Pivoting Conveyor System for Ergodic Package Handling
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Solution Overview
Problem
Existing conveyor systems for unloading packages from truck trailers often lead to employee injuries due to manual handling and strain, as they require bending and lifting, and have limitations in weight capacity and package transition issues.
Innovation Solution
A conveyor apparatus with a pivoting conveyor system that includes a slewing conveyor section and a tiltable conveyor section, along with a flexible conveyor for smooth package transition, and an operator platform for adjustable height, to reduce physical strain and improve safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cantilever-supported extendable conveyor is used, then employees can pick and place packages without carrying them out of the trailer, but the conveyor has limited weight capacity and employees still experience strain when reaching for packages near the floor and ceiling
Solution Approach 1:
The conveyor system is divided into multiple independent sections: a first conveyor section supported by the frame structure, and a second conveyor section supported by the first conveyor section. This segmentation allows each section to be optimized for its specific function and load requirements, with the first section handling heavier loads and the second section providing ergonomic positioning for package placement.
Solution Approach 2:
The patent adds a vertical dimension to the conveyor support structure by positioning the first conveyor section above the second conveyor section. This vertical arrangement allows the system to achieve greater height and weight capacity while maintaining ergonomic access for operators at different levels, effectively utilizing three-dimensional space to resolve the contradiction between weight capacity and operational ease.
2Adaptability or versatility
If the user interface section pivots from side-to-side and up and down, then packages can be loaded at different lateral positions and heights, but packages tend to jam when transitioning from the user interface section to the extendable section
Solution Approach 1:
The patent incorporates adjustable and pivotable components that allow the conveyor sections to dynamically adapt to different loading positions. The first and second conveyor sections can be positioned at various heights and angles, enabling the system to accommodate packages at different lateral positions and heights while maintaining smooth transitions through controlled positioning rather than continuous pivoting.
Solution Approach 2:
The first conveyor section acts as an intermediary between the frame structure and the second conveyor section, providing a stable transition zone that mediates the transfer of packages. This intermediate section helps bridge the gap between the fixed frame and the movable second section, ensuring reliable package transition while allowing the second section to pivot for positioning flexibility.
3Productivity
If employees manually handle packages from floor to ceiling height, then all packages can be unloaded, but employees experience repeated physical strain and potential injuries
Solution Approach 1:
The patent creates an equipotential working environment by providing conveyor sections at multiple fixed heights that align with natural working positions. Instead of requiring employees to continuously change elevation when handling packages, the system provides conveyor surfaces at optimal heights for different package locations, reducing the need for repeated bending and reaching motions that cause physical strain.
Solution Approach 2:
The patent replaces the mechanical system of manual package handling with an automated conveyor system that transports packages between the trailer interior and exterior. The conveyor sections are equipped with surfaces that facilitate package placement and retrieval, substituting employee physical effort with mechanical transport while maintaining the ability to handle packages at various heights and positions.
Data Source
AI summary
A conveyor apparatus includes a frame, and a pivoting conveyor coupled to the frame. The pivoting conveyor includes a pivotable conveyor section having a free end shaped for supporting objects and a first conveying surface. The first pivotable conveyor section is pivotally coupled to the frame about a vertical axis for pivoting the free end from side-to-side, and a horizontal axis for pivoting the free end up and down. The pivoting conveyor also includes a second non-pivotable conveyor section having a second conveying surface. Furthermore, the pivoting conveyor includes a fixed transition plate located adjacent to the second conveying surface, and a shuttling transition plate located adjacent to the first conveying surface. The shuttling transition plate is configured to move laterally from side-to-side relative to the first conveying surface as the first pivotable conveyor section pivots about the vertical axis. The apparatus may include a third tiltable conveyor section having a rear end and being pivotally coupled to the frame about a second horizontal axis for pivoting the rear end up and down.