Sensor-Guided Loading Conveyor for Precise Pick Point Alignment
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Solution Overview
Problem
Existing loading and unloading systems are inefficient, inconsistent, and simplistic, often requiring unnecessary vertical movements and lacking parallel pathways for transporting objects, and are unable to accurately identify pick points on objects.
Innovation Solution
A system with a support structure, transport apparatus, sensors, and manipulators that monitor interior areas to perform efficient and consistent loading and unloading operations, minimizing vertical movements by aligning object edges with conveyors for precise pick and place operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional loading and unloading systems are used, then operations can be performed, but unnecessary vertical movements occur and efficiency is reduced
Solution Approach 1:
The system positions the manipulator at a fixed height within the support structure and uses a conveyor system to move objects horizontally at the same level. This eliminates the need for vertical lifting and lowering operations, as all pick and place operations occur at the manipulator's fixed operational height, making the working level equipotential throughout the process.
Solution Approach 2:
The invention transitions from traditional vertical loading/unloading operations to horizontal operations by introducing a conveyor system that moves objects along a horizontal axis. The manipulator remains stationary in the vertical dimension while the conveyor handles horizontal transport, effectively changing the primary dimension of operation from vertical to horizontal.
2Measurement precision
If simple loading and unloading systems are used, then device complexity is low, but accuracy in identifying pick points is insufficient
Solution Approach 1:
The system introduces sensors as intermediary devices between the manipulator and the objects. These sensors detect the position, orientation, and characteristics of objects on the conveyor, providing precise information about pick points to the controller, which then guides the manipulator with high accuracy without requiring direct manual intervention or complex mechanical positioning systems.
Solution Approach 2:
The invention replaces complex mechanical positioning and alignment mechanisms with an automated sensing and control system. Instead of using elaborate mechanical guides or manual alignment procedures, the system uses sensors to detect object positions and a controller to calculate and execute precise manipulator movements, substituting mechanical complexity with electronic sensing and control.
3Ease of operation
If manual loading and unloading methods are used, then ease of operation is maintained, but consistency and sophistication of operations are reduced
Solution Approach 1:
The system is designed to be self-regulating and self-correcting through automated feedback. The sensors continuously monitor object positions and conveyor status, and the controller automatically adjusts manipulator movements to maintain precision. This self-service capability ensures consistent operation without requiring constant human intervention or decision-making, achieving both ease of operation and high reliability.
Solution Approach 2:
The system incorporates sensor feedback loops that continuously monitor object positions, conveyor movement, and manipulator status. This feedback information is processed by the controller, which makes real-time adjustments to maintain operational consistency. The feedback mechanism ensures that variations in object placement or conveyor speed do not compromise the reliability or consistency of loading and unloading operations.
Data Source
AI summary
An example system and associated methods are provided herein. In some embodiments, the system includes an apparatus. In some embodiments, the apparatus includes a support structure comprising an interior area. In some embodiments, the apparatus includes a transport apparatus coupled to the support structure and configured to move a unit through the interior area. In some embodiments, the unit comprises an object and a pallet configured to support the object. In some embodiments, the apparatus includes a plurality of sensors. In some embodiments, each of the plurality of sensors is configured to monitor a portion of the interior area. In some embodiments, first sensor of the plurality of sensors is configured to detect that a bottom edge of the object is in line with an object conveyor. In some embodiments, the apparatus includes one or more manipulators.