Telescopic Stack Pusher for Automated Tray Loading
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Solution Overview
Problem
Manual handling of stackable trays in warehouse operations is labor-intensive, prone to errors, and poses risks of fatigue and injury, especially in line kitting tasks where mixed stacks of trays need to be assembled efficiently.
Innovation Solution
A robotic stack pusher system with nested pusher structures that telescopically extend and retract to load and move payloads, such as stacks of trays, using an actuation device to control the position of pusher structures, facilitated by a control system that integrates sensors and a robotic control system for efficient payload handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If human workers manually handle trays, then flexibility and adaptability are maintained, but labor intensity increases and risk of fatigue and injury occurs
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system featuring a pusher mechanism. The robot arm with pusher structure automatically pushes trays from source stacks onto conveyor belts, eliminating direct human contact with heavy trays and thereby reducing labor intensity and injury risk while maintaining operational flexibility through programmable control.
2Productivity
If automated robotic systems are introduced, then productivity and precision improve, but device complexity increases
Solution Approach 1:
The automated system is divided into distinct functional modules: source stacks, robotic arm with pusher mechanism, conveyor belts, and control system. This segmentation allows each component to perform its specific function independently, simplifying the overall system design and maintenance while enabling high-speed automated operation for improved productivity.
3Volume of moving object
If nested telescopic pusher structures are used, then space utilization improves, but manufacturing complexity increases
Solution Approach 1:
The pusher structure employs nested telescopic segments that can extend and retract like nested dolls. When not in use, the pusher segments are compacted into a small volume within the robotic arm. When activation is needed, the segments extend sequentially to reach the trays. This nesting principle maximizes space utilization while the modular design facilitates manufacturing through standardized component assembly.
Data Source
AI summary
The present application discloses a robotic stack pusher system, and a method and a computer system for controlling the robotic stack pusher system. The robotic stack pusher system includes an actuation device and a plurality of pusher structures that are substantially planar. At least one of the plurality of pusher structures is nested within one or more other pusher structures of the plurality of pusher structures. The actuation device is the actuation device is operatively coupled to at least one of the plurality of pusher structures. The actuation device is configured to actuate a position of the plurality of pusher structures between a retracted state and an extended state in response to a control signal. Actuation of the actuation device causes the one of the plurality of structures that is nested to extend telescopically with sufficient force and to controllably push a payload.