US20160220038A1 - Mobile inventory rack apparatus and inventory rack system - Google Patents
Mobile inventory rack apparatus and inventory rack system Download PDFInfo
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- US20160220038A1 US20160220038A1 US14/609,278 US201514609278A US2016220038A1 US 20160220038 A1 US20160220038 A1 US 20160220038A1 US 201514609278 A US201514609278 A US 201514609278A US 2016220038 A1 US2016220038 A1 US 2016220038A1
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- inventory
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- supply
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- 238000013519 translation Methods 0.000 claims abstract description 23
- 230000004044 response Effects 0.000 claims description 7
- 238000012384 transportation and delivery Methods 0.000 description 10
- 230000007246 mechanism Effects 0.000 description 7
- 238000000034 method Methods 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 238000012546 transfer Methods 0.000 description 4
- 238000013461 design Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 241000208199 Buxus sempervirens Species 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000001934 delay Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000001960 triggered effect Effects 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
- B65G1/02—Storage devices
- B65G1/04—Storage devices mechanical
- B65G1/06—Storage devices mechanical with means for presenting articles for removal at predetermined position or level
- B65G1/08—Storage devices mechanical with means for presenting articles for removal at predetermined position or level the articles being fed by gravity
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47F—SPECIAL FURNITURE, FITTINGS, OR ACCESSORIES FOR SHOPS, STOREHOUSES, BARS, RESTAURANTS OR THE LIKE; PAYING COUNTERS
- A47F1/00—Racks for dispensing merchandise; Containers for dispensing merchandise
- A47F1/04—Racks or containers with arrangements for dispensing articles, e.g. by means of gravity or springs
- A47F1/12—Racks or containers with arrangements for dispensing articles, e.g. by means of gravity or springs dispensing from the side of an approximately horizontal stack
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G11/00—Chutes
- B65G11/20—Auxiliary devices, e.g. for deflecting, controlling speed of, or agitating articles or solids
- B65G11/203—Auxiliary devices, e.g. for deflecting, controlling speed of, or agitating articles or solids for articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G13/00—Roller-ways
- B65G13/075—Braking means
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16M—FRAMES, CASINGS OR BEDS OF ENGINES, MACHINES OR APPARATUS, NOT SPECIFIC TO ENGINES, MACHINES OR APPARATUS PROVIDED FOR ELSEWHERE; STANDS; SUPPORTS
- F16M11/00—Stands or trestles as supports for apparatus or articles placed thereon ; Stands for scientific apparatus such as gravitational force meters
- F16M11/42—Stands or trestles as supports for apparatus or articles placed thereon ; Stands for scientific apparatus such as gravitational force meters with arrangement for propelling the support stands on wheels
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B31/00—Service or tea tables, trolleys, or wagons
- A47B2031/003—Service or tea tables, trolleys, or wagons with drawers, trays or shelves
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
- A47B31/00—Service or tea tables, trolleys, or wagons
- A47B2031/004—Service or tea tables, trolleys, or wagons having four vertical uprights
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
- B65G1/02—Storage devices
- B65G1/023—Arrangements of article supporting rollers on racks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G65/00—Loading or unloading
Definitions
- the manufacturing and assembly process for vehicles requires workers to install various parts to the vehicle as the vehicle moves along an assembly line.
- the supply of these parts, or inventory, must be replenished during the assembly process, with some parts requiring replenishment more often than others.
- the frequency of replenishment can depend on the storage area allotted to the parts adjacent to the installation location along the assembly line, the size of the parts, the quantity of the parts used per vehicle, and how many vehicles traveling the assembly line require use of the specific parts.
- Traditional part-replenishment systems can include delivery of inventory according to a detailed schedule or delivery of inventory upon specific request by workers on the assembly line.
- Parts can be delivered, for example, by forklift drivers or automated guided vehicles (AGVs) traveling between an inventory storage location and the various stations of the assembly line requiring the specified parts.
- AGVs automated guided vehicles
- Schedule-based delivery systems can be overly complicated to manage, and request-based delivery systems can cause delays along the assembly line.
- a better part-replenishment system for supplying inventory is thus required to improve the manufacturing and assembly process.
- a mobile inventory rack apparatus serving as part of an inventory rack system can receive articles of inventory on an as-needed basis from a stationary supply rack apparatus and deliver articles of inventory on an as-needed basis to a receiver rack apparatus located adjacent to the assembly line for a vehicle.
- the mobile inventory rack apparatus can include an inventory conveyor designed to receive an article of inventory when a requirement indicator has an inventory required state as denoted by the lack of contact with an article of inventory.
- the mobile inventory rack apparatus can also supply articles of inventory by repositioning a set of paired stoppers that prevent translation of the articles of inventory to allow at least one article of inventory to be removed from the inventory conveyor when a supply lever is contacted by a requirement pin extending from a receiver rack apparatus.
- a mobile inventory rack apparatus in one implementation, includes an inventory conveyor configured to translate articles of inventory and a receiving system including a requirement indicator disposed along the inventory conveyor.
