Self-aligning interface for robotic carton unloader
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Solution Overview
Problem
Manual unloading of truck shipments is physically demanding and costly due to the time and labor involved, necessitating an efficient system for unloading bulk quantities of stacked cases and cargo from truck trailers.
Innovation Solution
A self-aligning interface for a robotic carton unloader that includes a positional measurement device and control unit to synchronize the extension and retraction of an extendable conveyor with the movements of the robotic unloader, ensuring continuous and efficient unloading of cartons onto the conveyor system, even in cases of lateral or angular misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used to unload truck shipments, then flexibility in handling various cargo types is maintained, but labor costs and time consumption increase significantly
Solution Approach 1:
The robotic unloader system performs autonomous unloading operations without requiring manual labor. The robot autonomously positions itself, identifies cartons, and transfers them to the conveyor system, eliminating the need for human workers while maintaining efficient unloading speeds.
Solution Approach 2:
The patent replaces manual mechanical labor with an automated robotic system equipped with sensors and control mechanisms. The robot uses vision systems and positional measurement devices to navigate and operate, substituting human mechanical actions with automated mechanical and sensor-based operations.
2Reliability
If an extendable conveyor is used to receive unloaded cartons, then continuous conveying path is maintained, but misalignment between conveyor and unloader causes cartons to fall into gaps
Solution Approach 1:
The system employs positional measurement devices that continuously monitor the relative position between the robotic unloader and the extendable conveyor. This feedback information is processed by the control unit to calculate and execute real-time adjustments, ensuring precise alignment and preventing cartons from falling into gaps during operation.
Solution Approach 2:
The extendable conveyor is dynamically adjusted during the unloading process. The conveyor's extension and retraction movements are synchronized with the robot's movements, allowing the system to adapt to changing positions and maintain continuous alignment throughout the operational cycle.
3Reliability
If the extendable conveyor is synchronized with robotic unloader movements, then cartons are prevented from falling into gaps, but the system requires complex control mechanisms
Solution Approach 1:
Positional measurement devices provide continuous feedback on the relative positions of the robotic unloader and extendable conveyor. The control unit processes this feedback data to calculate precise synchronization movements, enabling accurate carton placement while managing system complexity through automated control algorithms.
Data Source
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AI summary
A self-aligning interface (6300) is attached to a robotic carton unloader (6100) and provides an interface between an extendable conveyor (6200) and the robotic carton unloader (6100). The self-aligning interface (6300) can include a positional measurement device (6320, 6320b, 6320c) mounted on the robotic carton unloader (6100) and operatively engaged with the extendable conveyor (6200) to provide positional information about the location of the extendable nose conveyor (6220) relative to the positional measurement device (6320, 6320b, 6320c). A control unit (61B0) is attached to the robotic carton unioader (6100) for full robotic control of robotic carton unloader (6100) and the unloading process. The control unit (6180) is connected to the positional measurement device (6320, 6320b, 6320c) and the extendable conveyor (6200). The control unit (6180) uses positional information to calculate and control extension and retraction movements of the extendable conveyor (6200) in unison with the forward and reverse movements of the robotic carton unloader 6100 to ensure unloaded cartons (12) exiting the moving truck unloader are received on the extendable conveyor (6200) .