Box Tray Assembly for Automated Sorting With Open-Flap Handling
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Solution Overview
Problem
Current automated sortation systems in distribution centers are inefficient and inflexible, requiring a large number of collection bins, high mechanical complexity, and costs, while also being limited by the need for human labor and the inability to efficiently process a large number of diverts.
Innovation Solution
A box handling system that includes a box tray with a recessed area for receiving a box, featuring identifying indicia for unique identification, and a box cover that maintains the box flaps open, allowing for efficient processing and alignment of boxes on conveyors, enabling automated sorting and movement of boxes between conveyors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If tilt-tray or bomb-bay style recirculating conveyors with actuators are used for each divert, then automated sorting capability is improved, but mechanical complexity and cost per divert increase significantly
Solution Approach 1:
The patent removes the actuator mechanism from each individual divert location and extracts only the essential function of object identification and routing. Instead of active actuators at each divert point, the system uses passive gravity-fed pathways and sweep arms that redirect objects based on their identified destination, eliminating complex mechanical actuation at multiple points.
Solution Approach 2:
The patent replaces the mechanical actuator-based divert system with an identification and routing system. Scanners identify objects and their destinations, and this information drives a central controller that manages gravity-based conveyance and passive sweep arm diverts, substituting complex mechanical actuation with optical identification and centralized control logic.
2Productivity
If more collection bins are arranged within reach of human workers, then sortation capacity is improved, but physical space requirements and capital costs increase
Solution Approach 1:
The patent transitions from a two-dimensional layout where bins must be within arm's reach of workers to a three-dimensional recirculating conveyor system. Objects move through multiple passes on elevated conveyors, allowing collection bins to be positioned along the conveyor path rather than requiring all bins to be accessible from a single ground-level workstation.
Solution Approach 2:
The recirculating conveyor system allows objects that miss their destination on one pass to continue circulating and be diverted on subsequent passes. This continuous circulation maximizes the utilization of collection bins and increases sortation capacity without requiring proportional increases in physical space or number of bins.
3Ease of manufacture
If manual sortation cells are used to increase number of diverts, then system installation cost is reduced, but operating costs increase due to additional human labor
Solution Approach 1:
The patent divides the sortation system into modular segments: identification zones with scanners, conveyance zones with gravity-fed pathways, and divert zones with sweep arms. Each segment can be independently configured and scaled, allowing the system to handle large numbers of diverts through repetition of modular units rather than requiring proportional increases in human labor.
Solution Approach 2:
The patent introduces a central controller as an intermediary between object identification and physical diverts. The controller processes scanner data and coordinates sweep arm activation, serving as a digital mediator that replaces human decision-making and coordination, thereby reducing operating costs while maintaining high divert capacity.
4Productivity
If parallel manual sortation cells work in parallel, then throughput is multiplied linearly, but number of expensive automated diverts must be minimized
Solution Approach 1:
The patent merges the functions of multiple parallel sortation cells into a single integrated recirculating conveyor system. Instead of having separate cells each requiring their own diverts, one consolidated conveyor loop serves multiple collection bins along its path, achieving high throughput through continuous circulation rather than parallel processing streams.
Data Source
AI summary
A box handling system is disclosed for use in an object processing system. The box handling system includes a box tray including a recessed area for receiving a box, and the recessed area includes a plurality of floor and edge portions for receiving the box that contains objects to be processed.