Conveyor Transfer Sortation Using Vertical Receiving Chutes

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Solution Overview

Problem

Existing object distribution systems require large numbers of collection bins and incur high costs due to inefficiencies in matching incoming objects to assigned destinations, often relying on human labor or complex mechanical diverts, and struggle with handling objects of varying sizes and weights.

Innovation Solution

A distribution system that uses an urging mechanism to direct objects onto adjacent receiving stations, employing perception units and conveyors to sort and filter objects based on size, weight, and identifying indicia, routing compatible objects to appropriate destinations while diverting incompatible ones to exception bins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional parcel sortation systems use human workers or automated systems to retrieve and sort objects into collection bins, then objects can be sorted to multiple destinations, but the number of collection bins must be large to handle large numbers of different object types, increasing physical space requirements and capital costs

Engineering Contradiction:

Improveability to sort to multiple destinationsVSAvoidphysical space for collection bins

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The system transitions from horizontal arrangement of many collection bins to a vertical arrangement with a single bin positioned below a recirculating conveyor. Objects are diverted vertically from the conveyor to the bin, effectively using the vertical dimension to reduce the horizontal footprint and number of bins needed.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

A single collection bin serves multiple destinations by receiving objects from different locations on the recirculating conveyor. The conveyor continuously brings objects from various product families to the same bin location, allowing one bin to handle what previously required many bins.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Extent of automation

If recirculating conveyors with tilt trays are used for automated sortation, then automation level increases, but the system requires objects to be scanned while in trays and assumes identifying codes are visible, limiting flexibility

Engineering Contradiction:

Improveautomation level of sortationVSAvoidflexibility in handling different object types

Core Design Contradiction:

Extent of automationVSAdaptability or versatility

Solution Approach 1:

The system introduces a robotic arm as an intermediary between the conveyor and collection bin. The robot can pick objects from the conveyor and place them in the bin, providing flexible automation that can handle various object types without requiring scanning infrastructure or assuming code visibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system uses a dynamically controllable robotic arm that can adjust its motion and positioning to handle different object types, sizes, and weights. This dynamic capability provides adaptability while maintaining automation, overcoming the rigidity of fixed tilt-tray systems.

Inventive Principle:

Principle #15Dynamics

3Productivity

If a large number of collection bins are used to handle diverse object types, then all object types can be sorted simultaneously, but the system requires large capital costs and operating costs

Engineering Contradiction:

Improvethroughput of diverse objectsVSAvoidnumber of collection bins

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The system merges multiple collection bin functions into a single bin by combining the recirculating conveyor that brings objects from multiple product families with one collection bin. This consolidation maintains the ability to sort diverse objects while dramatically reducing the number of bins from many to one.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If fixed divert locations are used on conveyors, then mechanical diverts can be simple, but the system cannot easily adapt to different sortation requirements

Engineering Contradiction:

Improvesimplicity of mechanical divertsVSAvoidflexibility in sortation configuration

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The system replaces fixed mechanical diverts with a dynamic robotic arm that can be programmatically controlled to divert objects to the collection bin at different times and from different conveyor positions. This provides flexibility in sortation configuration while keeping the physical divert mechanism simple.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12475340B2Systems and methods for separating objects using conveyor transfer with one or more object processing systems

Publication Date: 2025.11.18 BERKSHIRE GREY OPERATING CO INC

AI summary

A distribution system is disclosed for use in an induction system with an object processing system. The distribution system provides distribution of dissimilar objects into one of a plurality of receiving units. The distribution system includes an urging system for urging an object on a conveyor from the conveyor to one of a plurality of adjacent receiving stations via a receiving chute, wherein each receiving station is lower than the conveyor.