Robotic Conveyor Path Assembly for Variable Truck Loading

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Solution Overview

Problem

Existing robotic systems struggle with efficiently automating the loading and unloading of items between dissimilar and variable geometry conveyance structures in warehouses and containers, often requiring manual intervention and inefficient use of mixed conveyance methods.

Innovation Solution

An autonomous robotic system that integrates multiple conveyance structures, including chutes, gravity-based rollers, and powered conveyors, to automatically position, configure, and assemble continuous paths for item movement, using robots and control computers to adjust and connect these structures for seamless operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple dissimilar conveyance structures are used to move items to or from trucks, then the system can handle various loading scenarios, but the complexity of coordinating and integrating these different structures increases significantly

Engineering Contradiction:

Improveability to handle various loading scenariosVSAvoidcomplexity of coordinating different conveyance structures

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The robotic system is designed with universal end-effectors and control architecture that can interface with multiple types of conveyance structures (conveyors, chutes, rollers, manual stations) through standardized protocols, allowing one robotic system to perform multiple loading functions across different truck types and configurations

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system implements a hierarchical control structure where a central control computer coordinates high-level loading strategies, while individual robotic units and conveyance structures operate as nested subsystems with their own local control, allowing complex coordination through layered management rather than direct point-to-point control

Inventive Principle:

Principle #7Nested doll (Nesting)

2Ease of operation

If manual loading and unloading operations are performed by human workers, then flexibility in handling different items is maintained, but productivity and efficiency are reduced

Engineering Contradiction:

Improveflexibility in handling different itemsVSAvoidloading and unloading efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The robotic system autonomously performs loading and unloading operations without continuous human intervention. The control computer automatically plans loading sequences, coordinates robotic movements, and manages conveyance structures, allowing the system to service itself through automated decision-making while maintaining operational flexibility

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system employs dynamic task allocation and adaptive planning where the control computer can reconfigure loading strategies in real-time based on item characteristics, truck configuration, and operational priorities, maintaining flexibility comparable to manual operations while achieving robotic productivity levels

Inventive Principle:

Principle #15Dynamics

3Productivity

If autonomous robotic systems are deployed to automate loading operations, then productivity increases, but the complexity of integrating and coordinating multiple robotic units and conveyance structures increases

Engineering Contradiction:

Improveloading automation efficiencyVSAvoidcomplexity of integrating robotic units and conveyance structures

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The loading system is divided into independent modular robotic units, each capable of autonomous operation on its own conveyance structure. This segmentation allows the system to achieve high productivity through parallel operations while reducing integration complexity, as each module can be developed, tested, and maintained independently

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A central control computer acts as an intermediary that coordinates between multiple robotic units and conveyance structures using standardized communication protocols. This mediator layer abstracts the complexity of inter-unit coordination, allowing robotic units to operate autonomously while maintaining system-wide coherence through centralized scheduling and resource management

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates efficient, automated loading and unloading of items by optimizing the use of conveyance structures, reducing manual intervention, and ensuring smooth item flow through intelligent positioning and configuration.

Implementation Method 1

gravity-based rollers

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS12391489B2Interoperable robotic system to load/unload trucks and other containers

Publication Date: 2025.08.19 DEXTERITY INC

AI summary

A robotic system is disclosed comprising a communication interface and a processor coupled to the communication interface and configured to: receive via the communication interface an indication to establish a conveyance path to convey one or more items from a source location at an originating end of the conveyance path to a destination location at a terminating end of the conveyance path; determine programmatically a plan to arrange and configured one or more conveyance structures to provide the conveyance path; and invoke one or more robots to position, couple as needed, and configure as needed the one or more conveyance structures to provide the conveyance path.