Robotic Carton Unloader Jacking Mechanism
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Solution Overview
Problem
Current unloading systems for trucks and trailers are inefficient and costly, particularly when unloading unpalletized cartons, as they require manual labor and can be physically demanding, and existing autonomous systems may get stuck in damaged floors.
Innovation Solution
A robotic carton unloader with a mobile body, pivotally attached robotic arms, and a telescoping conveyor system that can navigate uneven floors, using a built-in jacking apparatus to avoid damage and a vision system for obstacle detection and alignment, enabling autonomous and efficient unloading of cartons from piles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an autonomous unloading system is used, then unloading speed and productivity are improved, but the system may become stuck in damaged floors
Solution Approach 1:
The robotic unloader incorporates a telescoping conveyor system that can dynamically adjust its length and configuration to adapt to uneven and damaged floor conditions. The mobile base can also dynamically adjust its wheel configuration, with some wheels being retractable or adjustable, allowing the system to navigate over debris and maintain stability while operating autonomously at high speed.
2Ease of operation
If a robotic arm is used to unload cartons, then labor costs and physical difficulty are reduced, but the system complexity increases
Solution Approach 1:
The robotic unloader integrates multiple functions into a single autonomous system: the mobile base provides both mobility and stability, the telescoping conveyor handles both transport and positioning, and the robotic arm performs both grasping and placement operations. This multi-functionality reduces the need for separate specialized equipment and simplifies overall system operation despite the inherent complexity of robotic components.
3Productivity
If the robotic arm reaches into the carton pile, then unloading efficiency is improved, but the risk of damaging the system increases
Solution Approach 1:
The system employs sensors and vision systems to detect carton positions and potential obstacles before the robotic arm makes contact. The telescoping conveyor pre-positions cartons in a safe zone away from the robotic arm's reach zone, allowing the arm to operate efficiently without risking damage to itself or the cartons. This preliminary arrangement and detection prevents harmful interactions before they occur.
Data Source
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AI summary
A robotic carton unloader (100) for unloading a carton pile (106) resting on a floor (118) includes a mobile body (114) movable across the floor on more than one wheel. A conveyor system (110) mounted on the mobile body (114) conveys unloaded cartons thereon. A robotic arm assembly (102) has a manipulator head (136) attached to a front end of the upper arm assembly. The manipulator head (136) engages at least one carton at a time from a carton pile resting on a floor for movement to the conveyor system. A built-in jacking apparatus (166) is extendable from the mobile body (114) to a floor to raise the mobile body a distance sufficient to raise at least one of the more than one wheel (162) away from contacting the floor.