Automated Processing Station for Dynamic Object Routing

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Solution Overview

Problem

Existing object distribution systems are inefficient and inflexible, requiring large numbers of collection bins, significant human labor, and limited throughput, especially when handling objects of varying sizes and weights.

Innovation Solution

A processing system utilizing a programmable motion device with a perception unit to identify objects and an acquisition system to retrieve objects using an end effector, which then delivers the objects to identified processing locations using a delivery system with a loop of carriers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manual sorting systems are used, then human workers can handle objects of varying sizes and weights, but the throughput is limited and labor costs are high

Engineering Contradiction:

ImprovethroughputVSAvoidhuman labor

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The system enables objects to be automatically identified and routed without human intervention. The perception unit detects objects and their destinations, the acquisition system grasps them, and the delivery system routes them autonomously, making the sorting process self-service and eliminating manual labor while maintaining high throughput

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical sorting with an automated system comprising a perception unit (optical/electronic detection), acquisition system (robotic gripper), and delivery system (conveyor/mechanical transfer). This substitution of human mechanical action with automated sensing and actuation systems resolves the contradiction by enabling high-speed automated processing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If multiple collection bins are used to handle diverse objects, then all object types can be sorted, but the system complexity and space requirements increase

Engineering Contradiction:

Improveobject type handlingVSAvoidnumber of collection bins

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The delivery system is designed as a universal platform that can handle multiple object types and route them to various destinations. The perception unit identifies different objects, the acquisition system adapts its grasp based on object characteristics, and the delivery system dynamically routes objects to appropriate collection bins or destinations, enabling one system to perform multiple sorting functions without requiring dedicated infrastructure for each object type

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system employs dynamic routing where collection bins are assigned to different destinations based on real-time sorting needs rather than fixed assignments. The control system dynamically adjusts which bins receive which objects, allowing the same physical bins to serve multiple destinations at different times, thereby reducing the total number of bins needed while maintaining high adaptability

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If fixed or handheld barcode scanners are used, then code identification can be achieved, but manual operation is required and processing speed is limited

Engineering Contradiction:

Improvecode detection accuracyVSAvoidprocessing speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The perception unit replaces manual barcode scanning with automated optical/electronic detection systems. These systems continuously scan and identify objects and their destinations without human intervention, dramatically increasing processing speed while maintaining accurate code detection through advanced image processing and pattern recognition algorithms

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The perception unit operates continuously as objects move through the system, constantly detecting and identifying objects rather than requiring discrete manual scanning actions. This continuous automated detection eliminates the stop-and-go nature of manual scanning, maintaining high processing speed and continuous throughput

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS20250162805A1Systems and methods for processing objects, including automated processing stations

Publication Date: 2025.05.22 BERKSHIRE GREY OPERATING CO INC

AI summary

A processing system for processing objects using a programmable motion device is disclosed. The processing system a perception unit for perceiving identifying indicia representative of an identity of an object associated with an input conveyance system, and an acquisition system for acquiring the object from a plurality of objects at an input area using an end effector of the programmable motion device, wherein the programmable motion device is adapted for assisting in the delivery of the object to an identified processing location. The identified processing location being associated with the identifying indicia and said identified processing location being provided as one of a plurality of processing locations. The processing system also includes a delivery system for receiving the object in a carrier and for delivering the object toward the identified processing location.