- the requirement indicator has an inventory required state when not in contact with an article of inventory.
- the mobile inventory rack apparatus further includes a supply system including a pair of spaced stoppers disposed along the inventory conveyor. Each stopper has an extended position preventing translation of the articles of inventory and a retracted position allowing translation of the articles of inventory.
- the inventory conveyor is configured to receive at least one article of inventory when the requirement indicator is in the inventory required state and to allow removal of at least one article of inventory when one of the stoppers is in the retracted position.
- an inventory rack system in another implementation, includes a supply rack apparatus and a mobile inventory rack apparatus.
- the supply rack apparatus includes a supply system.
- the supply system includes a pair of spaced stoppers disposed along a supply conveyor, each stopper having an extended position preventing translation of articles of inventory and a retracted position allowing translation of the articles of inventory.
- the supply system also includes a supply lever extending from the supply rack apparatus configured to switch the positions of both of the spaced stoppers.
- the mobile inventory rack apparatus includes a receiving system.
- the receiving system includes a requirement indicator disposed along an inventory conveyor, the requirement indicator having an inventory required state when not in contact with an article of inventory.
- the receiving system also includes a requirement pin extending from the mobile inventory rack apparatus when the requirement indicator is in the inventory required state.
- the inventory conveyor is configured to receive at least one article of inventory from the supply conveyor in response to the requirement pin of the mobile inventory rack apparatus being contacted by the supply lever of the supply rack apparatus.
- FIG. 1 is a side view of a mobile inventory rack apparatus
- FIG. 2 is an end view of the mobile inventory rack apparatus of FIG. 1 ;
- FIG. 3 is another side view of the mobile inventory rack apparatus of FIG. 1 ;
- FIG. 4 is a side sectional view of an inventory rack system including a supply rack apparatus, the mobile inventory rack apparatus of FIGS. 1-3 , and a receiver rack apparatus.
- the mobile inventory rack apparatus can include at least one inventory conveyor configured to translate articles of inventory.
- the mobile inventory rack apparatus can deliver the articles of inventory from an inventory source to a line-side storage location for use in a vehicle assembly process.
- the mobile inventory rack apparatus can include a receiving system including a requirement indicator that has an inventory required state only when not in contact with an article of inventory and a supply system preventing translation of articles of inventory until a supply lever on the mobile inventory rack apparatus is contacted by a requirement pin on a receiver rack apparatus located at the line-side storage location.
- FIG. 1 is a side view of a mobile inventory rack apparatus 100 .
- the mobile inventory rack apparatus 100 described below can move through an assembly plant, either automatically if controlled by an AGV or manually if controlled by an operator.
- the mobile inventory rack apparatus 100 can be driven adjacent to a stationary supply rack apparatus in order to receive new inventory as needed and be driven adjacent to a stationary receiver rack apparatus to deliver inventory as needed to various stations on an assembly line.
- the mobile inventory rack apparatus 100 thus facilitates part delivery to the assembly line without the need for either scheduling deliveries or manually requesting parts.
- the mobile inventory rack apparatus 100 includes a requirement indicator 102 as part of an upper conveyor receiving system 104 shown in an inventory required state and a requirement indicator 106 as part of a lower conveyor receiving system 108 shown in an inventory not required state.
- the upper conveyor receiving system 104 of the mobile inventory rack apparatus 100 (including the requirement indicator 102 ) is disposed along an upper inventory conveyor 110
- the lower conveyor receiving system 108 (including the requirement indicator 106 ) is disposed along a lower inventory conveyor 112 .
- the two inventory conveyors 110 , 112 are configured to translate articles of inventory within containers, such as boxes 114 a - c , from one side of the mobile inventory rack apparatus 100 to the other side.
- the boxes 114 a - c are designed to hold vehicle parts, i.e. inventory, for use in the vehicle assembly process.
- the mobile inventory rack apparatus 100 is described here in the context of part delivery for a vehicle assembly line, it is also possible to use the mobile inventory rack apparatus 100 in other delivery contexts, such as in grocery stores or warehouses.
- two inventory conveyors 110 , 112 are shown, any number of inventory conveyors can be included as part of the mobile inventory rack apparatus 100 since the design is scalable.
- Each inventory conveyor 110 , 112 can be configured to deliver different types of parts on an as-needed schedule given the design of the delivery mechanisms described below.
- the inventory conveyors 110 , 112 can be sloped in order to use gravity to assist in translation of the boxes 114 a - c and can optionally include spaced roller channels to further assist in translation.
- the requirement indicators 102 , 106 can be disposed between the spaced roller channels and are designed to collapse beneath the boxes 114 a - c upon contact with the boxes 114 a - c in order to indicate the inventory not required state.
- the requirement indicators 102 , 106 can include rollers at distal ends for ease of collapse upon contact. In the example shown in FIG.
