Carrier Handling Conveyors With Leak Detection and Staging Transfer
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Solution Overview
Problem
Conventional AS/RS systems using articulated robotic arms for carrier handling are inefficient due to complex movements, limited versatility in handling various product types and sizes, and require specialized maintenance, increasing operational costs and downtime.
Innovation Solution
A carrier handling system (CHS) that performs case-to-carrier and carrier-to-case processes without articulated robotic arms, incorporating leak detection and utilizing conveyors, grip assemblies, and a controller to manage operations, allowing for faster handling and reduced maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If articulated robotic arms are used for carrier handling, then product loading and unloading can be automated, but the handling speed decreases due to complex precise movements required
Solution Approach 1:
The system divides the carrier handling process into separate functional modules: conveyors for carrier transport, grip assemblies for product engagement, and controllers for coordination. This segmentation allows each component to operate independently and efficiently, eliminating the complex coordinated movements required by articulated robotic arms while maintaining automation.
Solution Approach 2:
The grip assemblies are designed with adjustable configurations that can handle various product types, sizes, and weights. The same grip assembly can be reconfigured for different products without requiring specialized robotic arms for each application, maintaining high handling speed across diverse product ranges.
2Extent of automation
If articulated robotic arms are used for carrier handling, then product loading and unloading can be performed, but the system becomes less versatile in handling various product types, sizes, and weights
Solution Approach 1:
The grip assemblies incorporate adjustable mechanisms that can be reconfigured to accommodate different product types, sizes, and weights. The controller system manages these adjustments, allowing a single automated system to handle diverse products without requiring multiple specialized robotic arms.
Solution Approach 2:
The grip assemblies feature dynamic, adjustable components that can change their configuration based on the product being handled. This dynamic adaptability allows the same hardware to optimize its grip for different product characteristics while maintaining automated operation.
3Extent of automation
If articulated robotic arms are used for carrier handling, then automated product handling is achieved, but maintenance complexity and costs increase due to specialized designs
Solution Approach 1:
By dividing the system into modular components (conveyors, grip assemblies, controllers), maintenance can be performed on individual modules rather than complex integrated robotic arms. Each module uses standardized components that are simpler to maintain and replace.
Solution Approach 2:
The system uses simpler, more replaceable grip assemblies and conveyor components rather than expensive, highly specialized robotic arms. When wear or failure occurs, these simpler components can be quickly replaced with standard parts, reducing maintenance costs and complexity.
Data Source
AI summary
A method comprising method comprising receiving a first load disposed in a first carrier at a first position on a first conveyor, receiving a second load disposed in a second carrier at a second position on the first conveyor, receiving, from a sensor, sensor data indicative of a humidity level near the second position, determining, based on the sensor data, that a leak associated with the second load has occurred, responsive in part to determining that the leak has occurred, transferring the first load disposed in the first carrier to a staging area, and transporting, via a second conveyor, the second load away from the first conveyor while the second load remains disposed in the second carrier.