Mobile Robot Payload Exchange via Stack Exchanger Alignment Rails

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Solution Overview

Problem

Existing systems for moving inventory in warehouses rely on fixed conveyors and infrastructure, which are time-consuming to set up, expensive, and inflexible, requiring robots to stop and align precisely for payload exchange.

Innovation Solution

A system of mobile robots with spring-loaded mechanisms and stack exchangers that allow payload exchange without stopping, using alignment rails and passive mechanical components for efficient and flexible movement, eliminating the need for extensive fixed infrastructure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mobile robots use traditional alignment processes to exchange payloads, then payload transfer reliability is improved, but time consumption increases and productivity decreases

Engineering Contradiction:

Improvepayload transfer reliabilityVSAvoidtime consumption

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The alignment rails and mechanical guides are pre-installed at stack exchanger locations to automatically guide mobile robots into the correct position during payload exchange, eliminating the need for time-consuming manual alignment procedures while ensuring reliable transfers

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Physical alignment rails and mechanical guides serve as intermediary elements between the mobile robot and stack exchanger, mediating the alignment process and enabling rapid, reliable payload transfers without requiring the robot to perform complex alignment maneuvers

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If fixed conveyor infrastructure is used for inventory movement, then manufacturing precision and reliability are improved, but device complexity and cost increase

Engineering Contradiction:

Improveinventory movement precisionVSAvoidinfrastructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system divides the inventory movement function into discrete mobile robot units that independently navigate and exchange payloads at distributed stack exchangers, replacing the monolithic fixed conveyor system with modular, flexible components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using fixed infrastructure to move inventory, the system inverts the approach by using mobile robots that navigate to fixed stack exchangers for payload exchange, transforming the traditional paradigm while reducing overall system complexity

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If mobile robots stop to align precisely for payload exchange, then transfer reliability is improved, but productivity and throughput decrease

Engineering Contradiction:

Improvetransfer reliabilityVSAvoidthroughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The alignment rails enable continuous movement of mobile robots through the stack exchanger area without requiring stops for alignment, maintaining productive action throughout the payload exchange process while ensuring reliable transfers through the mechanical guidance system

Inventive Principle:

Principle #20Continuity of useful action

4Productivity

If extensive fixed conveyor infrastructure is deployed, then inventory movement capability is improved, but adaptability to changing demands decreases

Engineering Contradiction:

Improveinventory movement capabilityVSAvoidflexibility to changing demands

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system replaces static fixed conveyor infrastructure with dynamic mobile robots that can autonomously navigate and adapt their paths in real-time, allowing the inventory movement capability to flexibly respond to changing demands while maintaining high productivity

Inventive Principle:

Principle #15Dynamics

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

Enables efficient, flexible, and high-throughput inventory management without requiring precise alignment or stopping, allowing for rapid payload transfer and adaptation to changing demands, reducing costs and infrastructure needs.

Implementation Method 1

A feature of the invention is that the mobile robots participating in the system require only the addition of a spring-loaded mechanism to operate with payload exchange elements of the system

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS10689194B2Mobile robot loader-unloader system and method

Publication Date: 2020.06.23 HDS MERCURY INC

AI summary

A system for moving payloads is described. It uses one or more mobile robots. Each mobile robot comprises a payload bearing platform, and a payload release latch. The system includes one or more stack exchangers having a set of alignment rails, a payload transfer ramp, and a latch engagement bar. The mobile robots pass through the stack exchanger and pick up a payload or drop off a payload without fully stopping motion.