Expandable Conveyor Shield for Robotic Carton Unloader
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Solution Overview
Problem
Current methods for unloading truck shipments, particularly those with stacked cases, are labor-intensive and costly due to the reliance on manual labor, necessitating a more efficient and automated solution for unloading bulk quantities from truck trailers.
Innovation Solution
A robotic carton unloader system equipped with a mobile body, a movable robotic arm, and an expandable conveyor system that can change width to catch and convey cartons, allowing for efficient unloading of cartons from a pile within a semi-trailer by using a combination of a central conveyor and a front conveyor that pivots to guide and discharge cartons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual labor is used to unload truck shipments, then flexibility and adaptability are maintained, but labor intensity and cost increase significantly
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system. The robotic arm with end effector performs the unloading function that would otherwise require human labor, enabling faster, more consistent, and scalable operation without the limitations of manual dexterity or physical constraints.
Solution Approach 2:
The robotic unloader system is designed to autonomously perform the unloading task without continuous human intervention. The system includes its own positioning, grasping, and conveying mechanisms that operate independently once deployed, transforming a labor-intensive process into an autonomous operation.
2Extent of automation
If a robotic arm with fixed-width conveyor is used, then automation is achieved, but the system cannot adapt to different trailer widths
Solution Approach 1:
The conveyor system incorporates movable side walls that can dynamically adjust their position to match different trailer widths. This dynamic adaptation allows the same automated system to operate in various trailer configurations without requiring multiple fixed-width conveyor designs, maintaining both automation and versatility.
Solution Approach 2:
The robotic unloader is designed as a universal system that can accommodate multiple trailer widths through adjustable components. The movable side walls and positionable robotic arm enable the same device to serve different trailer types, eliminating the need for specialized equipment for each trailer configuration.
3Adaptability or versatility
If the conveyor system is made expandable to match trailer width, then adaptability improves, but device complexity increases
Solution Approach 1:
Rather than using complex expandable mechanisms, the patent employs simple movable side walls that slide or pivot to adjust conveyor width. This dynamic adjustment is achieved through straightforward mechanical movements rather than complicated expansion systems, maintaining structural simplicity while providing adaptability.
Solution Approach 2:
The conveyor system is divided into modular sections with independent movable side walls. Each segment can adjust independently to match the required width, allowing for simple, distributed control rather than a single complex expansion mechanism. This segmentation simplifies the overall system architecture while enabling width adaptation.
Data Source
AI summary
A robotic carton unloader for unloading cartons in a carton pile has a mobile body and a movable robotic arm attached to the mobile body that has an end effector at a movable end thereof to unload cartons from the carton pile. A conveyor system is attached to the mobile body and extends from front to rear of the carton unloader to convey cartons received thereon by the moveable robotic arm. The conveyor system comprises a central portion carried on the mobile body and a front portion extending therefrom towards the carton pile. The front portion is configured to change width from narrow to wider to act as a shield to catch and then move falling cartons received thereon.