3D Keyed Connector Assembly for Aligned Inventory Stations
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Solution Overview
Problem
Existing inventory handling stations in storage and retrieval systems are often bespoke constructions, requiring adjustments and varying lengths of conveyor units to ensure alignment, leading to increased cost and complexity due to misalignment issues and potential snagging of storage containers.
Innovation Solution
A modular inventory handling station assembly using connectors that control the orientation of support elements in three dimensions, allowing for regular cuboidal structures that can be easily assembled without adjustments, ensuring aligned conveyor units and minimizing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If bespoke constructions are used for inventory handling stations, then alignment can be achieved, but cost and complexity increase due to adjustments and varying lengths of conveyor units
Solution Approach 1:
The inventory handling station is divided into modular sections that can be assembled in different configurations. Each module contains standardized conveyor units with fixed lengths, eliminating the need for custom-cut varying length units while maintaining alignment through the modular interface design.
Solution Approach 2:
Standardized modules are designed to perform multiple functions and can be used in various positions and orientations within the inventory handling station. This universality allows the same module type to serve different purposes, reducing the need for bespoke constructions while maintaining alignment through consistent module interfaces.
2Manufacturing precision
If adjustments are made to conveyor units for alignment, then alignment can be achieved, but cost and complexity increase
Solution Approach 1:
Alignment features are pre-built into the modular sections during manufacturing, eliminating the need for field adjustments. The modules are designed with built-in alignment mechanisms such as guide rails, positioning pins, or keyed interfaces that automatically ensure proper alignment when modules are assembled together.
3Device complexity
If standardized modules are used, then cost and complexity are reduced, but alignment may be compromised
Solution Approach 1:
Alignment features act as intermediaries between standardized modules, ensuring precise connection and positioning. These features may include guide rails, positioning pins, or keyed interfaces that are integrated into the module design, allowing standardized modules to align perfectly without requiring custom modifications.
4Productivity
If misalignment occurs, then conveyor units can still function, but container snagging occurs and efficiency decreases
Solution Approach 1:
The modular design with built-in alignment features prevents misalignment before it can cause container snagging. By ensuring proper alignment through the modular interface design, the system eliminates the harmful effect of snagging entirely, allowing containers to move smoothly through the conveyor system without interference.
Data Source
AI summary
A connector for connecting to at least three support elements of a three dimensional modular structure is disclosed. The connector includes a single body having a first connector portion for connecting a support element extending in a first direction; a second connector portion for connecting a support element extending in a second direction; a third connector portion for connecting a support element extending in a third direction, the first, second and third directions being substantially perpendicular to each other; and mounting projections each having a substantially flat mating face for mating with a corresponding mounting projection of an adjacent connector. Each connecting portion includes a key that is profiled for controlling the orientation of the support elements.