Automatic Tray Loading in Airline Service Carts
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Solution Overview
Problem
Manual loading of meal trays into airline service carts is time-consuming and labor-intensive, requiring automation to improve efficiency and reduce stress within tight departure schedules while maintaining a simple construction and high operating speed.
Innovation Solution
An apparatus comprising a lifting device and a conveyor arrangement with tray stoppers, sensors, and a tray pushing unit to automatically load trays into carts at different vertical levels, allowing for efficient and reliable tray loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading of trays is used, then the construction remains simple, but the loading speed and productivity are low
Solution Approach 1:
The loading system is divided into independent functional modules: a conveyor arrangement for tray transport, a lifting device for vertical positioning, sensor systems for detection, and control units for coordination. Each module operates semi-independently, allowing the system to achieve high productivity through coordinated automation while maintaining manageable complexity through modular design.
2Productivity
If automation is introduced to increase loading speed, then productivity improves, but the device complexity increases
Solution Approach 1:
The conveyor arrangement serves multiple functions: it transports trays horizontally, positions them vertically through integration with the lifting device, and coordinates with sensors and stoppers for precise loading. This multi-functionality reduces the need for separate dedicated components for each operation, thereby increasing productivity while controlling overall system complexity.
Solution Approach 2:
Sensor systems detect tray positions and loading status, providing feedback to the control unit which adjusts the conveyor and lifting device operations accordingly. This automated feedback loop enables high-speed operation with precise control, improving productivity while reducing the need for complex manual coordination mechanisms.
3Reliability
If multiple sensors and control mechanisms are added for precise tray positioning, then loading reliability improves, but device complexity increases
Solution Approach 1:
The conveyor arrangement acts as an intermediary mechanism between the tray source and the cart loading position. It coordinates with the lifting device and sensor systems to ensure precise positioning without requiring direct complex interaction between all components. The conveyor belt and stopper mechanisms provide intermediate control points that enhance reliability while managing system complexity.
Data Source
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AI summary
A method for automatic loading of trays into a cart, where the cart is adapted to receive trays at different vertical tray levels, comprises detecting the tray levels with a tray level sensor and lifting the cart with a lifting device from a floor to different vertical positions such that the tray levels in the cart will be at the same vertical level as a loading surface of a conveyer arrangement, which transports the trays to the cart on the loading surface. The method also comprises activating tray stoppers to stop the movement of the trays on the loading surface until the cart is at a correct vertical position, and deactivating the tray stoppers to allow the trays to be loaded into the cart when the cart is at a correct vertical position. The cart is lifted and loaded until all tray levels have been filled, and then the cart is again lowered to the floor. An apparatus for automatic loading of trays into a cart according to the method is also provided.