Roller Conveyor Loading Control for Automated Warehouse Transfer

Solution Overview

Problem

Existing warehousing systems require manual loading and unloading of goods, leading to low automation and poor operation efficiency, especially when multiple trays are involved or trays are at high positions.

Innovation Solution

A goods loading or unloading device with a roller conveyor that rotates to generate traction force, allowing automatic conveyance of goods using a control device and transport robot, eliminating the need for manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual loading and unloading processes are used in the warehousing system, then the system structure remains simple, but the degree of automation is low and operation efficiency is poor

Engineering Contradiction:

Improvedegree of automationVSAvoidsystem complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The transport robot performs self-loading and self-unloading operations through the roller conveyor mechanism. The robot's tray automatically engages with the roller conveyor, which rotates to convey goods onto the tray without requiring external manual intervention. This self-service mechanism increases automation while keeping the added complexity minimal by utilizing the existing robot structure and a single rotational component.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The roller conveyor acts as an intermediary mechanism between the storage unit and the transport robot's tray. It provides a automated transfer interface that facilitates goods movement from the storage unit to the robot's tray, enabling automated loading and unloading operations without direct manual handling.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If manual loading and unloading processes are used, then the device complexity is low, but the operation efficiency is poor

Engineering Contradiction:

Improveoperation efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The transport robot performs self-loading and self-unloading operations through the roller conveyor mechanism. The robot's tray automatically engages with the roller conveyor, which rotates to convey goods onto the tray without requiring external manual intervention. This self-service mechanism increases automation while keeping the added complexity minimal by utilizing the existing robot structure and a single rotational component.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The roller conveyor operates continuously to facilitate uninterrupted goods transfer between the storage unit and the transport robot. The rotational motion of the conveyor maintains continuous contact with the goods, enabling smooth and efficient transfer operations without idle time or manual intervention gaps.

Inventive Principle:

Principle #20Continuity of useful action

3Quantity of substance

If multiple trays are arranged on the transport robot at high positions, then the storage capacity increases, but the manual loading and unloading becomes more complex and time-consuming

Engineering Contradiction:

Improvestorage capacityVSAvoidloading and unloading time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

The transport robot performs self-loading and self-unloading operations through the roller conveyor mechanism. The robot's tray automatically engages with the roller conveyor, which rotates to convey goods onto the tray without requiring external manual intervention. This self-service mechanism increases automation while keeping the added complexity minimal by utilizing the existing robot structure and a single rotational component.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The roller conveyor is pre-positioned and ready to receive goods from the storage unit before the transport robot arrives. The conveyor's rotational mechanism is pre-configured to automatically transfer goods to the robot's tray, eliminating the need for manual preparation and reducing the overall loading and unloading time.

Inventive Principle:

Principle #10Preliminary action

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

The solution achieves high automation and efficiency in goods handling by automating the loading and unloading process, enhancing the overall operation efficiency.

Implementation Method 1

The roller conveyor has an outer contour surface configured for rolling contact with goods in the storage unit. The roller conveyor is configured to rotate about a rotation axis thereof, so as to convey goods outside the storage unit to outside of the goods outlet through the storage unit

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12600570B2Goods loading or unloading control method, control device, goods loading or unloading device, and warehousing system

Publication Date: 2026.04.14 HAI ROBOTICS CO LTD

AI summary

A goods loading or unloading control method is applicable to a goods loading or unloading device. The goods loading or unloading device includes a storage unit. The storage unit is provided with a goods outlet and a roller conveyor. The roller conveyor has an outer contour surface configured for rolling contact with goods in the storage unit. The roller conveyor is configured to rotate about a rotation axis thereof. The method includes: receiving a goods loading or unloading instruction; and controlling a rotation state of the roller conveyor according to the goods loading or unloading instruction, so as to convey goods outside the storage unit to outside of the goods outlet through the storage unit.