Discontinuous Track Carrier Grid With Pivotable Wheel Redirection
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Solution Overview
Problem
Current object processing systems, such as sortation and automated storage and retrieval systems, face inefficiencies and inflexibilities due to the need for a large number of collection bins and high mechanical complexity, which increases costs and limits throughput and the number of divert locations.
Innovation Solution
An automated carrier system with pivotable wheels allows for movement along discontinuous track sections, enabling efficient redirection and realignment without changing the carrier's orientation, thus reducing the need for multiple bins and complex divert mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then the number of diverts increases, but the system area and capital costs increase significantly
Solution Approach 1:
The patent replaces static collection bins with mobile robots that dynamically move throughout the workspace. Instead of having fixed diverts for each destination, mobile robots transport objects to collection bins on demand, allowing the system to adapt to varying sortation needs without expanding physical infrastructure.
Solution Approach 2:
Mobile robots serve as intermediary carriers between the induction area and collection bins. Rather than objects moving directly through fixed conveyors to dedicated bins, robots act as flexible intermediaries that can transport objects to any destination, reducing the need for dedicated physical pathways and collection points for each object type.
2Adaptability or versatility
If human workers perform sortation manually, then operational flexibility is maintained, but system throughput is limited by worker speed
Solution Approach 1:
The system combines automated object identification and robot navigation with human workers performing only the sortation decision and placement actions. The mobile robots autonomously navigate to collection bins, retrieve objects, and return them, eliminating the need for human workers to physically transport objects while maintaining human cognitive flexibility in sortation decisions.
Solution Approach 2:
The system performs preliminary automated actions including object scanning, identification, and robot navigation to the collection bin location before human workers arrive. This allows human workers to focus solely on the value-added sortation decision and object placement, increasing throughput while maintaining flexibility.
3Productivity
If recirculating conveyors with tilt trays are used for automation, then throughput increases, but the system becomes inflexible and requires objects to be visible to scanners
Solution Approach 1:
Mobile robots serve multiple functions: they transport objects, navigate autonomously, interact with various collection bin types, and can handle objects of different sizes and weights. This universal platform replaces specialized conveyor systems for different object types, maintaining throughput while increasing flexibility and removing scanner visibility requirements.
4Device complexity
If the system uses fixed sequences of operations, then process control is simplified, but the system cannot accommodate varying object types and destinations efficiently
Solution Approach 1:
The system uses dynamic task assignment and real-time route planning for mobile robots based on current sortation needs. Instead of fixed operation sequences, the control system dynamically determines which robots perform which tasks and in what order, allowing flexible accommodation of varying object types and destinations while maintaining coordinated control through software.
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.