Tote Handling Assembly Wiper Bar Synchronization
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Solution Overview
Problem
Existing tote handling systems in warehousing and pick-to-order environments are expensive, complex, and time-consuming to manufacture, due to the number and complexity of components required to synchronize the arrival timing and sequencing of totes at operator stations, which hampers efficiency and reliability.
Innovation Solution
A tote handling assembly comprising a wiper bar, actuators, and rollers that allow for the controlled movement and sequencing of totes, with a unique arrangement of components that reduces costs and complexity, enabling efficient transfer and synchronization of totes to operator stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing tote handling systems use multiple complex components (right-angle pop-up wheels, motors, etc.) to synchronize tote arrival timing and sequencing, then tote arrival control functionality is achieved, but system cost and complexity increase significantly
Solution Approach 1:
The patent extracts and eliminates unnecessary complex components from the tote handling system. By removing right-angle pop-up wheels, multiple motors, and other complex mechanisms, the system achieves tote arrival synchronization through a simplified design that uses only essential components, thereby reducing system complexity while maintaining the required functionality.
Solution Approach 2:
The patent employs simpler, more cost-effective components in place of expensive and complex mechanisms. The simplified tote handling assembly uses readily available, less expensive parts that can be easily manufactured and replaced, reducing overall system cost while achieving the same operational goals of tote arrival timing and sequencing control.
2Manufacturing precision
If existing tote handling systems incorporate numerous complex components to control tote sequencing, then precise tote arrival timing is achieved, but manufacturing time increases
Solution Approach 1:
The patent removes complex components that lengthen manufacturing processes. By eliminating right-angle pop-up wheels, multiple motors, and associated complex assemblies, the system reduces the number of parts that need to be manufactured, sourced, and assembled, thereby significantly reducing manufacturing time while maintaining precise tote arrival timing control through the simplified design.
Solution Approach 2:
The patent combines multiple functions into fewer integrated components. By merging the functions of tote movement, positioning, and sequencing control into a unified simplified assembly, the system reduces the overall number of discrete parts that need to be manufactured separately, thereby reducing total manufacturing time while maintaining the required precision in tote arrival timing.
3Adaptability or versatility
If existing tote handling systems use complex components and arrangements to synchronize totes with pods, then tote sequencing functionality is achieved, but ease of operation decreases
Solution Approach 1:
The patent eliminates complex components that complicate system operation. By removing right-angle pop-up wheels, multiple motors, and other intricate mechanisms, the system becomes easier to operate and maintain. The simplified design reduces the number of moving parts and potential failure points, making the tote sequencing system more user-friendly while retaining full adaptability for synchronizing totes with pod arrivals.
Solution Approach 2:
The patent uses uniform, standardized components throughout the tote handling system rather than a mix of specialized and complex parts. This homogenization of components simplifies operation and maintenance, as operators deal with consistent, familiar elements rather than diverse complex mechanisms, while the system maintains its versatility in handling various tote sequencing requirements.
Data Source
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AI summary
An example system includes a first tote handling assembly having a wiper bar, a first plurality of actuators connected to and moveable with the first wiper bar, and a first tab associated with a first actuator of the first plurality of actuators. The system may also include a second tote handling assembly disposed substantially adjacent and substantially parallel to the first tote handling assembly. The second tote handling assembly includes a second wiper bar, a second plurality of actuators connected to and moveable with the second wiper bar, and a second tab associated with a second actuator of the second plurality of actuators. In such a system, movement of the first wiper bar in a first direction along a transverse axis of the first tote handling assembly, while the first tab is engaged with a tote disposed on the first tote handling assembly, transfers the tote from the first tote handling assembly to the second tote handling assembly.