Nested Conveyor Carousel With Radial Chute for Item Retrieval
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Solution Overview
Problem
Current automation systems for storage and retrieval of items rely on complex robotic systems that mimic human carrying, stowing, and picking, which are costly, inefficient, and impose grueling work conditions on human operators, and lack versatile grippers for varied items.
Innovation Solution
A conveyor system comprising nested circular disks with rotating segments and a radial chute mechanism, controlled by a hardware processor, to efficiently move and sort items using a coordinated system of conveyors, allowing for simultaneous loading and unloading of items without complex mechanical robotics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If complex robotic systems with grippers are used to pick and place items, then automation capability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical robotic grippers with a simpler conveyor-based system that uses friction and gravity to move items. Items are placed on inclined conveyor belts that automatically transport them to destination points, eliminating the need for sophisticated gripping mechanisms while maintaining automation capability.
Solution Approach 2:
The system divides the storage and retrieval operation into segmented conveyor zones, each handling specific item types or destinations. This segmentation allows independent control of each conveyor section, simplifying the overall system architecture compared to a monolithic robotic system while preserving automation functionality.
2Ease of operation
If human operators perform carrying and picking tasks, then operational flexibility is maintained, but labor intensity and operational costs increase
Solution Approach 1:
The conveyor system is designed to automatically perform the carrying and picking tasks that would otherwise require human operators. Items are self-propelled along the conveyors by friction and gravity, and the system autonomously sorts and delivers items to designated locations, eliminating manual labor while maintaining operational flexibility through programmable control.
3Productivity
If automated mobile manipulating robots are deployed, then item throughput is doubled, but work conditions become grueling and safety concerns arise
Solution Approach 1:
The patent employs multiple simple, independent conveyor units that can be easily replaced or reconfigured if needed. Each conveyor is a simple, robust mechanism without complex electronics or sensors, making them safe to operate in proximity to human workers while maintaining high throughput capability through parallel operation of multiple units.
4Stability of the object's composition
If fixed shelves are used for storage, then storage stability is improved, but retrieval efficiency and automation integration worsen
Solution Approach 1:
The patent replaces static fixed shelves with dynamic conveyor-based storage positions. Items are not permanently fixed but are temporarily held on conveyor belts that can move them to retrieval points on demand. This dynamic approach maintains storage stability during holding while enabling efficient automated retrieval when needed.
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 system enables efficient, scalable, and safe automation of item movement and sorting, reducing human labor intensity and operational costs, while handling items of varied sizes and shapes with minimal mechanical complexity.
Implementation Method 1
each of the plurality of nested conveyors is configured to rotate around the central axis, such that each of the plurality of segments in the circular disk of the nested conveyor is rotatable into the chute
Implementation Method 2
a chute mechanism configured to radially move items, along the radial axis, across the top surfaces of all of the plurality of segments that are in the chute
Data Source
AI summary
Conventional automated fulfillment systems require complex technology, such as robots and autonomous guided vehicles. Accordingly, embodiments are disclosed for a conveyor system that can perform automated fulfillment with the simplicity of conveyor technologies. The conveyor system may comprise a plurality of concentric, circular, nested conveyors or parallel linear conveyors that each comprises a plurality of segments. The conveyor system may also comprise a chute along a radial or orthogonal axis. Each conveyor is configured to move, such that each segment of the conveyor is movable into the chute. A chute mechanism may be configured to move items in and/or out of a chute. Thus, for example, a control system may move items, stowed on the conveyors, into the chute, and utilize the chute mechanism to move all of these items out of the chute and off of the conveyor system with a single sweep operation.