- the requirement indicator 106 has an inventory not required state, i.e., no inventory is required to be added to the lower inventory conveyor 112 , since the requirement indicator 106 is in contact with and has collapsed beneath the box 114 b.
- the requirement indicator 102 is not in contact with anything and is positioned upright between the spaced roller channels of the upper inventory conveyor 110 .
- the requirement indicator 102 has an inventory required state, that is, the upper inventory conveyor 110 is ready to receive an additional article of inventory, e.g. another box of parts.
- the upper conveyor receiving system 104 further includes a requirement pin 116 configured to extend from the mobile inventory rack apparatus 100 when the requirement indicator 102 is in the inventory required state as shown.
- the extension of the requirement pin 116 is based on the upright position of the requirement indicator 102 and the lack of contact with an article of inventory.
- the requirement pin 116 and the requirement indicator 102 can be joined, for example, by a cable and/or lever system as part of the upper conveyor receiving system 104 .
- the upper inventory conveyor 110 can be designed to receive at least one article of inventory, for example, another box of parts, from a supply rack apparatus in response to the requirement pin 116 being contacted by a supply lever extending from the supply rack apparatus when the mobile inventory rack apparatus 100 passes by the supply rack apparatus.
- the lower conveyor receiving system 108 also includes a requirement pin 118 , the requirement pin 118 having a retracted position shown in dotted line based on the requirement indicator 106 having an inventory not required state.
- the retracted position of the requirement pin 118 is thus based on the collapsed position of the requirement indicator 106 below and in contact with the box 114 b. Since the requirement pin 118 is in the retracted position, a corresponding supply lever on a supply rack apparatus will not be able to contact the requirement pin 118 , and no parts will be transferred to the lower inventory conveyor 112 when the mobile inventory rack apparatus 100 passes by the supply rack apparatus.
- the mobile inventory rack apparatus 100 also includes stoppers 200 , 202 at the end of the inventory conveyors 110 , 112 forming part of an upper conveyor supply system 204 and a lower conveyor supply system 206 .
- the stoppers 200 , 202 prevent translation of articles of inventory.
- the upper conveyor supply system 204 includes the stopper 200 as part of a pair of spaced stoppers 200 , 208 disposed along the upper inventory conveyor 110 .
- the lower conveyor supply system 206 includes the stopper 202 as part of another pair of spaced stoppers 202 , 210 disposed along the lower inventory conveyor 112 .
- Each of the stoppers 200 , 202 , 208 , 210 has an extended position preventing translation of articles of inventory and a retracted position allowing translation of articles of inventory.
- the extended position of the stopper 200 in the upper conveyor supply system 204 is preventing the box 114 a from sliding off of the upper inventory conveyor 110 .
- the extended position of the stopper 202 in the lower conveyor supply system 206 is preventing the box 114 c from sliding off of the lower inventory conveyor 112 .
- the stoppers 200 , 208 are paired, or coupled, in that the extension of the stopper 200 leads to the retraction of the stopper 208 .
- the stoppers 202 , 210 are paired, and the extension of the stopper 202 leads to the retraction of the stopper 210 .
- the paired extension and retraction can be accomplished using a lever system and common axes of rotation for the connected pairs of stoppers 200 , 208 and 202 , 210 .
- the mechanisms shown are similar in function to a see-saw, though other mechanical, hydraulic, or electric mechanisms for paired extension and retraction are also possible.
- the upper conveyor supply system 204 further includes a supply lever 212 configured to switch the positions of both of the spaced stoppers 200 , 208 when contacted by a requirement pin extending from a receiver rack apparatus.
- the lower conveyor supply system 206 further includes a supply lever 214 configured to switch the positions of both of the spaced stoppers 202 , 210 when contacted by a requirement pin extending from a receiver rack apparatus.
- the spacing between the paired stoppers 200 , 208 and 202 , 210 is such that a single article of inventory can be positioned along the inventory conveyors 110 , 112 between the sets of paired stoppers 200 , 208 and 202 , 210 .
- the spacing can be such that any number of articles of inventory can be designed to be released from the respective inventory conveyors 110 , 112 upon retraction of the respective stoppers 200 , 202 .
- FIG. 2 is an end view of the mobile inventory rack apparatus 100 of FIG. 1 , more specifically, a right-end view of FIG. 1 .
- the supply levers 212 , 214 are shown in a stacked vertical condition, with the supply lever 212 directly above the supply lever 214 .
- the boxes 114 a - c are shown in dotted line so that the details of the conveyor receiving systems 104 , 108 and the conveyor supply systems 204 , 206 located along the inventory conveyors 110 , 112 are visible.
- FIG. 2 is a mobile inventory rack apparatus 100 capable of receiving and supplying four different types of inventory.
- the remainder of the description refers only to the left side of the mobile inventory rack apparatus 100 of FIG. 2 for simplicity, but it is understood that the mechanisms associated with the inventory conveyors 110 , 112 can also be implemented with additional inventory conveyors forming a larger mobile inventory rack apparatus 100 .
- the design is scalable.
