Elevated Trailer Unloading Conveyor with Rotational Adjustment

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Solution Overview

Problem

Existing parcel distribution systems rely heavily on human labor for sorting and processing, which is inefficient and can lead to capacity issues in processing stations, as they do not effectively account for the delivery of objects from vehicles like tractor trailers in an organized manner.

Innovation Solution

A system comprising a collection conveyor and an evacuation conveyor, where the collection conveyor is adjustable and rotatably coupled to the evacuation conveyor, allowing for the controlled unloading of objects from an elevated trailer by adjusting its position to retain and then release objects for further processing, utilizing magnets and perception units for precise engagement and load assessment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If human workers manually sort and process parcels, then flexibility in handling various object types is maintained, but processing efficiency and productivity are reduced

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidmanual labor dependency

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The patent replaces manual mechanical sorting operations with an automated robotic system. Robots equipped with sensors and control systems automatically retrieve objects from the elevated trailer, identify them through perception units, and transport them to destination containers, eliminating the need for human workers to manually handle each parcel

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service processing where the robotic system autonomously performs the entire sorting workflow. The perception units automatically detect object locations, the control system determines destination containers, and the robotic arms execute retrieval and transport without human intervention, allowing the system to service itself

Inventive Principle:

Principle #25Self-service

2Productivity

If processing stations operate at full capacity, then throughput is maximized, but space constraints and capacity issues arise

Engineering Contradiction:

ImprovethroughputVSAvoidfloor space requirements

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The patent introduces a vertical dimension by elevating the trailer above the processing station floor. This allows objects to be unloaded directly onto the conveyor system from an elevated position, utilizing three-dimensional space rather than being constrained to horizontal floor area, thereby increasing throughput without proportionally increasing footprint

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The elevated trailer acts as an intermediary buffer between the arrival of objects and their processing. By holding objects in an elevated holding area, the system can receive objects in batches and then process them at a controlled rate, decoupling the arrival rate from the processing rate and allowing the station to operate at optimal capacity without being constrained by continuous floor space requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If objects are unloaded in a disorganized stream, then unloading speed is maintained, but sorting efficiency and organization are compromised

Engineering Contradiction:

Improveunloading speedVSAvoidsorting organization

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system performs preliminary organization by elevating and holding objects in a structured manner before they are processed. The elevated trailer position allows objects to be arranged in an organized fashion as they are unloaded, and the perception units pre-identify object locations and destinations, so that when objects reach the processing station, they are already organized and ready for efficient sorting

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The perception units provide continuous feedback on object locations, types, and destinations to the control system. This feedback loop allows the system to dynamically adjust the unloading process to maintain organization, ensuring that objects are positioned correctly as they are removed from the trailer and that the sorting process can proceed efficiently without disorganization

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20250002260A1Dynamic processing of objects provided in elevated vehicles with evacuation systems and methods for receiving objects

Publication Date: 2025.01.02 BERKSHIRE GREY OPERATING CO INC

AI summary

A system is disclosed for receiving a plurality of objects from an elevated trailer of a tractor trailer. The system includes a collection conveyor extending between a base end and a coupled end, the coupled end being rotatably coupled to an evacuation conveyor, said collection conveyor including an object facing surface between the base end and the coupled end for receiving the plurality of objects, said collection conveyor being rotatably adjustable with respect to the evacuation conveyor at the coupled end, and both the evacuation conveyor and the coupled end of the collection conveyor being elevationally adjustable.