Common Outfeed Conveyor for Bin Sortation
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Solution Overview
Problem
Current object processing systems in store-replenishment applications face challenges such as labor intensity, single points of failure, and the need for human labor to service destinations and count items, leading to inefficiencies and high costs.
Innovation Solution
The proposed object processing system includes an infeed processing system with a source bin feed conveyor and a distribution system that receives both source and empty bins, directing objects to processing locations where empty bins become processed bins. The system features a common outfeed conveyor for both empty and processed bins, optimizing bin handling and reducing labor requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple collection bins are used for different destinations, then sortation capability is improved, but physical space requirements and investment costs increase
Solution Approach 1:
The patent implements a common outfeed conveyor that serves multiple destinations and functions. Instead of having dedicated conveyors for each destination, a single common outfeed conveyor handles objects for multiple destinations sequentially, making the system multi-functional and reducing the total number of conveyor systems needed
Solution Approach 2:
The system transitions from a two-dimensional layout with separate conveyors for each destination to a three-dimensional approach where a single common outfeed conveyor serves multiple destinations at different locations, optimizing space utilization through vertical and temporal arrangement
2Device complexity
If manual labor is used for sortation and bin servicing, then system complexity is reduced, but labor costs and throughput limitations increase
Solution Approach 1:
The system implements automated monitoring and tracking of bin locations, object counts, and conveyor status. The control system automatically manages bin assignments, tracks objects through the system, and coordinates the common outfeed conveyor operations without requiring manual intervention for basic operations
Solution Approach 2:
The patent incorporates monitoring systems that track bin locations, object volumes, and conveyor status in real-time. This feedback enables the control system to make automated decisions about bin assignments, object routing, and conveyor activation, improving throughput while maintaining manageable system complexity
3Extent of automation
If unit sorters are used for automated sortation, then labor requirements are reduced, but single point of failure risks and servicing needs increase
Solution Approach 1:
The system divides the sortation function into multiple independent components: induction area, distribution system with multiple conveyors, processing locations, and common outfeed conveyor. This segmentation ensures that a failure in one component does not necessarily halt the entire system, as other components can continue operating
Solution Approach 2:
The patent combines multiple destination-specific conveyors into a single common outfeed conveyor that serves all destinations. This merging reduces the number of potential failure points while maintaining the ability to service multiple destinations, as the common conveyor can be serviced as a single unit rather than multiple separate conveyors
4Productivity
If bins are positioned on moving carriers during induction, then processing continuity is improved, but object induction accuracy deteriorates due to carrier motion
Solution Approach 1:
The system positions empty bins on the common outfeed conveyor in advance, before they are needed at processing locations. This preliminary positioning allows the bins to be staged and ready for object induction, while the induction process itself can occur with minimal carrier motion, maintaining accuracy
Solution Approach 2:
The patent implements a dynamic bin management system where bins are moved to different positions on the common outfeed conveyor based on real-time system needs. Bins can be positioned at processing locations when needed, then returned to the common conveyor for refilling or servicing, optimizing both continuity and accuracy
Data Source
AI summary
An object processing system is disclosed that includes an infeed processing system including a source bin feed conveyor for providing source bins, a distribution system for receiving the source bins and for receiving a plurality of empty bins, and for providing objects from the source bins to a collection of processing locations, each processing location including an empty bin of the plurality of empty bins thereby providing the previously empty bins as processed bins when completed, and an outfeed processing system for moving the processed bins away from the collection of processing locations, wherein the empty bins and the processed bins are each positioned at some point in their respective output paths on a common out-feed conveyor.