- FIG. 3 is another side view of the mobile inventory rack apparatus 100 of FIG. 1 .
- the requirement indicators 102 , 106 of both the upper conveyor receiving system 104 and the lower conveyor receiving system 108 have an inventory not required state.
- another box 114 d of parts has been received on the upper inventory conveyor 110 , thus both the upper inventory conveyor 110 and the lower inventory conveyor 112 are full, with the boxes 114 a and 114 d located on the upper inventory conveyor 110 and the boxes 114 b and 114 c located on the lower inventory conveyor 112 .
- the box 114 d makes contact with the requirement indicator 102 , moving the requirement indicator 102 beneath the box 114 d as shown.
- the box 114 b remains in contact with the requirement indicator 106 .
- both of the requirement pins 116 , 118 are in the retracted state, indicating that no additional inventory is currently required by the mobile inventory rack apparatus 100 . If the mobile inventory rack apparatus 100 passes a supply rack apparatus in this configuration, no articles of inventory will be transferred from the supply rack apparatus to the mobile inventory rack apparatus 100 .
- the stopper 202 in the pair of spaced stoppers 202 , 210 in the lower conveyor supply system 206 has a retracted position allowing translation of an article of inventory, i.e. box 114 c, from the lower inventory conveyor 112 .
- the supply lever 214 has been contacted by a requirement pin extending from a receiver rack apparatus, leading to the rotated state of the supply lever 214 as shown.
- the stopper 202 was retracted at the same time that the stopper 210 was extended.
- This coordinated motion is achieved by coupling the motion of the paired stoppers 202 , 210 to the motion of the supply lever 214 , using, for example, a combination of cables and levers.
- the box 114 c can slide from the lower inventory conveyor 112 to, for example, a receiver rack apparatus.
- the sliding motion of the box 114 c is indicated by an arrow.
- the box 114 b is halted by the extension of the stopper 210 .
- the stopper 210 extends into the space between the boxes 114 b and 114 c to stop the motion of the box 114 b, but if no space is present between the boxes 114 b and 114 c, the stopper 210 can be designed to impact the bottom of the box 114 b to stop its motion while the box 114 c slides off of the lower inventory conveyor 112 .
- the spacing of the paired stoppers 202 , 210 controls the number of articles of inventory that are released from the lower inventory conveyor 112 upon contact with the supply lever 214 .
- the paired stoppers 202 , 210 can also include a counter-weight return mechanism. Once the appropriate number of articles of inventory is released, in this example, just the single box 114 c, the stopper 202 can return to its extended position and the leftmost stopper 210 can return to its retracted position, allowing the box 114 b to slide down the lower inventory conveyor 112 to rest at the stopper 202 . In turn, the requirement indicator 106 will be released from contact with the box 114 b to return to the inventory required state extending up through the lower inventory conveyor 112 , and the requirement pin 118 will be triggered to extend from the mobile inventory rack apparatus 100 .
- the same supply mechanisms described in respect to the lower inventory conveyor 112 are present on the upper inventory conveyor 110 . That is, the paired stoppers 200 , 208 are coupled to the supply lever 212 . Contact made with the supply lever 212 will retract the stopper 200 and allow removal of the box 114 a while at the same time extending the stopper 208 and stopping translation of the box 114 d just until removal of the box 114 a is complete and the counter-weight mechanism returns the stopper 200 to the extended position and the stopper 208 to the retracted position. At this point, the box 114 d will be free to slide into contact with the stopper 200 and the requirement indicator 102 will be released, allowing extension of the requirement pin 116 indicating the inventory required state for the upper conveyor receiving system 104 .
- the mobile inventory rack apparatus 100 described in the preceding figures is further described as part of an inventory rack system below.
- FIG. 4 is a side sectional view of an inventory rack system including a supply rack apparatus 500 , the mobile inventory rack apparatus 100 of FIGS. 1-3 , and a receiver rack apparatus 502 .
- the supply rack apparatus 500 includes a pair of supply systems 504 , 506 each disposed along a supply conveyor 508 , 510 and including a pair of spaced stoppers 512 , 514 and 516 , 518 .
- Each stopper 512 , 514 , 516 , 518 has an extended position preventing translation of articles of inventory and a retracted position allowing translation of articles of inventory.
- the upper pair of spaced stoppers 512 , 514 is coupled to a supply lever 520 extending from the supply rack apparatus 500 and the lower pair of spaced stoppers 516 , 518 is coupled to a supply lever 522 extending from the supply rack apparatus 500 .
- the supply levers 520 , 522 are configured to switch the positions of the respective spaced stoppers 512 , 514 and 516 , 518 upon contact, for example, between retracted and extended positions.
- the supply lever 522 is being contacted by the requirement pin 118 of the mobile inventory rack apparatus 100 , and the stopper 516 is consequently retracted, allowing box 114 e to move from the supply rack apparatus 500 to the mobile inventory rack apparatus 100 .
- the stopper 518 is extended, impeding the motion of box 114 f until the transfer of the box 114 e is complete.
