Box Tray Assembly With Programmable Sorting and Box Alignment
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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 diverters and collection bins.
Innovation Solution
A box handling system with programmable motion control and identifying indicia on box trays and covers, allowing for precise sorting and alignment of boxes on conveyors, enabling automated processing and reduced mechanical complexity by using robotic systems and image recognition to direct the movement of boxes to appropriate destinations.
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 improved, but mechanical complexity and cost per divert increase significantly
Solution Approach 1:
The patent extracts the actuator mechanism from each individual divert location and consolidates it into a single central actuator. This single actuator controls a movable divider that can be positioned to direct objects to different collection bins, eliminating the need for multiple actuators while maintaining automated sortation capability.
Solution Approach 2:
The single central actuator serves multiple functions by controlling the movable divider to direct objects to any of the collection bins. This multi-functional approach allows one actuator to perform the role of what would traditionally require multiple actuators, reducing mechanical complexity while maintaining automation.
2Adaptability or versatility
If more collection bins are arranged within reach of human workers to increase divert capacity, then number of diverts is improved, but physical space requirements and capital costs increase
Solution Approach 1:
The patent arranges collection bins in a linear array rather than spreading them out in a two-dimensional workspace around the worker. The movable divider extends across the conveyor to create multiple diversion points along the linear arrangement, allowing many bins to be accessed within a compact linear footprint rather than requiring extensive radial space.
Solution Approach 2:
The movable divider is dynamically positioned by the central actuator to create diversion paths to different bins as needed. This dynamic reconfiguration allows the system to handle many more divert destinations than would be statically accessible to a worker, increasing adaptability without proportionally increasing the physical workspace.
3Adaptability or versatility
If human workers perform manual sortation to increase the number of diverts, then adaptability is improved, but operating costs and throughput limitations increase
Solution Approach 1:
The system uses image recognition technology to automatically identify objects and determine their destination, eliminating the need for human workers to scan and identify items. The programmable motion control system then automatically directs objects to the correct bins, making the system self-sufficient in both identification and sortation functions.
Solution Approach 2:
The patent replaces the human worker's manual sortation actions with an automated system combining image recognition for identification and programmable motion control for physical diversion. This substitution maintains high adaptability in routing decisions while dramatically increasing throughput beyond human capabilities.
4Productivity
If parallel manual sortation cells are used to multiply throughput, then productivity is improved, but system complexity and installation costs increase
Solution Approach 1:
The system performs preliminary identification and routing determination using image recognition before the object reaches the diversion point. The programmable motion control system pre-calculates the required divider position based on the identified object and its destination, allowing smooth continuous operation at high speeds without the coordination complexity of multiple parallel cells.
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.