Warehouse Tote Unloading Arms With Motorized Conveyor Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing forklifts or lift trucks require significant manual effort to unload totes from shelves, especially with heavy loads, and lack an automated and convenient solution.
Innovation Solution
An unloading device with motorized arms and a roller belt that can adjust to the shape and position of individual totes, allowing seamless unloading without changing the tote's direction, using a motorized conveyor belt to pull the tote onto the roller belt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If forklifts or lift trucks are used to unload totes from shelves, then the unloading operation can be performed with existing equipment, but significant manual effort is required and the operation is not automated
Solution Approach 1:
The unloading device is equipped with a motorized conveyer belt that automatically pulls the tote off the shelf and onto the roller belt without requiring manual pulling. The system performs the unloading operation autonomously through coordinated movement of arms and conveyer belts, eliminating the need for operator intervention during the actual unloading action.
Solution Approach 2:
The patent replaces the manual mechanical operation of forklifts with an automated system comprising motorized arms and conveyer belts. The motorized conveyer belt specifically substitutes for the manual pulling action, while the automated arm positioning replaces manual insertion and lifting operations.
2Reliability
If the arms are fully inserted into or moved underneath the tote and the whole forklift is pulled back, then the tote can be securely unloaded, but the process requires great effort especially with heavy totes
Solution Approach 1:
The unloading function is divided into separate components: arms for positioning and grabbing, a motorized conveyer belt for pulling the tote off the shelf, and a roller belt for receiving and dispatching the tote. This segmentation allows each component to perform its specific function efficiently without requiring the entire system to exert force simultaneously.
Solution Approach 2:
The motorized conveyer belt acts as an intermediary between the arms and the tote, transferring the pulling force. Instead of the arms directly pulling the heavy tote, the conveyer belt provides the pulling force, reducing the effort required by the arm mechanism and making the system capable of handling heavy totes.
3Productivity
If the forklift with arms is pushed forward, lifted the tote, and then pulled back, then the tote can be unloaded, but the whole unloading device must move which increases complexity and effort
Solution Approach 1:
The patent extracts the pulling function from the main unloading device structure and implements it as a separate motorized conveyer belt system. This allows the arms to remain stationary or make minimal movements while the conveyer belt handles the pulling action, simplifying the overall device structure and reducing the complexity of coordinating large-scale device movement.
4Adaptability or versatility
If conventional forklifts are used for unloading, then existing equipment can be utilized, but the solution is not automatic and convenient for totes of different sizes
Solution Approach 1:
The arms are designed to be movable in both vertical and horizontal directions, allowing automatic adjustment to accommodate totes of different sizes and positions on the shelf. The motorized conveyer belt can also adjust its operation parameters automatically, enabling the system to adapt to various tote configurations without manual intervention.
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
Enables easy and automated unloading of totes of varying sizes without manual effort, ensuring safe and efficient transfer from shelves to a roller belt for further handling.
Implementation Method 1
each arm comprises a motorized conveyer belt extending along the essential horizontal direction on the arm for unloading the tote from the shelf in particular in essentially horizontal direction onto the roller belt
Implementation Method 2
a roller belt adjoining the at least two arms for dispatching the tote unloaded from the shelf
Data Source
AI summary
An unloading device for unloading a tote from a shelf in a warehouse includes at least two arms for grabbing the tote in the shelf, whereby the arms essentially each extend in a horizontal direction and are arranged distant and parallel to each other. The arms are movable in a vertical and/or horizontal direction in respect to a position of the tote in the shelf and in their horizontal distance to each other in respect to the shape of the tote. Additionally, each arm includes a motorized conveyer belt extending along the essential horizontal direction on the arm up to touching a tip of the respective arm for unloading the tote from the shelf.