- the supply lever 520 is not contacted by the corresponding requirement pin 116 because the requirement pin 116 is retracted based on the presence of the box 114 d in contact with the requirement indicator 102 on the upper inventory conveyor 110 of the mobile inventory rack apparatus 100 .
- the receiver rack apparatus 502 includes a pair of receiving systems 524 , 526 each disposed along a receiver conveyor 528 , 530 and including a requirement indicator 532 , 534 .
- the requirement indicators 532 , 534 have inventory required states when not in contact with an article of inventory and inventory not required states when in contact with an article of inventory.
- the receiving systems 524 , 526 further include requirement pins 536 , 538 configured to extend from the receiver rack apparatus 502 when the requirement indicators 532 , 534 are in the inventory required state.
- the box 114 c was previously transferred to the receiver conveyor 530 by the mobile inventory rack apparatus 100 and is now in contact with the requirement indicator 534 . Consequently, the related requirement pin 538 is retracted and does not contact the supply lever 214 of the mobile inventory rack apparatus 100 . Thus, no articles of inventory will be transferred between the lower inventory conveyor 112 and the receiver conveyor 530 .
- the example shown in FIG. 4 has the requirement indicator 532 in a position extending upright through the receiver conveyor 528 , making no contact with any articles of inventory.
- the requirement pin 536 is extended from the receiver rack apparatus 502 and can contact the supply lever 212 when the mobile inventory rack apparatus 100 travels by the receiver rack apparatus 502 .
- the stopper 200 located on the upper inventory conveyor 110 is retracted, and the box 114 a can transfer between the upper inventory conveyor 110 and the receiver conveyor 528 .
- the stopper 208 extends to impede motion of the box 114 d until the transfer of the box 114 a is complete.
- the box 114 a transfers from the mobile inventory rack apparatus 100 to the receiver rack apparatus 502 , the box 114 a will contact the requirement indicator 532 which in turn will retract the requirement pin 536 , indicating that the receiver conveyor 528 is full.
- the mobile inventory rack apparatus 100 described in the preceding figures allows for as-needed supply of inventory between an inventory source, such as the stationary supply rack apparatus 500 , and assembly stations on the assembly line that include limited storage for inventory, such as the receiver rack apparatus 502 , each shown in FIG. 4 .
- the mobile inventory rack apparatus 100 can also be designed to receive receptacles for articles of inventory, for example, empty boxes, from the assembly stations and return the empty boxes back to the inventory source to be refilled using either the same receiving systems and supply systems described above, or simplified receiving systems and supply systems designed for empty box return, but designed in a reverse direction.
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Abstract
Description
- The manufacturing and assembly process for vehicles requires workers to install various parts to the vehicle as the vehicle moves along an assembly line. The supply of these parts, or inventory, must be replenished during the assembly process, with some parts requiring replenishment more often than others. The frequency of replenishment can depend on the storage area allotted to the parts adjacent to the installation location along the assembly line, the size of the parts, the quantity of the parts used per vehicle, and how many vehicles traveling the assembly line require use of the specific parts.
- Traditional part-replenishment systems can include delivery of inventory according to a detailed schedule or delivery of inventory upon specific request by workers on the assembly line. Parts can be delivered, for example, by forklift drivers or automated guided vehicles (AGVs) traveling between an inventory storage location and the various stations of the assembly line requiring the specified parts. Schedule-based delivery systems can be overly complicated to manage, and request-based delivery systems can cause delays along the assembly line. A better part-replenishment system for supplying inventory is thus required to improve the manufacturing and assembly process.
- A mobile inventory rack apparatus serving as part of an inventory rack system is disclosed. The mobile inventory rack apparatus can receive articles of inventory on an as-needed basis from a stationary supply rack apparatus and deliver articles of inventory on an as-needed basis to a receiver rack apparatus located adjacent to the assembly line for a vehicle. The mobile inventory rack apparatus can include an inventory conveyor designed to receive an article of inventory when a requirement indicator has an inventory required state as denoted by the lack of contact with an article of inventory. The mobile inventory rack apparatus can also supply articles of inventory by repositioning a set of paired stoppers that prevent translation of the articles of inventory to allow at least one article of inventory to be removed from the inventory conveyor when a supply lever is contacted by a requirement pin extending from a receiver rack apparatus.
- In one implementation, a mobile inventory rack apparatus is disclosed. The mobile inventory rack apparatus includes an inventory conveyor configured to translate articles of inventory and a receiving system including a requirement indicator disposed along the inventory conveyor. The requirement indicator has an inventory required state when not in contact with an article of inventory. The mobile inventory rack apparatus further includes a supply system including a pair of spaced stoppers disposed along the inventory conveyor. Each stopper has an extended position preventing translation of the articles of inventory and a retracted position allowing translation of the articles of inventory. The inventory conveyor is configured to receive at least one article of inventory when the requirement indicator is in the inventory required state and to allow removal of at least one article of inventory when one of the stoppers is in the retracted position.
