Cart Flow Control Track with Cam Follower Guidance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing non-motorized cart movement control tracks in automotive assembly plants pose trip hazards and ergonomic issues for operators due to their design, which requires stepping over the track and inefficient use of floor space with a large radius arc.
Innovation Solution
A cart directional flow control apparatus featuring a track with cam followers of varying elevations and an intermediate wall that directs the cart around the track, allowing for a more efficient and safe movement by guiding the cart through a series of channels and turn segments, reducing the need for operators to step over the track and optimizing floor space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the track is placed immediately in front of the parts bins, then the cart can be easily accessed, but the operator must step over the track creating trip hazards and ergonomic issues
Solution Approach 1:
The track is elevated to a higher dimension (raised floor level) and configured as a loop that routes around the parts bins rather than across them. This dimensional change allows the operator to access the cart from the same side without stepping over the track, eliminating the trip hazard while maintaining cart accessibility.
Solution Approach 2:
The raised track structure acts as an intermediary element that separates the operator's working area from the cart access area. By elevating and routing the track around the bins, it mediates between the need for cart accessibility and the need to eliminate trip hazards, allowing smooth passage around the track rather than over it.
2Ease of operation
If the track uses a single large radius arc at the ends, then the cart can move smoothly, but a considerable amount of valuable floor space is consumed
Solution Approach 1:
The track end segments are divided into multiple smaller radius arcs rather than using a single large radius arc. This segmentation allows the track to make tighter turns, reducing the overall space required while maintaining smooth cart movement through the segmented curved path. The loop configuration with multiple turn segments achieves the same smooth transition in a more compact area.
Solution Approach 2:
The track is configured as a raised loop structure that utilizes vertical elevation and compact planar routing. By raising the track and using a loop configuration with multiple turn segments, the design achieves smooth cart movement while consuming less floor space than a traditional single large radius arc configuration.
3Stability of the object's composition
If the track is raised above the floor level, then the cam followers can be properly supported, but the operator must step over the track
Solution Approach 1:
The track is elevated to a raised floor level to provide proper structural support for the cam followers, but it is configured as a loop that routes around the parts bins. This allows the operator to access the cart from the same side without stepping over the raised track, eliminating the trip hazard while maintaining the structural benefits of elevation.
Solution Approach 2:
The raised track structure serves as an intermediary that provides structural support for cam follower movement while being routed to eliminate trip hazards. By elevating and looping the track around the bins, it mediates between the need for structural stability and the need to prevent operator injury.
Data Source
AI summary
A cart is movably engaged with a flow control track by a pair of different height cam followers. An end track segment between parallel side leg track segments of the track contains inner and outer end channels. An intermediate wall in the end track segment forms the outer and inner end channels and cooperates with the height of the cam followers to direct one cam follower on each cart into one of the inner and outer end tracks and the other cam follower on the cart into the other of the inner and outer end channels to smoothly control the movement of the cart around the end segment between the ends of the first and second side leg track segments.