Cart Caster Rail Alignment for Orderly Collection Chamber Loading

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Solution Overview

Problem

Existing delivery systems face challenges in aligning carts efficiently in collection chambers due to the freely pivoting casters, which hinder orderly arrangement, and require manual operation for closing and opening closure doors, increasing operator workload.

Innovation Solution

A cart alignment device with rail members guiding casters into a predetermined arrangement direction, fixed in collection chambers, and a vehicle retaining member to secure carts, along with automatic movement devices to facilitate easy alignment and reduce operator workload.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If casters are allowed to pivot freely to enable smooth cart movement, then cart mobility is improved, but cart alignment in collection chamber deteriorates

Engineering Contradiction:

Improvecart mobilityVSAvoidcart alignment

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

A guide member is introduced as an intermediary element between the caster and the collection chamber. The guide member has a guide surface that contacts the caster and constrains its pivoting motion, allowing the caster to rotate only in the predetermined arrangement direction while still enabling smooth cart movement. This mediator resolves the contradiction by permitting mobility while enforcing alignment.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The constraint mechanism is applied locally at the interaction point between the guide member and caster, rather than constraining the entire cart system. The guide surface on the guide member provides localized directional guidance to the caster, allowing free movement along the arrangement direction while restricting pivoting perpendicular to this direction.

Inventive Principle:

Principle #3Local quality

2Ease of operation

If closure door is operated manually to enable cart loading and unloading, then operational simplicity is improved, but operator workload deteriorates

Engineering Contradiction:

Improvedoor operation simplicityVSAvoidoperator workload

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The closure door is equipped with an automatic opening/closing function that operates autonomously without requiring manual intervention. The door automatically opens when a cart approaches and automatically closes after the cart passes through, enabling the system to serve itself and eliminating the need for operator involvement in door operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical operation of the closure door is replaced with an automated control system. The automatic opening/closing function uses sensors and actuators to detect cart presence and control door movement, substituting the manual mechanical system with an automated electromechanical system that reduces operator workload.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12528647B2Cart alignment device, delivery system, and control method

Publication Date: 2026.01.20 FUJI CORP

AI summary

A cart alignment device of the present disclosure is used in a delivery system that delivers an article using a cart including a loading section for loading articles and a caster disposed in the loading section and having wheels capable of changing a movement direction of the loading section. The cart alignment device includes a rail member configured to guide the caster of the cart in a predetermined arrangement direction, and a disposition section configured to dispose and fix the rail member in a collection chamber for accommodating one or more carts.