- In another implementation, an inventory rack system is disclosed. The inventory rack system includes a supply rack apparatus and a mobile inventory rack apparatus. The supply rack apparatus includes a supply system. The supply system includes a pair of spaced stoppers disposed along a supply conveyor, each stopper having an extended position preventing translation of articles of inventory and a retracted position allowing translation of the articles of inventory. The supply system also includes a supply lever extending from the supply rack apparatus configured to switch the positions of both of the spaced stoppers. The mobile inventory rack apparatus includes a receiving system. The receiving system includes a requirement indicator disposed along an inventory conveyor, the requirement indicator having an inventory required state when not in contact with an article of inventory. The receiving system also includes a requirement pin extending from the mobile inventory rack apparatus when the requirement indicator is in the inventory required state. The inventory conveyor is configured to receive at least one article of inventory from the supply conveyor in response to the requirement pin of the mobile inventory rack apparatus being contacted by the supply lever of the supply rack apparatus.
- The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
-
FIG. 1 is a side view of a mobile inventory rack apparatus; -
FIG. 2 is an end view of the mobile inventory rack apparatus ofFIG. 1 ; -
FIG. 3 is another side view of the mobile inventory rack apparatus ofFIG. 1 ; and -
FIG. 4 is a side sectional view of an inventory rack system including a supply rack apparatus, the mobile inventory rack apparatus ofFIGS. 1-3 , and a receiver rack apparatus. - A mobile inventory rack apparatus and an inventory rack system including the mobile inventory rack apparatus are described below. The mobile inventory rack apparatus can include at least one inventory conveyor configured to translate articles of inventory. The mobile inventory rack apparatus can deliver the articles of inventory from an inventory source to a line-side storage location for use in a vehicle assembly process. To accomplish delivery on an as-needed basis, the mobile inventory rack apparatus can include a receiving system including a requirement indicator that has an inventory required state only when not in contact with an article of inventory and a supply system preventing translation of articles of inventory until a supply lever on the mobile inventory rack apparatus is contacted by a requirement pin on a receiver rack apparatus located at the line-side storage location.
-
FIG. 1 is a side view of a mobileinventory rack apparatus 100. The mobileinventory rack apparatus 100 described below can move through an assembly plant, either automatically if controlled by an AGV or manually if controlled by an operator. The mobileinventory rack apparatus 100 can be driven adjacent to a stationary supply rack apparatus in order to receive new inventory as needed and be driven adjacent to a stationary receiver rack apparatus to deliver inventory as needed to various stations on an assembly line. The mobileinventory rack apparatus 100 thus facilitates part delivery to the assembly line without the need for either scheduling deliveries or manually requesting parts. - To facilitate receipt of new inventory on an as-needed basis, the mobile
inventory rack apparatus 100 includes arequirement indicator 102 as part of an upperconveyor receiving system 104 shown in an inventory required state and arequirement indicator 106 as part of a lowerconveyor receiving system 108 shown in an inventory not required state. The upperconveyor receiving system 104 of the mobile inventory rack apparatus 100 (including the requirement indicator 102) is disposed along anupper inventory conveyor 110, and the lower conveyor receiving system 108 (including the requirement indicator 106) is disposed along alower inventory conveyor 112. - The two
inventory conveyors inventory rack apparatus 100 to the other side. In this example, the boxes 114 a-c are designed to hold vehicle parts, i.e. inventory, for use in the vehicle assembly process. Though the mobileinventory rack apparatus 100 is described here in the context of part delivery for a vehicle assembly line, it is also possible to use the mobileinventory rack apparatus 100 in other delivery contexts, such as in grocery stores or warehouses. Further, though twoinventory conveyors inventory rack apparatus 100 since the design is scalable. Eachinventory conveyor - The
inventory conveyors requirement indicators requirement indicators FIG. 1 , therequirement indicator 106 has an inventory not required state, i.e., no inventory is required to be added to thelower inventory conveyor 112, since therequirement indicator 106 is in contact with and has collapsed beneath thebox 114 b. Therequirement indicator 102 is not in contact with anything and is positioned upright between the spaced roller channels of theupper inventory conveyor 110. Thus, therequirement indicator 102 has an inventory required state, that is, theupper inventory conveyor 110 is ready to receive an additional article of inventory, e.g. another box of parts. - The upper
conveyor receiving system 104 further includes arequirement pin 116 configured to extend from the mobileinventory rack apparatus 100 when therequirement indicator 102 is in the inventory required state as shown. The extension of therequirement pin 116 is based on the upright position of therequirement indicator 102 and the lack of contact with an article of inventory. Therequirement pin 116 and therequirement indicator 102 can be joined, for example, by a cable and/or lever system as part of the upperconveyor receiving system 104. Theupper inventory conveyor 110 can be designed to receive at least one article of inventory, for example, another box of parts, from a supply rack apparatus in response to therequirement pin 116 being contacted by a supply lever extending from the supply rack apparatus when the mobileinventory rack apparatus 100 passes by the supply rack apparatus. - The lower
