Parcel Transfer System for Conveyor and Self-Driving Vehicle
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Solution Overview
Problem
In shipping and sorting facilities, it is challenging to transfer parcels directly from a conveyor to a self-driving vehicle without manual intervention or stopping the conveyor, especially for fragile items, as existing methods often result in damage due to dropping.
Innovation Solution
A parcel transfer system that includes a conveyor and a self-driving vehicle (SDV) configured to move in sync, with a vision and control subsystem using sensors and a controller to coordinate the offloading process, ensuring both systems remain moving and the parcel is transferred laterally without dropping, by aligning the upper surfaces of the conveyor and SDV for safe transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If parcels are dropped from the end of the conveyor onto a lower-positioned SDV, then the transfer can be completed, but fragile items break due to the dropping motion
Solution Approach 1:
The conveyor and SDV are positioned at the same vertical level, creating an equipotential transfer interface. This eliminates the vertical height difference that causes dropping and damage, allowing parcels to be transferred horizontally without impact forces.
Solution Approach 2:
Instead of the conventional approach where the conveyor is higher and drops parcels down to a lower SDV, the invention inverts this arrangement by positioning the SDV at the same level as the conveyor, transforming the transfer from a vertical drop to a horizontal slide.
2Ease of operation
If the conveyor stops to offload parcels onto the SDV, then direct transfer is possible, but the sorting and processing speed decreases
Solution Approach 1:
The system employs dynamic synchronization where the SDV moves alongside the conveyor at matching speeds during the transfer process. This dynamic approach allows continuous motion operation, eliminating the need for conveyor stoppages while maintaining precise parcel transfer.
Solution Approach 2:
The conveyor continues to move continuously without stopping during parcel transfer operations. The SDV synchronizes its motion to receive parcels while both systems remain in motion, ensuring uninterrupted sorting and processing flow.
3Manufacturing precision
If manual intervention is used to transfer parcels from conveyor to SDV, then precise placement is achieved, but the operation becomes complex and time-consuming
Solution Approach 1:
The system achieves self-service automated transfer through sensor detection and control system coordination. The conveyor and SDV automatically synchronize their positions and speeds, and parcels are automatically transferred without manual intervention, combining precision with operational simplicity.
Solution Approach 2:
Sensor systems continuously monitor the positions of the conveyor and SDV, providing feedback to the control system. This feedback mechanism enables automatic adjustment of speeds and positions to achieve precise parcel transfer without manual intervention.
Data Source
AI summary
A parcel transfer system transfers a parcel or a similar article directly between a conveyor and a self-driving vehicle (“SDV”) while the conveyor and SDV are moving. The conveyor, SDV, or both may be configured to initially transport a parcel in a first direction of travel and then subsequently offload the parcel in a second direction of travel. The SDV is configured to travel alongside of the conveyor in the first direction of travel and either receive the parcel as it is offloaded from the conveyor or offload the parcel onto the conveyor in the second direction of travel. The parcel transfer system further includes a vision and control subsystem, which regulates movement of the SDV and offloading of the parcel from the conveyor or SDV.