Box Tray Assembly With Vision-Guided Robotic 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 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 a robotic system with image collection units 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 device complexity and cost per divert increase significantly
Solution Approach 1:
The patent removes the actuator from each individual divert location and extracts the automation function to a centralized robotic system with vision guidance. Instead of having mechanical actuators distributed throughout the conveyor system, a single robotic end effector performs all sortation decisions based on image recognition, eliminating the need for complex mechanical divert mechanisms at each station.
Solution Approach 2:
The patent replaces the mechanical actuator-based divert system with an optical recognition system (image collection units) combined with a robotic manipulation system. The mechanical complexity of tilt-tray and bomb-bay actuators is substituted with a programmable robotic end effector that uses visual feedback to identify and divert objects, transforming a mechanically complex system into an optically-guided robotic system.
2Device complexity
If multiple parallel manual sortation cells are used to increase the number of diverts, then cost per divert decreases, but operating costs and labor requirements increase
Solution Approach 1:
The robotic end effector serves as a universal sortation device that can direct objects to any of multiple collection bins without requiring separate manual workers for each bin. The single robotic system performs the function of multiple manual sortation cells, maintaining the ability to handle numerous diverts while reducing labor requirements and operating costs.
Solution Approach 2:
The system enables self-service sortation where the robotic end effector autonomously identifies objects using image collection units and automatically diverts them to the correct bins without human intervention. This eliminates the need for manual workers to physically handle and sort objects, reducing labor costs while maintaining or increasing throughput capacity.
3Adaptability or versatility
If a large number of collection bins are arranged within reach of workers, then sortation capability is improved, but physical space requirements and capital costs increase
Solution Approach 1:
The patent arranges collection bins in a multi-dimensional layout that extends beyond the immediate reach of a single worker position. The robotic end effector moves along the conveyor and can access bins positioned at various distances and angles, effectively utilizing three-dimensional space rather than being constrained to a two-dimensional workspace within arm's reach of a stationary worker.
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.