Modular Conveyor Base With Telescoping Reach for Ergonomic Unloading
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Solution Overview
Problem
Existing conveyor systems in warehouses and distribution centers often require manual labor for loading and unloading packages due to ergonomic inefficiencies, leading to health and safety concerns, especially when handling varying load configurations and object sizes.
Innovation Solution
A modular driving apparatus and bi-directional conveyor system with adjustable components, including telescoping sections and a movable operator platform, that can extend into confined spaces to facilitate ergonomic loading and unloading of packages, reducing the need for manual handling and improving safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixed conveyor system is used for unloading packages from trailers, then the structure is simple and stable, but the conveyor cannot reach the end of the trailer or adjust to different heights, causing operators to hand-carry objects or lift from awkward positions
Solution Approach 1:
The conveyor system incorporates telescoping sections that can extend and retract, allowing the conveyor to dynamically adjust its reach into the trailer. The height-adjustable support legs enable the conveyor to adapt to different trailer bed heights, transforming a static system into a dynamic one that responds to varying operational requirements.
Solution Approach 2:
The conveyor is divided into multiple telescoping sections that can extend independently, allowing the system to reach deeper into trailers while maintaining structural integrity. This segmentation enables the conveyor to adapt to different trailer lengths and load configurations without requiring a completely different system.
2Productivity
If operators manually load or unload packages faster to meet productivity goals, then the loading/unloading rate increases, but injuries result from moving equipment such as straining when bending or over-reaching
Solution Approach 1:
The height-adjustable support legs and movable operator platform create an ergonomic working environment by allowing operators to work at optimal heights rather than constantly bending or reaching. This reduces physical strain and the risk of injury while maintaining high productivity levels.
Solution Approach 2:
The conveyor system acts as an intermediary that bridges the gap between the trailer and the operator, allowing packages to be transferred mechanically rather than requiring operators to manually lift and carry heavy loads, thereby reducing physical strain and injury risk.
3Ease of operation
If the conveyor is extended into the confined space of the trailer to facilitate loading/unloading, then operator access to floor-loaded and stacked objects is improved, but the operator platform may obstruct movement around palletized objects
Solution Approach 1:
The operator platform is designed to be movable and retractable, allowing it to extend into the trailer when needed for accessing floor-loaded objects, and retract when palletized objects need to be moved around. This dynamic adjustment enables the system to adapt to different load configurations and mixed-load scenarios.
4Adaptability or versatility
If a customizable interface is provided for various conveyor types, then the system can interface with different conveyor configurations, but the device complexity increases
Solution Approach 1:
The modular driving apparatus is designed with universal mounting capabilities that can interface with multiple types of conveyors (belt conveyors, roller conveyors, etc.). The standardized mounting interface and adjustable positioning mechanisms allow a single driving apparatus design to serve multiple conveyor configurations, achieving versatility without proportionally increasing complexity.
Data Source
AI summary
The various conveying embodiments disclosed are directed to systems, methods and components enabling extendible conveying mechanisms to reach into trailers and storage containers so that operators may safely and ergonomically load and unload objects such as packages, etc. The disclosed embodiments include a modular driving apparatus suitable for driving an extendible conveyor as well as supporting and moving an associated interface conveyor and configurable (e.g., width and height) operator platform. Also disclosed is a telescoping, bi-directional conveyor embodiment and a movable conveyor interface.