/or compute a mode of approach (e.g., navigating angle, deviating from obstacle(s), sliding through pallet/roller cages, and the like) to handle payload(s).