Vertically-Adjustable Transfer Modules for Independent Object Sorting
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Solution Overview
Problem
Current warehouse storage and retrieval systems face inefficiencies due to manual labor, human error, and limitations in robotic forklifts, such as high personnel costs, fatigue, and complex maintenance requirements, as well as the inflexibility of conveyor belts.
Innovation Solution
The use of vertically-adjustable low friction transfer modules controlled by processors to sort and move objects independently in multiple dimensions, allowing for efficient and flexible movement of objects across surfaces, reducing the need for manual labor and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic forklifts are used to automate storage and retrieval, then productivity and reliability are improved, but device complexity and maintenance requirements increase
Solution Approach 1:
The system divides the warehouse floor into a grid of modular transfer modules, each capable of independent vertical movement. This segmentation replaces complex robotic forklifts with simple, standardized modules that can be individually controlled to move objects horizontally across the warehouse floor.
Solution Approach 2:
The patent replaces the mechanical complexity of robotic forklifts with a simpler system using vertically-adjustable transfer modules combined with gravity-based horizontal movement. Objects are moved horizontally by tilting the module surface rather than using complex drive mechanisms.
2Productivity
If conveyor belts are used for automatic object transport, then productivity is improved, but adaptability and flexibility deteriorate
Solution Approach 1:
The transfer modules can dynamically change their vertical position and tilt angle in response to control signals, allowing the system to adapt its configuration on-demand. This enables flexible routing and sorting capabilities without requiring physical reconfiguration of the infrastructure.
Solution Approach 2:
Each transfer module serves multiple functions: it can transport objects horizontally, sort objects to different destinations, and be reconfigured for different routing patterns. This multi-functionality replaces the need for dedicated conveyor belts for each routing scenario.
3Adaptability or versatility
If human operators use forklifts for storage and retrieval, then adaptability is maintained, but productivity and reliability worsen due to fatigue and error
Solution Approach 1:
The system uses sensors to automatically detect objects on the warehouse floor and computes optimal routing paths without human intervention. The transfer modules autonomously execute the sorting and transport operations based on computed instructions, eliminating the need for human operators while maintaining adaptability.
4Productivity
If robotic forklifts are deployed to increase object handling density, then productivity is improved, but the space required for maneuvering limits the density
Solution Approach 1:
By dividing the warehouse floor into a grid of small, discrete transfer modules, the system eliminates the need for large maneuvering spaces required by robotic forklifts. Each module occupies minimal space and can independently move objects to adjacent modules, enabling high-density object handling in compact areas.
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 approach enhances the efficiency and safety of object movement, reduces personnel costs, and increases the density of object handling, while being scalable for various sizes and environments, thus improving the overall warehouse management system.
Implementation Method 1
vertically-adjustable low friction transfer modules
Implementation Method 2
the modules are tilted at an angle so that the objects move horizontally across the surface
Data Source
AI summary
An approach is provided to sort objects on a surface of vertically-adjustable low friction transfer modules that are controlled by processors. A request to sort the plurality of objects in a horizontal direction is received with each of the objects is assigned a sort position. Sets of the vertically-adjustable low friction transfer modules are selected. The vertically-adjustable low friction transfer modules are arranged in a grid formation on the surface, with each of the sets of selected transfer modules being underneath a different object. The sets of selected transfer modules are vertically adjusted causing each of the objects to move independently from the other objects while avoiding the other objects in two or more dimensions formed on the surface. The result of the movement is that each of the objects is moved to a position respective of the other objects according to each object's respective sort position.