Automated Singulation System with Modular Conveyor Control

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Solution Overview

Problem

The process of singulating items from larger groups in facilities is often labor-intensive and inefficient, requiring effective automation to separate items on conveyor belts while ensuring proper spacing and handling of non-singulated items.

Innovation Solution

An automated system utilizing multiple conveyor belts with sensors and a control system to independently control each belt, ensuring items are separated by a specified gap distance, with a scan tool for verification and a divert tool for recirculating non-singulated items back to the singulation tool via a conveyor belt system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual singulation is used, then flexibility in handling is maintained, but labor intensity increases and processing efficiency decreases

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidautomation level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The system uses sensors to automatically detect items and their positions, with the control system autonomously determining singulation actions without human intervention. The robotic arm performs self-directed manipulation based on sensor feedback, enabling the system to serve itself in the singulation process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical handling is replaced with an automated robotic system that uses sensors for detection and a robotic arm for manipulation. This substitution of mechanical systems with automated control mechanisms resolves the contradiction by maintaining handling flexibility while dramatically improving processing efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Extent of automation

If automated singulation is implemented, then labor requirements are reduced, but system complexity increases

Engineering Contradiction:

Improveautomation levelVSAvoidsystem complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The automated singulation system is divided into distinct functional modules: sensor array for detection, control system for decision-making, and robotic arm for execution. This segmentation allows each component to be optimized independently while working together as an integrated system, managing complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic arm and conveyor system are designed to handle multiple item types and configurations through programmable control. The same hardware infrastructure serves multiple singulation scenarios, reducing overall system complexity by avoiding dedicated equipment for each specific task.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If items are closely spaced on conveyor, then throughput increases, but singulation difficulty increases

Engineering Contradiction:

ImprovethroughputVSAvoidsingulation difficulty

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

Sensors continuously monitor item positions and provide real-time feedback to the control system. This feedback loop enables the system to detect closely spaced items by comparing actual positions against target positions, dynamically adjusting singulation actions based on measured deviations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary detection and positioning adjustments before final singulation actions. Sensors identify item locations in advance, allowing the control system to plan and execute precise manipulation sequences that separate closely spaced items without disrupting overall throughput.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If non-singulated items are diverted, then processing accuracy improves, but additional processing steps are required

Engineering Contradiction:

Improvesingulation accuracyVSAvoidprocessing steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Non-singulated items are extracted from the main conveyor stream and diverted to a separate recirculation path. This extraction allows the primary processing line to maintain high accuracy while the diverted items receive additional singulation attempts, separating the accuracy-critical path from the reprocessing path.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Items that fail initial singulation attempts are temporarily set aside in the divert path and then recovered for recirculation back to the singulation point. This discarding-and-recovering process maintains overall system accuracy by ensuring only properly singulated items proceed while giving retry opportunities to borderline cases.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS11691827B2Robotic surgical tool with pivotable transmission linkage on translating carriage

Publication Date: 2023.07.04 AMAZON TECH INC

AI summary

An automated system for singulating items is provided. The automated system includes a singulation apparatus. The singulation apparatus includes multiple conveyor modules and a vertical frame structure. Each of the multiple conveyor modules has an identical physical structure. The vertical frame structure provides multiple horizontal mounting locations, each at a different height along the vertical frame structure. Each of the conveyor modules is mounted to a different one of the multiple horizontal mounting locations.