Discontinuous Track Grid With Pivoting Wheels for Flexible Sortation
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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 large numbers of collection bins and high mechanical complexity, leading to increased costs and limited throughput in handling objects of varying sizes and weights.
Innovation Solution
An automated carrier system with pivotable wheel assemblies that move along discontinuous track sections, allowing for efficient direction changes without rotating the carrier, enabling flexible movement and reduced mechanical complexity, and a method involving carriers with swivel-mounted wheels to navigate a grid of track sections for efficient object processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then automation level increases, but device complexity and cost per divert increase due to requiring an actuator for every divert
Solution Approach 1:
A single robotic manipulator with vision guidance performs sortation to multiple collection bins, replacing the need for dedicated actuators at each divert location. The robot can service many bins sequentially, making one device perform multiple sortation functions that previously required many separate actuators.
Solution Approach 2:
The system uses vision systems (cameras and scanners) to capture optical information about objects, creating a digital representation that guides the robotic manipulator. This allows the system to identify and sort objects based on their visual characteristics without physical contact during identification.
2Adaptability or versatility
If a large number of collection bins are deployed to handle diverse object types, then sortation capability increases, but system area and capital costs increase
Solution Approach 1:
The system arranges collection bins in a three-dimensional workspace around the robotic manipulator, utilizing vertical space and radial positioning rather than only linear horizontal arrangement. This allows more bins to be accessed within a compact footprint by the robot's multi-axis movement capability.
Solution Approach 2:
The system uses software-configurable bin assignments that can be dynamically changed without physical reconfiguration. The robotic manipulator can adapt its motion paths and sorting logic in real-time based on changing sortation requirements, providing versatility without adding physical infrastructure.
3Adaptability or versatility
If human workers perform manual sortation, then system flexibility is maintained, but throughput is limited by worker speed
Solution Approach 1:
The system replaces human manual sortation with an automated robotic manipulator guided by vision systems and control software. This substitution maintains flexibility through programmable logic while dramatically increasing throughput by operating at robotic speeds without fatigue or breaks.
Solution Approach 2:
The vision system continuously monitors objects on the conveyor and provides real-time feedback to the control system, which adjusts the robotic manipulator's actions accordingly. This closed-loop control enables flexible adaptation to different object types while maintaining high-speed automated operation.
4Adaptability or versatility
If the number of diverts is increased to handle more destinations, then sortation versatility improves, but the number of required actuators and mechanical components increases
Solution Approach 1:
A single robotic manipulator with multiple degrees of freedom serves multiple collection bins, replacing the need for individual actuators at each divert point. The robot's workspace encompasses many bins, allowing one universal device to perform sortation to numerous destinations without proportionally increasing actuator count.
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.