Box Tray Assembly With Programmable Positioning for Automated Sortation
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Solution Overview
Problem
Current automated sortation systems in distribution centers are inefficient and inflexible, relying heavily on human labor and mechanical complexity, which increases costs and limits throughput due to the need for numerous diverts and collection bins, and fail to efficiently match objects with assigned bins.
Innovation Solution
A box handling system with programmable motion control and identifying indicia on box trays and covers, allowing for precise identification and sorting of objects into appropriate collection bins using robotic systems and conveyors, enabling efficient alignment and processing of objects.
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 sortation capability is achieved, but mechanical complexity and cost per divert increase significantly
Solution Approach 1:
The system divides the sortation function into two independent segments: (1) a single actuator that controls box tray positioning, and (2) passive gravity-based object release at multiple divert locations. This eliminates the need for actuators at each divert point while maintaining automated sortation capability across hundreds of destinations.
Solution Approach 2:
The box tray assembly acts as an intermediary carrier that holds the object and transports it to the correct divert location. The tray itself becomes the sorting mechanism through its programmable positioning, rather than requiring active control mechanisms at each destination point.
2Ease of operation
If numerous collection bins are arranged within reach of human workers, then sortation functionality is provided, but physical space requirements and capital costs increase
Solution Approach 1:
The system transitions from a two-dimensional arrangement where all bins must be within arm's reach of workers, to a three-dimensional recirculating conveyor system where bins can be distributed along the conveyor path. Objects are sorted by position along the conveyor rather than by proximity to a fixed work station.
Solution Approach 2:
The recirculating conveyor system serves multiple functions: it transports objects to numerous divert locations, provides recirculation for missed sorts, and accommodates dynamic bin assignments. A single conveyor infrastructure supports hundreds of diverts without requiring proportional increases in worker reach area.
3Adaptability or versatility
If human workers perform manual sortation, then flexibility in handling various objects is maintained, but throughput is limited by worker speed
Solution Approach 1:
The system replaces human manual sortation with an automated control system that uses scanners, processors, and programmable box tray positioning to identify and route objects. This mechanical-to-automated substitution maintains flexibility through programmable logic while dramatically increasing throughput beyond human capabilities.
Solution Approach 2:
The system incorporates dynamic bin assignments where collection bin mappings are not fixed but can be changed programmatically. The box tray positions and bin assignments are dynamically adjusted based on real-time sortation requirements, providing adaptability equivalent to human workers with automated speed.
4Measurement precision
If the number of diverts is increased to match more collection bins, then sortation precision improves, but the cost per divert increases due to additional actuators
Solution Approach 1:
The system segments the sorting function so that precision is achieved through programmable positioning of a single actuator-controlled box tray, rather than through multiple actuators. Each divert location benefits from the precision positioning capability without requiring its own expensive actuator mechanism.
Solution Approach 2:
Instead of physically replicating actuator mechanisms at each divert location, the system uses a single actuator that is programmatically controlled to serve multiple divert positions. The control system creates virtual copies of the sorting function for each destination, eliminating the need for physical hardware replication.
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.