Vertical Unload System for Unit Load Devices
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The unloading of shipments from unit load devices (ULDs) is currently manual and time-consuming, especially when dealing with 'mixed' shipments that require both conveyable and forkable items, leading to increased costs and inefficiencies.
Innovation Solution
A vertical unload system featuring a framework with an elevator that elevates ULDs from a ground load deck to an offset unload deck, allowing for ergonomic and efficient unloading by enabling operators to unload conveyable items at a raised platform and forkable items at ground level, with customizable roller systems and a programmable logic controller for precise elevation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual unloading of shipments from ULDs is performed, then flexibility to handle mixed shipments is maintained, but unloading time and labor costs increase significantly
Solution Approach 1:
The system introduces a vertical dimension by elevating the unload deck above ground level. The elevator mechanism transports the ULD vertically from the ground load deck to the elevated unload deck, enabling operators to work at an optimal height without manual lifting or excessive bending, thus dramatically reducing unloading time while maintaining handling capability for mixed shipments.
Solution Approach 2:
The elevator acts as an intermediary mechanism between the ground level and the unload deck. It mediates the vertical transport of ULDs, allowing operators to efficiently unload shipments at an elevated position while the elevator handles the vertical movement, separating the transport function from the unloading operation.
2Ease of operation
If operators work at ground level, then equipment access is simplified, but ergonomic conditions deteriorate due to manual lifting and bending
Solution Approach 1:
By moving the unload deck to an elevated vertical position, the system improves ergonomic conditions. Operators work at a height that eliminates the need for excessive bending or lifting, as the ULD is brought to their level via the elevator. This vertical repositioning transforms the working conditions from ground-level manual handling to elevated ergonomic operation.
Solution Approach 2:
The elevator system automatically handles the vertical transport of ULDs between ground level and the unload deck. Once the ULD is loaded onto the elevator at ground level, the system self-manages the vertical elevation without requiring operator intervention during the transport process, reducing physical strain on workers.
3Productivity
If a vertical elevator system is implemented, then unloading efficiency improves, but system complexity and initial costs increase
Solution Approach 1:
The elevator system is designed to handle multiple ULD types and configurations, serving as a universal transport mechanism. The same elevator infrastructure can accommodate different ULD sizes and weights, and the system can handle various unloading scenarios including mixed shipments, making the complexity investment worthwhile through broad applicability.
Solution Approach 2:
The system segments the unloading process into distinct functional zones: the ground load deck for ULD reception, the elevator for vertical transport, and the elevated unload deck for shipment extraction. This segmentation allows each component to be optimized independently while working together to achieve high unloading efficiency, justifying the increased system complexity through functional specialization.
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
This system reduces unloading time by over 50% from 40 minutes to 18 minutes, enhancing ergonomics and reducing costs by allowing for safer and more efficient handling of mixed shipments.
Implementation Method 1
the cargo space and/or the elevator comprises rollers for loading and unloading the unit load device into and out of the elevator
Data Source
AI summary
The invention relates to a vertical unload system for an unit load device, comprising a framework, the framework delimiting a cargo space arranged on a ground load deck and the framework comprising an unload deck for unloading shipments out of the unit load device and comprising an elevator, whereby the unload deck is arranged distant above the ground load deck and extends in an offset plane adjacent to the cargo space, the cargo space and/or the elevator comprises rollers for loading and unloading the unit load device into and out of the elevator, and the elevator is adapted for vertically elevating the unit load device between the ground load deck and the unload deck such that the unit load device is stoppable at any intermediate stop locations.