Picking Attachment Positioner for Dual-Axis Tote Retrieval
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Solution Overview
Problem
Current materials handling vehicles lack adaptability and efficiency in navigating and engaging with multilevel warehouse racking systems, particularly in accurately positioning and retrieving totes, due to limitations in vertical displacement and anti-rocking mechanisms.
Innovation Solution
The integration of a dual-axis vertical displacement system with a mast assembly and X-Y-Z-Ψ positioner, coupled with an anti-rock cart engagement mechanism, enables independent movement of the picking attachment for precise engagement and disengagement of totes, and the use of a mobile storage cart support platform with anti-rock cart engagement to stabilize carts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the picking attachment is integrated with the fork carriage assembly, then the device complexity is reduced, but the adaptability for independent vertical displacement is limited
Solution Approach 1:
The system divides the vertical displacement function into two independent segments: the mast assembly moves the fork carriage assembly along the Z' axis, while the X-Y-Z-Ψ positioner on the picking attachment provides independent Z axis movement. This segmentation allows each component to perform its specific function without interfering with the other, achieving both structural organization and operational adaptability.
Solution Approach 2:
The invention adds an additional vertical dimension (Z axis) to the existing vertical movement (Z' axis through the mast assembly). By introducing the Z-positioner on the picking attachment, the system creates independent vertical displacement capability in a second dimension, allowing the picking attachment to move vertically relative to the fork carriage assembly while the fork carriage moves vertically relative to the vehicle body.
2Adaptability or versatility
If the fork carriage assembly is moved frequently to adjust picking positions, then the adaptability is improved, but the energy consumption increases
Solution Approach 1:
The system separates the functions of gross vertical positioning (handled by the mast assembly moving the entire fork carriage assembly) from fine vertical positioning (handled by the Z-positioner on the picking attachment). This allows the heavier fork carriage assembly to remain stationary while only the lighter picking attachment moves for precise positioning, significantly reducing energy consumption.
Solution Approach 2:
By adding the independent Z axis movement capability to the picking attachment, the system creates a two-stage vertical positioning system. The mast assembly handles coarse positioning along Z', while the Z-positioner handles fine adjustments along Z, eliminating the need to move the entire fork carriage assembly for minor position adjustments.
3Measurement precision
If the picking attachment moves independently along the Z axis, then the picking precision is improved, but the device complexity increases
Solution Approach 1:
The X-Y-Z-Ψ positioner is designed as a multi-functional unit that provides four degrees of freedom (X, Y, Z, and Ψ rotation) through an integrated mechanism. This universal positioner handles multiple positioning tasks simultaneously, reducing the need for separate mechanisms for each degree of freedom and thereby limiting the increase in overall device complexity.
Solution Approach 2:
The positioner mechanisms are arranged in a nested configuration where the X-positioner, Y-positioner, Z-positioner, and Ψ-positioner are hierarchically integrated. Each positioner is nested within or coupled to the previous one, allowing compact integration of multiple movement capabilities without proportionally increasing the space or complexity required.
4Stability of the object's composition
If the mobile storage cart is stabilized with anti-rock mechanism, then the stability is improved, but the device complexity increases
Solution Approach 1:
The anti-rock cart engagement mechanism utilizes the natural interaction between the mobile storage cart structure and the engagement features on the fork carriage assembly. The mechanism engages with existing structural elements of the cart (such as the deck or frame) to provide stabilization, rather than requiring additional components on the cart itself, thereby achieving stability with minimal added complexity.
Solution Approach 2:
The anti-rock engagement function is merged with the existing cart engagement mechanism of the fork carriage assembly. The same engagement features that secure the cart to the forks also provide the anti-rock stabilization, eliminating the need for a completely separate stabilization system and reducing overall device complexity.
Data Source
AI summary
A variety of vehicle-based and warehouse-based solutions are provided to increase the adaptability, utility, and efficiency of materials handling vehicles in the warehouse environment, such as a materials handling vehicle comprising a picking attachment is secured to a fork carriage assembly and comprising an X-Y-Z-Ψ positioner to engage and disengage a target tote such that movement of the picking attachment along a Z axis by the X-Y-Z-Ψ positioner is independent of movement of the fork carriage assembly along the vertical axis Z′ by the mast assembly and mast assembly control unit. The fork carriage assembly may comprise a mobile storage cart support platform defined by one or more cart lifting forks, and an anti-rock cart engagement mechanism configured to engage a mobile storage cart supported by the cart lifting forks.