Deployable Conveyor Mat Assembly with Tensioning System
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Solution Overview
Problem
Manual loading of packages onto vehicles is inefficient, leading to increased personnel risk of injury and package damage due to repeated entry and exit from the vehicle.
Innovation Solution
A conveyor mat assembly that transitions between a retracted and deployed state, allowing packages to be pushed or slid onto the vehicle, reducing the need for personnel to enter and exit the vehicle frequently, featuring a tensioning system for easy deployment and retraction, and a rolling surface with compressible rollers for stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading of packages is used, then personnel can load packages onto vehicles, but personnel must enter and exit the vehicle multiple times which increases the risk of injury and package damage
Solution Approach 1:
The conveyor mat serves as an intermediary device between the personnel and the vehicle interior. Instead of personnel directly entering the vehicle to load packages, they operate the conveyor mat from the exterior, which mediates the loading process and eliminates the need to enter the vehicle multiple times, thereby improving both safety and package integrity
Solution Approach 2:
The conveyor mat assembly is designed to be self-deploying and self-retracting through the tensioning system. The mat automatically extends when needed and retracts when not in use, eliminating the need for personnel to manually handle the mat itself and reducing their exposure to potential hazards inside the vehicle
2Productivity
If a conveyor mat assembly is deployed, then multiple packages can be loaded at once improving efficiency, but the device becomes more complex
Solution Approach 1:
The conveyor mat assembly is segmented into modular components including the mat itself, the frame, and the tensioning system. This segmentation allows each component to be independently designed and optimized, making the overall system more manageable despite its functional complexity. The mat can be deployed and retracted in sections if needed
Solution Approach 2:
The conveyor mat assembly serves multiple functions: it acts as a loading aid, a protective barrier for packages, and a space-efficient storage solution when retracted. The same device enables both high-speed loading and compact storage, reducing the need for separate systems and thereby managing complexity through multi-functionality
3Reliability
If the conveyor mat is made compressible with rollers for stability, then package damage is minimized, but the device complexity increases
Solution Approach 1:
The rollers are designed with compressible materials or spring mechanisms that change their physical parameters (compression, elasticity) based on the load. This allows the rollers to adapt to different package sizes and weights, providing protection without requiring a complex adjustable mechanism. The parameter change occurs passively through material properties rather than active control
Data Source
AI summary
An assembly includes a frame and a conveyor mat configured to transition between a retracted state in which the conveyor mat is disposed within a footprint of the frame, and a deployed state in which the conveyor mat is disposed at least partially disposed outside the footprint of the frame. The conveyor mat has a plurality of linkages, a plurality of rollers, a plurality of supports, and a plurality of axles. Individual axles couple to individual linkages of the plurality of linkages, individual rollers of the plurality of rollers, and individual supports of the plurality of supports together. A tensioning system is configured to control the conveyor mat transitioning between the retracted state and the deployed state.