Magnetic AGV Coupler for Stable Utility Cart Towing
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Solution Overview
Problem
Workers are at risk of injury when transporting heavy loads using utility carts, and robots or machines struggle to securely connect to these carts, leading to instability during transport.
Innovation Solution
A coupler system that uses magnetic elements, such as electromagnets, to securely attach autonomous guided vehicles (AGVs) to utility carts like pallet jacks, ensuring stable transport by maintaining engagement through rotational mechanisms and sensor-controlled power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic elements are used to securely attach AGVs to utility carts, then the reliability of connection is improved, but the device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical coupling mechanisms (such as hooks, latches, or fasteners) with magnetic elements that use magnetic attraction forces to secure the connection between the AGV and utility cart. This substitution improves connection reliability by providing continuous magnetic holding force while reducing mechanical complexity by eliminating complex mechanical fastening components.
Solution Approach 2:
The patent utilizes changes in magnetic field parameters (strength, polarity, activation state) to control the coupling and decoupling processes. By adjusting magnetic field parameters through electromagnetic actuators, the system achieves reliable connection control without requiring complex mechanical actuation mechanisms, thus improving reliability while managing device complexity.
2Object-affected harmful factors
If sensor-controlled power management is implemented for automatic disengagement, then safety is improved, but the device complexity increases
Solution Approach 1:
The patent implements sensor-controlled power management that continuously monitors the environment and connection status, providing feedback to the control system. When sensors detect obstacles or abnormal conditions, the system automatically adjusts power to magnetic elements to initiate safe disengagement. This feedback mechanism improves safety by enabling automatic response to hazardous conditions while using straightforward sensor-control logic to manage complexity.
Solution Approach 2:
The system enables automatic safety responses where the sensor-controlled power management system itself performs the disengagement action when hazards are detected, without requiring external human intervention. This self-service capability improves safety by ensuring immediate response to hazards while reducing the complexity of manual override mechanisms.
3Stability of the object's composition
If rotational mechanisms are used to maintain engagement during transport, then the stability of transport is improved, but the device complexity increases
Solution Approach 1:
The patent incorporates rotational mechanisms that allow the coupler assembly to dynamically adjust its orientation during transport. These mechanisms enable the magnetic elements and connection components to rotate and maintain proper alignment with the utility cart despite movements or position changes, thereby improving transport stability. The rotational capability is achieved through relatively simple rotary joints or bearings that reduce complexity compared to rigid fixed-position coupling systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coupler system enhances safety and efficiency by securely transporting carts, reducing human error and increasing throughput, while preventing injuries by automatically disengaging when obstacles are detected.
Implementation Method 1
A magnetic element, such as an electromagnet, is configured to engage the cart
Data Source
AI summary
A coupler has a housing including a first end configured to couple to an autonomous guided vehicle (AGV) and a second end having a receptacle. A cabinet operably couples to the housing and is at least partially disposed within the receptacle. A magnetic element is disposed at least partially within the cabinet. The magnetic element is configured to magnetically engage with a portion of a towable cart for transport by the AGV.