conveyor receiving system 108 also includes arequirement pin 118, therequirement pin 118 having a retracted position shown in dotted line based on therequirement indicator 106 having an inventory not required state. The retracted position of therequirement pin 118 is thus based on the collapsed position of therequirement indicator 106 below and in contact with thebox 114 b. Since therequirement pin 118 is in the retracted position, a corresponding supply lever on a supply rack apparatus will not be able to contact therequirement pin 118, and no parts will be transferred to thelower inventory conveyor 112 when the mobileinventory rack apparatus 100 passes by the supply rack apparatus. - The mobile
inventory rack apparatus 100 also includesstoppers inventory conveyors conveyor supply system 204 and a lowerconveyor supply system 206. When in an extended position as shown, thestoppers conveyor supply system 204 includes thestopper 200 as part of a pair of spacedstoppers upper inventory conveyor 110. Similarly, the lowerconveyor supply system 206 includes thestopper 202 as part of another pair of spacedstoppers lower inventory conveyor 112. Each of thestoppers - For example, the extended position of the
stopper 200 in the upperconveyor supply system 204 is preventing thebox 114 a from sliding off of theupper inventory conveyor 110. Similarly, the extended position of thestopper 202 in the lowerconveyor supply system 206 is preventing thebox 114 c from sliding off of thelower inventory conveyor 112. In the example shown inFIG. 1 , thestoppers stopper 200 leads to the retraction of thestopper 208. Similarly, thestoppers stopper 202 leads to the retraction of thestopper 210. The paired extension and retraction can be accomplished using a lever system and common axes of rotation for the connected pairs ofstoppers - The upper
conveyor supply system 204 further includes asupply lever 212 configured to switch the positions of both of the spacedstoppers conveyor supply system 206 further includes asupply lever 214 configured to switch the positions of both of the spacedstoppers stoppers boxes 114 a,c can be automatically released from therespective inventory conveyors stoppers inventory conveyors stoppers respective inventory conveyors respective stoppers -
FIG. 2 is an end view of the mobileinventory rack apparatus 100 ofFIG. 1 , more specifically, a right-end view ofFIG. 1 . In this view, the supply levers 212, 214 are shown in a stacked vertical condition, with thesupply lever 212 directly above thesupply lever 214. The boxes 114 a-c are shown in dotted line so that the details of theconveyor receiving systems conveyor supply systems inventory conveyors inventory rack apparatus 100, for example, in the form of another column of two inventory conveyors located to the right of theinventory conveyors FIG. 2 is a mobileinventory rack apparatus 100 capable of receiving and supplying four different types of inventory. The remainder of the description refers only to the left side of the mobileinventory rack apparatus 100 ofFIG. 2 for simplicity, but it is understood that the mechanisms associated with theinventory conveyors inventory rack apparatus 100. Thus, the design is scalable. -
FIG. 3 is another side view of the mobileinventory rack apparatus 100 ofFIG. 1 . In this example, therequirement indicators conveyor receiving system 104 and the lowerconveyor receiving system 108 have an inventory not required state. As compared toFIG. 1 , anotherbox 114 d of parts has been received on theupper inventory conveyor 110, thus both theupper inventory conveyor 110 and thelower inventory conveyor 112 are full, with theboxes upper inventory conveyor 110 and theboxes lower inventory conveyor 112. - Once received on the
upper inventory conveyor 110, thebox 114 d makes contact with therequirement indicator 102, moving therequirement indicator 102 beneath thebox 114 d as shown. Thebox 114 b remains in contact with therequirement indicator 106. Given the presence of theboxes requirement indicators inventory rack apparatus 100. If the mobileinventory rack apparatus 100 passes a supply rack apparatus in this configuration, no articles of inventory will be transferred from the supply rack apparatus to the mobileinventory rack apparatus 100. - In
FIG. 3 , thestopper 202 in the pair of spacedstoppers conveyor supply system 206 has a retracted position allowing translation of an article of inventory, i.e.box 114 c, from thelower inventory conveyor 112. Thesupply lever 214 has been contacted by a requirement pin extending from a receiver rack apparatus, leading to the rotated state of thesupply lever 214 as shown. In response to thesupply lever 214 being contacted and rotated, thestopper 202 was retracted at the same time that thestopper 210 was extended. This coordinated motion is achieved by coupling the motion of the pairedstoppers supply lever 214, using, for example, a combination of cables and levers. Once thestopper 202 is retracted, thebox 114 c can slide from thelower inventory conveyor 112 to, for example, a receiver rack apparatus. The sliding motion of thebox 114 c is indicated by an arrow. - At the same time that the
box 114 c is released by the retraction of thestopper 202, thebox 114 b is halted by the extension of thestopper 210. In this example, thestopper 210 extends into the space between theboxes box 114 b, but if no space is present between theboxes stopper 210 can be designed to impact the bottom of thebox 114 b to stop its motion while thebox 114 c slides off of thelower inventory conveyor 112. Thus, the spacing of the pairedstoppers lower inventory conveyor 112 upon contact with thesupply lever 214. - The paired
