Universal Plastic Base Frame for Modular Conveying Vehicles
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Solution Overview
Problem
Current shuttle base frames in intralogistics are complex, costly, and time-consuming to manufacture, with multiple components requiring manual assembly and high tooling investments, limiting their scalability and flexibility for various conveying vehicles.
Innovation Solution
A universal base frame made entirely of plastic, featuring integrated component-specific seatings that securely hold functional components such as bearings, driving units, and sensors, reducing the need for multiple components and tools, allowing for simplified assembly and toolless mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple separate components are used to manufacture the base frame, then the structural strength and functionality are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate frame components into a single integrated base frame made of plastic. This merging of components reduces the overall number of parts, simplifies assembly, and lowers manufacturing complexity while maintaining the necessary structural strength through the inherent properties of plastic material and integrated design.
Solution Approach 2:
The base frame is designed as a universal component that can serve multiple functions and accommodate different conveying vehicles. The integrated design includes standardized mounting positions and interfaces that allow various functional components to be attached, making the single base frame structure multi-functional and adaptable to different applications.
2Ease of manufacture
If manual assembly of multiple components is used, then the manufacturing flexibility is improved, but the productivity and assembly time decrease
Solution Approach 1:
By integrating multiple components into a single molded base frame, the patent eliminates the need for manual assembly of separate parts. The single-component design allows for automated injection molding production, significantly increasing productivity while maintaining manufacturing flexibility through mold design variations.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated injection molding processes. This substitution of manufacturing methods increases productivity by enabling high-volume production of the base frame as a single integrated component, while the mold design provides the necessary manufacturing flexibility.
3Ease of manufacture
If thin sheet metal is used for frame parts, then the manufacturing cost is reduced, but the structural strength and durability decrease
Solution Approach 1:
The patent changes the material parameter from thin sheet metal to plastic, which offers a different strength-to-cost ratio. Plastic provides sufficient structural strength for the base frame application while being cost-effective to manufacture through injection molding, eliminating the need for expensive metal processing and assembly operations.
Solution Approach 2:
The patent uses plastic as a composite material that combines the benefits of low cost with adequate structural strength. The integrated plastic base frame provides the necessary durability and strength while being manufactured at lower cost compared to metal alternatives, achieving an optimal balance between these competing requirements.
4Productivity
If integrated plastic structure is used, then the manufacturing time and assembly complexity are reduced, but the adaptability to different functional components decreases
Solution Approach 1:
The integrated plastic base frame incorporates universal mounting interfaces and standardized attachment points designed to accommodate various functional components. This universality allows the single molded structure to adapt to different conveying vehicle configurations and functional requirements, maintaining versatility despite the simplified integrated design.
Solution Approach 2:
While the base frame itself is integrated, the patent maintains adaptability by providing standardized segmentation points and mounting positions where different functional components can be attached. This allows the integrated structure to be configured for different applications without requiring changes to the base frame manufacturing process.
Data Source
AI summary
A base frame (34) which is universally usable for different modular structured conveying vehicles (30), in particular for shuttles (32), wherein the conveying vehicles (30) can travel horizontally along a travelling direction (52) in a storage and order-picking system (10), wherein the base frame (34) comprises a supporting frame (36) and a structure (38) connected to the frame (36), wherein at least the structure (38) is made of plastic only, and wherein the structure (38) comprises a plurality of component-specific seatings (58) being formed integrally with the structure (38) and being configured to positively hold in a resilient clamp at least one of the following functional components (60) of the respective conveying vehicle (30): a bearing (62); a driving unit (64); a sensor (66); an actuator (68); a load-handling device (70); a communication unit (78); a cabling (76); and an electric controlling unit (80) wherein each of the functional components (60) is positively insertable in or on the respective component-specific seating (58) along a component-specific mounting direction.