Nose Conveyor Speed Control for Robotic Unloading
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Solution Overview
Problem
Existing unloading systems for truck trailers are inefficient and costly, relying heavily on manual labor, which is physically demanding and time-consuming, especially when dealing with bulk quantities of stacked cargo.
Innovation Solution
A robotic material handling system equipped with a nose conveyor surface featuring multiple parallel conveyors that can operate at different speeds, coupled with 3D and 2D sensors for article detection and positioning, allowing for automated and efficient unloading by scanning and adjusting conveyor speeds based on article placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple parallel conveyors are used to increase throughput, then unloading speed is improved, but the complexity of the conveyor system increases
Solution Approach 1:
The conveyor system is divided into multiple parallel conveyors (first conveyor and second conveyor) that operate independently but feed into a common rearward conveyor. This segmentation allows simultaneous transport of multiple articles, increasing throughput while maintaining manageable complexity through modular design
Solution Approach 2:
The system dynamically adjusts the speed of individual parallel conveyors based on real-time detection of articles on the conveyor surface. When articles are detected, the system slows down or stops specific conveyors to prevent collisions, while others continue operating at full speed. This dynamic control optimizes throughput while managing the complexity through intelligent coordination
2Productivity
If articles are conveyed at high speed, then unloading efficiency is improved, but the risk of articles colliding or jamming increases
Solution Approach 1:
The system performs preliminary detection of articles on the conveyor surface using sensors before high-speed conveyance begins. Based on this preliminary scan, the control system pre-adjusts the speed of individual conveyors to appropriate levels, preventing potential collisions before they occur during high-speed operation
Solution Approach 2:
The system continuously monitors the conveyor surface for article presence and position during operation. When articles are detected in positions that could cause collisions during high-speed conveyance, the system provides feedback to adjust conveyor speeds in real-time, maintaining reliability while preserving high throughput capability
3Productivity
If a single conveyor surface is used, then the system structure is simple, but the throughput rate is limited
Solution Approach 1:
The conveyor system is divided into multiple parallel conveyors (first conveyor and second conveyor) that operate independently but feed into a common rearward conveyor. This segmentation allows simultaneous transport of multiple articles, increasing throughput while maintaining manageable complexity through modular design
Solution Approach 2:
The system transitions from a single-conveyor approach to a multi-dimensional conveyor arrangement where multiple parallel conveyors operate simultaneously. This dimensional expansion allows the system to handle multiple articles in parallel, significantly increasing throughput rate
Data Source
AI summary
A robotic material handling system has a controller that positions a nose conveyor surface proximate to an article pile, uses a robotic manipulator to robotically move one or more articles per operation onto the nose conveyor from the article pile, and receives a scan of the nose conveyor surface to detect respective locations of any articles received on the nose conveyor surface. The controller determines whether the respective locations of any scanned articles prevent immediate rearward conveyance by the two or more parallel conveyors at a first speed. If so detected, the controller causes at least one of the two or more parallel conveyors to operate at the first speed and at least another one of two or more parallel conveyors to operate at a second speed that is not equal to the first speed so that cartons do not jam or overwhelm a narrower rearward conveyor.