stoppers single box 114 c, thestopper 202 can return to its extended position and theleftmost stopper 210 can return to its retracted position, allowing thebox 114 b to slide down thelower inventory conveyor 112 to rest at thestopper 202. In turn, therequirement indicator 106 will be released from contact with thebox 114 b to return to the inventory required state extending up through thelower inventory conveyor 112, and therequirement pin 118 will be triggered to extend from the mobileinventory rack apparatus 100. - The same supply mechanisms described in respect to the
lower inventory conveyor 112 are present on theupper inventory conveyor 110. That is, the pairedstoppers supply lever 212. Contact made with thesupply lever 212 will retract thestopper 200 and allow removal of thebox 114 a while at the same time extending thestopper 208 and stopping translation of thebox 114 d just until removal of thebox 114 a is complete and the counter-weight mechanism returns thestopper 200 to the extended position and thestopper 208 to the retracted position. At this point, thebox 114 d will be free to slide into contact with thestopper 200 and therequirement indicator 102 will be released, allowing extension of therequirement pin 116 indicating the inventory required state for the upperconveyor receiving system 104. The mobileinventory rack apparatus 100 described in the preceding figures is further described as part of an inventory rack system below. -
FIG. 4 is a side sectional view of an inventory rack system including asupply rack apparatus 500, the mobileinventory rack apparatus 100 ofFIGS. 1-3 , and areceiver rack apparatus 502. Thesupply rack apparatus 500 includes a pair ofsupply systems supply conveyor stoppers stopper stoppers supply lever 520 extending from thesupply rack apparatus 500 and the lower pair of spacedstoppers supply lever 522 extending from thesupply rack apparatus 500. The supply levers 520, 522 are configured to switch the positions of the respective spacedstoppers - In the example shown in
FIG. 4 , thesupply lever 522 is being contacted by therequirement pin 118 of the mobileinventory rack apparatus 100, and thestopper 516 is consequently retracted, allowingbox 114 e to move from thesupply rack apparatus 500 to the mobileinventory rack apparatus 100. At the same time, thestopper 518 is extended, impeding the motion ofbox 114 f until the transfer of thebox 114 e is complete. Thesupply lever 520 is not contacted by thecorresponding requirement pin 116 because therequirement pin 116 is retracted based on the presence of thebox 114 d in contact with therequirement indicator 102 on theupper inventory conveyor 110 of the mobileinventory rack apparatus 100. - The
receiver rack apparatus 502 includes a pair of receivingsystems receiver conveyor requirement indicator requirement indicators systems receiver rack apparatus 502 when therequirement indicators box 114 c was previously transferred to thereceiver conveyor 530 by the mobileinventory rack apparatus 100 and is now in contact with therequirement indicator 534. Consequently, therelated requirement pin 538 is retracted and does not contact thesupply lever 214 of the mobileinventory rack apparatus 100. Thus, no articles of inventory will be transferred between thelower inventory conveyor 112 and thereceiver conveyor 530. - The example shown in
FIG. 4 has therequirement indicator 532 in a position extending upright through thereceiver conveyor 528, making no contact with any articles of inventory. Thus, therequirement pin 536 is extended from thereceiver rack apparatus 502 and can contact thesupply lever 212 when the mobileinventory rack apparatus 100 travels by thereceiver rack apparatus 502. Upon contact between therequirement pin 536 and thesupply lever 212, thestopper 200 located on theupper inventory conveyor 110 is retracted, and thebox 114 a can transfer between theupper inventory conveyor 110 and thereceiver conveyor 528. At the same time, thestopper 208 extends to impede motion of thebox 114 d until the transfer of thebox 114 a is complete. Once thebox 114 a transfers from the mobileinventory rack apparatus 100 to thereceiver rack apparatus 502, thebox 114 a will contact therequirement indicator 532 which in turn will retract therequirement pin 536, indicating that thereceiver conveyor 528 is full. - The mobile
inventory rack apparatus 100 described in the preceding figures allows for as-needed supply of inventory between an inventory source, such as the stationarysupply rack apparatus 500, and assembly stations on the assembly line that include limited storage for inventory, such as thereceiver rack apparatus 502, each shown inFIG. 4 . Though not shown in the figures, the mobileinventory rack apparatus 100 can also be designed to receive receptacles for articles of inventory, for example, empty boxes, from the assembly stations and return the empty boxes back to the inventory source to be refilled using either the same receiving systems and supply systems described above, or simplified receiving systems and supply systems designed for empty box return, but designed in a reverse direction. - The foregoing description relates to what are presently considered to be the most practical embodiments. It is to be understood, however, that the disclosure is not to be limited to these embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
Claims (20)
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US14/609,278 US9420900B1 (en) | 2015-01-29 | 2015-01-29 | Mobile inventory rack apparatus and inventory rack system |
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