Vertical Conveyor Intersection for Robotic Loading Efficiency
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Solution Overview
Problem
Existing loading systems for sorting facilities are inefficient and unreliable in loading individual objects from bulk supplies onto main conveyors, particularly due to their design focusing on human operation rather than robotic capabilities.
Innovation Solution
A loading system featuring intersecting conveyor paths with a main conveyor and a supply conveyor, where the loading robot transfers objects vertically at a conveyor intersection area, optimizing robotic efficiency and flexibility, allowing for multiple robots to work in parallel and improving ergonomic conditions for robotic operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If objects are loaded by pushing them sideways onto the main conveyor from a supply area arranged to one lateral side, then the loading system is simple in design, but the loading efficiency and reliability are reduced due to horizontal transfer being less suitable for robotic operation
Solution Approach 1:
The patent transitions from horizontal object transfer to vertical object transfer by arranging the supply conveyor and main conveyor at different vertical levels. The loading robot transfers objects vertically from the supply conveyor to the main conveyor, exploiting the vertical dimension to improve robotic gripping performance and loading efficiency while maintaining design simplicity
2Device complexity
If objects are loaded by pushing them sideways onto the main conveyor, then the system structure is straightforward, but the reliability of robotic transfer is reduced because robots perform better under vertical loads
Solution Approach 1:
The patent arranges the supply conveyor and main conveyor at different vertical levels, enabling the loading robot to transfer objects vertically. This dimensional change aligns with robotic gripping capabilities, as robots perform better under vertical loads, thereby significantly improving transfer reliability while keeping the system structure straightforward
3Device complexity
If the supply conveyor path terminates at one lateral side of the main conveyor, then the layout is simple, but the design flexibility and scalability of the sorting facility are limited
Solution Approach 1:
The patent arranges conveyors at different vertical levels rather than limiting the supply conveyor to a lateral termination. This vertical arrangement frees the supply conveyor path from lateral constraints, allowing it to extend beyond the main conveyor and connect to multiple destinations, thereby significantly improving design flexibility and scalability while maintaining layout simplicity
Solution Approach 2:
The vertical conveyor arrangement enables the supply conveyor to serve multiple main conveyors simultaneously, as it can extend beyond any single main conveyor and connect to multiple destinations. This multi-functional capability improves the adaptability and versatility of the sorting facility
Data Source
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Figure 3
AI summary
A loading system for loading objects individually onto a main conveyor, comprising: the main conveyor defining a main conveyor path and configured to receive the objects and to convey the received objects along the main conveyor path; a supply conveyor defining a supply conveyor path and configured to convey objects along the supply conveyor path; and a loading robot configured to transfer objects individually from the supply conveyor to the main conveyor, wherein, when viewed from above, the main conveyor path and the supply conveyor path mutually intersect at a conveyor intersection area where the main conveyor path and the supply conveyor path extend at mutually different vertical levels.