Nose Conveyor Jam Recovery via Segmentation and Dynamics

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Solution Overview

Problem

Conventional methods for unloading truck trailers are inefficient and costly, as they rely on manual labor, which is physically demanding and time-consuming, and existing automation solutions are limited in handling bulk quantities of stacked cases due to the risk of jamming and the need for singulated carton conveyance.

Innovation Solution

A robotic material handling system with a vertically-movable nose conveyor surface and parallel conveyors that can detect and dislodge jammed articles by repositioning the conveyor and activating conveyors to move articles in a forward direction, allowing for efficient unloading of bulk quantities without manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple parallel conveyors are used to convey bulk quantities of articles simultaneously, then productivity is improved, but articles may jam between the conveyors

Engineering Contradiction:

Improveunloading speedVSAvoidjam risk

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The conveyor system is divided into multiple independent parallel conveyors (first conveyor, second conveyor, third conveyor, fourth conveyor) that can operate independently. Each conveyor is controlled separately to prevent articles from jamming between them while maintaining high throughput capability for unloading bulk quantities of cartons

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts the operation of individual conveyors based on real-time conditions. When a jam is detected, the controller selectively stops or reverses specific conveyors (e.g., stopping the second conveyor when a jam is detected between first and second conveyors) to resolve the jam while maintaining operation of other conveyors

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If the rearward conveyor is laterally narrower than the nose conveyor surface, then articles are forced into a singulated fashion, but unloading rate is limited

Engineering Contradiction:

Improvesingulated conveyance controlVSAvoidunloading rate

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system uses multiple parallel conveyors at the nose conveyor surface (first, second, third, fourth conveyors) to handle multiple articles simultaneously, while the rearward conveyor maintains a narrower profile. This segmentation allows bulk quantities to be conveyed through the wider nose area and then singulated as they transition to the narrower rearward conveyor

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a two-dimensional bulk conveyance approach at the nose conveyor surface to a one-dimensional singulated conveyance approach at the rearward conveyor. The lateral dimension is utilized at the nose to accommodate multiple articles, then they are singulated as they move to the rearward conveyor

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If manual labor is used to unload truck trailers, then flexibility is maintained, but labor costs and physical difficulty increase

Engineering Contradiction:

Improvemanual flexibilityVSAvoidunloading speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The robotic material handling system performs the unloading operation autonomously without requiring manual labor. The system includes a robotic manipulator that automatically retrieves cartons from the trailer and places them on the conveyor system, eliminating the need for human workers while maintaining adaptability to different trailer configurations

Inventive Principle:

Principle #25Self-service

4Device complexity

If conventional unloading methods are used, then system simplicity is maintained, but time consumption increases

Engineering Contradiction:

Improvesystem simplicityVSAvoidunloading time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The conveyor system is divided into multiple independently controllable parallel conveyors (first, second, third, fourth conveyors) with separate drive mechanisms. This segmentation allows the system to handle multiple cartons simultaneously, reducing unloading time while the modular design keeps the overall system relatively simple and maintainable

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS10597234B2Carton unloader tool for jam recovery

Publication Date: 2020.03.24 INTELLIGRATED HEADQUARTERS LLC

AI summary

A controller of a robotic material handling system performs a method that conveys articles from a pile within a confined space. One or more articles per operation are robotically moved onto a vertically-positionable nose conveyor surface conveys toward a narrower rearward conveyor. Controller detects a jammed article that is at least partially supported by the nose conveyor and that has failed to fully convey onto the rearward. The controller attempts to dislodge the jammed article by causing at least one of: (i) vertically repositioning the nose conveyor surface; and (ii) activating at least one of the two or more parallel conveyors of the nose conveyor surface to run in a forward direction. After the attempt to dislodge, the controller activates at least one parallel conveyor that is contact with the jammed article in a rearward direction.