Automated Container Carrier Sequencing for Multi-Wave Object Sortation
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Solution Overview
Problem
Current object processing systems, such as sortation and storage systems, face inefficiencies and inflexibilities due to the need for a large number of collection bins and manual labor, leading to high costs and limited throughput, especially when handling a variety of objects of different sizes and weights.
Innovation Solution
An object processing system that uses automated carriers to move containers between input, intermediate, and output stations, with programmable motion devices and vertical levels, allowing for dynamic assignment and movement of objects within the system, optimizing the use of space and reducing the need for multiple bins through automated sorting and distribution.
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 system can accommodate more object types and destinations, but the physical space, capital costs, and operating costs increase significantly
Solution Approach 1:
The system dynamically reconfigures bin assignments and routing paths based on real-time sortation needs. Collection bins are reassigned to different destination groups across multiple waves, and the system adapts routing sequences to optimize throughput while minimizing the number of bins required at any given time.
Solution Approach 2:
The system adds the time dimension to the sortation process by implementing multi-wave sorting. Instead of requiring all bins to be simultaneously accessible, objects are sorted in sequential waves where bins are reused across different time periods, effectively increasing capacity without increasing physical footprint.
2Adaptability or versatility
If human workers manually sort objects to collection bins, then flexibility in handling diverse objects 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 robotic arms performing the physical sortation. This self-service approach eliminates human labor constraints while maintaining flexibility through programmable routing logic that can adapt to different object types and destination configurations.
Solution Approach 2:
Manual human sorting is replaced with an automated system combining optical scanning, computer control, and robotic manipulation. The mechanical action of sorting is performed by robotic arms that can quickly transfer objects between containers, dramatically increasing throughput while maintaining adaptability through software control.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput increases, but the system requires objects to have visible identifying codes and follows an inflexible sequence
Solution Approach 1:
The system uses multiple scanning locations and multiple identification methods (barcodes, RFID, vision systems) that can detect object identities regardless of orientation or position. This universal detection capability allows the system to process objects in flexible sequences and from various induction points, unlike single-point scanning systems.
Solution Approach 2:
The system dynamically determines routing sequences based on current sortation needs rather than following a fixed predetermined path. Objects can be routed to different destinations based on real-time conditions, and the system can reconfigure which objects are sorted together in each wave, providing flexibility while maintaining high throughput.
4Productivity
If the system processes all objects to all destinations at once, then complete sortation is achieved, but the system requires a large number of collection bins and physical space
Solution Approach 1:
The sortation process is segmented into multiple waves, with each wave handling a subset of objects and destinations. Instead of requiring all bins to be simultaneously populated, the system divides the sortation task into sequential batches, reusing bins across different waves to complete full sortation with fewer physical bins.
Solution Approach 2:
The system implements periodic wave-based sortation cycles where groups of objects are processed together in discrete batches. Each wave completes sortation for its assigned objects and destinations, then the system transitions to the next wave, creating a rhythmic periodic operation that maximizes bin utilization over time rather than requiring all bins simultaneously.
Data Source
AI summary
A method is disclosed of providing processing of a plurality of objects. the method comprising providing a plurality of containers from an input conveyance system to a plurality of container input stations, actuating a plurality of remotely actuatable carriers to move the containers from the plurality of input stations to a plurality of container support structures, as well as to any of a plurality of programmable motion devices for moving objects between containers; scheduling movement of the containers to and from the plurality of programmable motion devices; and providing a completed subset of the plurality of containers to an output conveyance system.