Conformable Robotic Manipulator for Irregular Carton Piles
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Solution Overview
Problem
Manual unloading of large truck shipments is physically demanding and costly due to the time and labor involved, necessitating a more efficient system for unloading bulk quantities of stacked cases and cargo from truck trailers.
Innovation Solution
A robotic carton unloader system comprising a conveyor system, a robotic positioner, and a manipulator with a conformable face that can attach to and unload cartons, featuring vacuum technology and independently movable banks of carton connectors to adapt to irregularities in the carton pile, along with a control and visualization system for automated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used to unload cartons from truck trailers, then flexibility and adaptability to irregular carton arrangements are maintained, but labor costs and time consumption increase significantly
Solution Approach 1:
The manipulator is divided into multiple independent banks of carton connectors that can move and adjust independently. Each bank can be controlled separately to adapt to different carton positions and arrangements, allowing the system to handle irregular configurations while maintaining high unloading speed and reducing the need for complex manual intervention
Solution Approach 2:
The carton connectors are designed with dynamic movement capabilities, allowing them to adjust their positions and orientations in real-time to accommodate irregular carton arrangements. This dynamic adaptability enables automated high-speed unloading without requiring the system to be reconfigured for each different load arrangement
2Adaptability or versatility
If a rigid manipulator structure is used, then manufacturing precision and structural stability are improved, but adaptability to irregular carton pile surfaces deteriorates
Solution Approach 1:
The manipulator face is segmented into multiple independent banks of connectors rather than using a single rigid structure. Each bank can move and adjust independently to conform to the irregular surface of the carton pile, maintaining both adaptability and precise positioning capability through modular design
Solution Approach 2:
The connectors incorporate dynamic adjustment mechanisms that allow them to move and adapt to irregular carton surfaces while maintaining precise contact points. This enables the system to achieve both adaptability to varying geometries and accurate positioning for reliable carton engagement
3Productivity
If traditional unloading methods are used, then equipment cost is reduced, but labor costs and unloading time increase
Solution Approach 1:
The automated manipulator is divided into multiple independent banks that can operate semi-independently, allowing for modular automation implementation. This segmentation enables progressive automation where different banks can be activated based on load requirements, achieving high productivity while managing automation complexity and cost
Solution Approach 2:
The system incorporates sensors and control mechanisms that allow the manipulator to automatically detect carton positions, adjust connector configurations, and execute unloading operations without continuous human intervention. This self-service capability achieves high automation levels while maintaining the flexibility to handle various carton arrangements
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
Enables rapid and cost-effective unloading of cartons from truck trailers by automating the process, reducing labor costs and improving efficiency through the use of robotic technology and adaptive carton handling.
Implementation Method 1
the conformable face may be configured to apply a vacuum to attach to the contacted cartons
Data Source
AI summary
A robotic carton unloader for automatic unloading of cartons from a carton pile, such as a carton pile stacked within a trailer. In various embodiments, a robotic carton unloader may comprise a conveyor system, a robotic positioner, and a manipulator having a conformable face configured to conform to irregularities of the carton pile, and the manipulator may be movable attached to an end of the robotic positioner.