Discontinuous Carrier Grid With Pivoting Wheels for Flexible Sortation
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Solution Overview
Problem
Current object processing systems, particularly in distribution centers, face inefficiencies and inflexibilities due to the need for a large number of collection bins, which increases physical space, capital, and operating costs. These systems struggle to efficiently sort and redistribute objects of varying sizes and weights.
Innovation Solution
An automated carrier system with discontinuous track sections and pivotable wheel assemblies allows for efficient movement of objects by changing direction without rotating the carrier, enabling flexible routing and reduced mechanical complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to sort all objects to all destinations at once, then the sortation capacity and number of diverts increase, but the physical space requirements, capital costs, and operating costs increase significantly
Solution Approach 1:
The sortation process is divided into multiple passes, with each pass handling a subset of destinations. Objects are sorted in stages rather than all at once, allowing the system to achieve high sortation capacity with a limited number of physical bins at any given time.
Solution Approach 2:
The system dynamically reconfigures bin assignments between passes. Collection bins are reassigned to different destination groups in subsequent passes, allowing the same physical bins to serve multiple destinations over time, thereby reducing the total number of bins needed.
2Ease of operation
If human workers manually sort objects to collection bins, then labor flexibility is maintained, but system throughput is limited by worker speed
Solution Approach 1:
The system uses automated scanning and identification to determine object destinations, with objects being automatically directed to the correct bins. This reduces reliance on human decision-making speed while maintaining operational simplicity, thereby increasing throughput without sacrificing ease of operation.
Solution Approach 2:
The system can operate in multiple modes: fully automated sortation for high-throughput scenarios and manual sortation for situations requiring human judgment. This multi-functionality allows the system to adapt to different operational requirements while maintaining high productivity capability.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput increases, but the system complexity and mechanical costs increase
Solution Approach 1:
The patent extracts the diverting function from complex mechanical mechanisms and replaces it with simpler directional carriers that follow predetermined track paths. This eliminates the need for tilt trays and bomb-bay doors, reducing mechanical complexity while maintaining automated throughput capability.
Solution Approach 2:
Directional carriers serve as intermediaries between the conveyor system and collection bins. These carriers transport objects along tracks and automatically divert objects to appropriate bins using simple wheel pivoting, replacing complex tilt-tray mechanisms with a more straightforward intermediary carrier system.
4Adaptability or versatility
If the carrier rotates to change direction, then the routing flexibility is achieved, but the mechanical complexity and space requirements increase
Solution Approach 1:
The carrier's directional control is segmented into independent wheel assemblies rather than requiring rotation of the entire carrier body. Each wheel assembly can pivot independently to steer the carrier along different track sections, reducing the mechanical complexity associated with full carrier rotation while maintaining routing flexibility.
Data Source
AI summary
An automated carrier system is disclosed for moving objects to be processed. The automated carrier system includes a discontinuous plurality of track sections on which an automated carrier may be directed to move, and the automated carrier includes a base structure on which an object may be supported, and at least two wheels assemblies being pivotally supported on the base structure for pivoting movement from a first position to a second position to effect a change in direction of movement of the carrier.