Automated Container Loading System with Dual Conveyors
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Solution Overview
Problem
Existing container loading and unloading systems require significant human intervention, leading to inefficient use of space and increased safety and physical concerns due to unorganized and uncontrolled loading and unloading processes, which result in interference and additional labor needs.
Innovation Solution
A system comprising a fixed staging unit, a first conveyor for horizontal movement, a second conveyor for horizontal and vertical movement, and a control unit that arranges containers in a predetermined pattern, allowing for controlled loading and unloading with minimal human intervention by guiding and positioning containers within a carrier using a combination of conveyors and a control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If containers are loaded manually into a carrier, then human flexibility and adaptability are improved, but safety risks and physical strain increase
Solution Approach 1:
The system enables self-service loading by using sensors to automatically detect container presence, a controller to manage the robotic arm's movements, and the robotic arm itself to execute pickup and placement operations without human intervention, thereby eliminating safety risks while maintaining adaptability
Solution Approach 2:
The patent replaces the mechanical human lifting and placing system with an automated robotic arm system controlled by electronic sensors and controllers, substituting human physical action with automated mechanical action to eliminate safety hazards
2Productivity
If containers are loaded without organization, then loading speed is improved, but space utilization and accessibility deteriorate
Solution Approach 1:
The system performs preliminary action by using sensors to detect container positions and the controller to pre-plan the loading sequence before actual placement, organizing containers in an optimized arrangement that maximizes space utilization while maintaining efficient loading speed
Solution Approach 2:
The patent implements feedback through sensors that continuously monitor container positions and provide information to the controller, which adjusts the robotic arm's actions to achieve optimal organization and space utilization while maintaining loading efficiency
3Manufacturing precision
If additional equipment is added to organize containers, then organization quality is improved, but system complexity increases
Solution Approach 1:
The robotic arm system serves multiple functions: it detects container positions via sensors, plans loading sequences through the controller, executes precise pickup and placement operations, and adjusts to different container configurations, achieving high organization quality without requiring multiple separate specialized devices
Solution Approach 2:
The patent merges detection (sensors), control (controller), and execution (robotic arm) functions into a single integrated automated system, reducing overall system complexity while achieving high organization quality compared to using separate manual organization equipment
Data Source
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AI summary
An apparatus for loading and unloading a plurality of shipping containers into a carrier (200). The containers are arranged according to a predetermined pattern on a fixed staging unit (140) of the apparatus. A first conveyor (160) of the apparatus receives and transports the arranged containers from the fixed staging unit (140). The first conveyor (160) is movable horizontally. A second conveyor (180) of the apparatus receives the containers from the first conveyor and transports the containers into the carrier (200. The second conveyor (180) is movable horizontally and vertically. A control unit (300) of the apparatus controls transportation of the containers from the second conveyor (180) into the carrier (200) when the second conveyor is vertically moved to a predetermined position.