Wedge-Block Unloading Robot for Floor-Loaded Box Transfer
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Solution Overview
Problem
Current trailer unloading processes for floor-loaded goods are manual, strenuous, and inefficient, with existing robotic solutions being too complex, costly, and limited in handling various goods due to precise detection and gripping requirements.
Innovation Solution
A robotic system with a mobile base assembly and lifting assembly, featuring wedge blocks with independent motors and actuators, allows for autonomous unloading by sliding under goods and transferring them onto a conveyor belt without precise detection or gripping, accommodating various goods and uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operators perform unloading operations, then flexibility in handling various goods is maintained, but productivity is low and operations are highly strenuous
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system that uses a mobile base, lifting assembly, and conveyor mechanism to automatically unload goods from trailers, eliminating the need for manual picking and transporting while significantly increasing productivity
Solution Approach 2:
The robotic system is designed to autonomously navigate to trailers, identify goods to be unloaded, lift them using the lifting assembly, and transfer them to the conveyor system without human intervention, making the unloading process self-service and highly efficient
2Productivity
If known robots are used for unloading tasks, then productivity increases, but design complexity and costs increase significantly
Solution Approach 1:
The robotic system is divided into distinct functional modules: a mobile base assembly for navigation, a lifting assembly for elevating goods, and a conveyor system for transport. This segmentation allows each component to be optimized independently and simplifies the overall system design and maintenance
Solution Approach 2:
The robotic system is designed with universal capabilities to handle various types of goods (packages, boxes, pallets) and adapt to different trailer configurations through its mobile base and adjustable lifting mechanism, reducing the need for multiple specialized robots
3Adaptability or versatility
If pneumatic grippers are used on robotic arms, then gripping capability is provided, but weight limits and surface compatibility are restricted
Solution Approach 1:
The patent extracts the gripping function from the system by using the lifting assembly to lift goods from below rather than gripping them from the side, eliminating the need for pneumatic grippers and their associated weight and surface compatibility limitations
Solution Approach 2:
The lifting assembly acts as an intermediary mechanism that lifts goods using a wedge or ramp mechanism from underneath, providing a reliable method to handle various goods regardless of their weight or surface characteristics without requiring direct gripping contact
4Measurement precision
If sensors are used to detect box positions, then positioning precision is improved, but system cost increases with only marginal productivity improvement
Solution Approach 1:
The robotic system uses vision systems and sensors to autonomously identify and locate goods, then self-corrects its positioning through the mobile base navigation and lifting assembly alignment, eliminating the need for complex sensor arrays while maintaining high positioning accuracy and productivity
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 system enhances unloading efficiency and reduces manual labor by enabling seamless transfer of multiple stacked goods, accommodating diverse items and irregular surfaces, while minimizing damage and equipment complexity.
Implementation Method 1
The lifting assembly may be embodied as a collection of wedge blocks, each of which is connected to a front edge of the mobile base assembly
Implementation Method 2
each wedge block of the lifting assembly includes a spring-loaded retracting mechanism for retracting a front portion of the wedge block towards the rear portion of the wedge block
Data Source
AI summary
A robotic system includes a mobile base assembly and a lifting assembly. The lifting assembly includes wedge blocks, each of which is pivotably connected to a front edge of the mobile base assembly and pivotable along a hinge axis. During an operation of the robotic system, at least a portion of the wedge blocks may be slid under the boxes to lift the boxes.