Automated Tugger Cart with Telescoping Clasping Arm
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Solution Overview
Problem
Current tugger cart systems require excessive manual effort for loading and unloading, leading to ergonomic issues, increased risk of injury, and fatigue due to the need for human operators to manually engage and disengage heavy loads on inclined planes without mechanical assistance.
Innovation Solution
An automated tugger cart assembly with a mechanical clasping member, including telescoping arms and an actuator, that automatically loads and unloads rider carts onto or off the tugger cart using sensors and an electric motor to reduce manual labor and enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading and unloading is used, then device complexity is reduced, but excessive manual effort is required leading to ergonomic issues and increased injury risk
Solution Approach 1:
The tugger cart system performs loading and unloading operations autonomously through its own integrated mechanical arm and actuator system, eliminating the need for external manual intervention. The system serves itself by automatically engaging rider carts, pulling them onto the inclined plane, and positioning them on the platform.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated mechanical arm system driven by an actuator. This substitution eliminates the need for human operators to physically push or pull heavy loads, transferring the mechanical work from human operators to the automated system while reducing overall system complexity in terms of operational procedures.
2Productivity
If automated loading and unloading is implemented, then productivity is improved, but device complexity increases due to additional mechanical components
Solution Approach 1:
The mechanical arm system serves multiple functions: it engages rider carts, pulls them onto the inclined plane, positions them on the platform, and can also perform unloading operations. This multi-functionality consolidates what could be multiple separate mechanisms into a single versatile system, improving productivity while limiting the increase in overall device complexity.
Solution Approach 2:
The system incorporates a telescoping arm with variable length capability, allowing the mechanical structure to dynamically adjust its configuration based on operational needs. This dynamic adaptation enables the system to handle different loading scenarios efficiently without requiring multiple fixed-configuration mechanisms.
3Ease of operation
If a mechanical arm with telescoping capability is used, then ease of operation is improved by reducing manual effort, but device complexity increases due to additional actuators and components
Solution Approach 1:
The telescoping arm employs a nested structure where one arm section is contained within another, allowing compact storage when retracted and extended configuration when needed. This nesting principle reduces the space required and simplifies the overall structure compared to having separate engagement and positioning mechanisms.
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
The automated system significantly reduces manpower requirements, enhances workplace safety by minimizing manual effort, and improves efficiency in material handling by automating the loading and unloading process.
Implementation Method 1
an actuator, and a grab arm extendable and retractable from the at least one telescoping arm, wherein the actuator converts the at least one telescoping arm between an extended position and a retracted position
Implementation Method 2
each of the first side member and the second side member comprise a plurality of roller wheels rotatably coupled to an inner side and rotatable about a horizontal axis
Data Source
AI summary
A tugger cart includes a tugger frame having a first side member, a second side member, and a clasping member. A plurality of wheels are coupled to a bottom of the tugger frame. Each of the first side member and the second side member include a plurality of roller wheels rotatably coupled to an inner side and rotatable about a horizontal axis. The plurality of roller wheels align along an angled plane that declines from a rear of the tugger frame to a front of the tugger frame. The clasping member includes at least one fixed arm, at least one telescoping arm, an actuator, and a grab arm extendable and retractable from the at least one telescoping arm. The actuator converts the telescoping arm between an extended position and a retracted position.