Mobile Robotic Unit for Automated Tote Stacking and Distribution
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Solution Overview
Problem
In material handling environments, manual replenishment of empty totes is time-consuming and laborious, and using conventional stationary stacker/de-stacker machines with conveyor belts is costly and impractical.
Innovation Solution
A mobile unit equipped with a telescopic platform, lifting apparatus, and grippers that can travel to different locations to collect and distribute totes, allowing for automated stacking and de-stacking operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual replenishment of totes is used, then labor flexibility is maintained, but time consumption and labor effort increase significantly
Solution Approach 1:
The mobile robotic unit autonomously performs tote collection, stacking, and distribution tasks without requiring human operators. The robot navigates independently, operates grippers and lifting mechanisms automatically, and manages its own movement between locations, enabling the system to service itself and eliminating dependency on manual labor for tote replenishment.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system equipped with sensors, processors, and automated control mechanisms. The robotic unit uses automated navigation, sensor-based tote detection, and programmable gripper/lifting mechanisms to perform tasks that were previously done manually, thereby increasing speed and reducing time loss.
2Extent of automation
If stationary stacker/de-stacker machines with conveyor belts are used, then automated stacking is achieved, but system cost and installation complexity increase
Solution Approach 1:
The patent transitions from a static stationary stacker/de-stacker machine to a dynamic mobile robotic unit. The robot can move autonomously to different locations within the warehouse, adapting its position and operation to various stacking points. This dynamic capability eliminates the need for fixed conveyor belt systems and complex infrastructure, reducing overall device complexity while maintaining high automation levels.
Solution Approach 2:
The mobile robotic unit is designed as a multi-functional system that can perform multiple tasks: navigating to different locations, collecting totes from various sources, stacking totes at different destinations, and distributing totes to multiple points. This universal design replaces the need for multiple specialized stationary machines and conveyor systems, thereby reducing device complexity and infrastructure requirements.
3Productivity
If conveyor belts are used to bring totes to stationary machines, then automated tote transport is achieved, but practical implementation difficulty and cost increase
Solution Approach 1:
The mobile robotic unit provides a dynamic, flexible transport solution that can adapt to changing warehouse layouts and requirements. Unlike fixed conveyor belts that require complex installation and modification, the robot can easily navigate to different locations and adjust its operation, making the system easier to manufacture, deploy, and reconfigure while maintaining high tote transport efficiency.
4Productivity
If mobile robotic units are deployed, then labor costs are reduced and operational efficiency improves, but device complexity and initial investment increase
Solution Approach 1:
The mobile robotic unit is designed as a modular system with distinct functional segments: navigation module, gripper mechanism, lifting apparatus, and control system. Each module can be independently developed, tested, and maintained, reducing overall system complexity. The segmentation allows for easier manufacturing, troubleshooting, and upgrades while maintaining high operational efficiency.
Data Source
AI summary
A method of operation of a mobile unit is described here. The method includes receiving a first signal to create a stack of totes on a conveying platform. Further, the method comprises receiving a second signal to lift the stack of totes in a vertical upward direction relative to the conveying platform. The method further comprises receiving a third signal to dispense a first tote from the stack of totes to a first location. The first tote is held at the conveying platform by a set of grippers of the mobile unit. Further, the method comprises receiving a fourth signal to travel to a second location to drop a second tote from the stack of totes. In some examples, the second tote corresponds to a current lowermost tote among the stack of totes and is held at the conveying platform by the set of grippers.