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 on a discontinuous track system, enabling efficient redirection and realignment without changing the carrier's orientation, thereby reducing the need for multiple bins and complex divert mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then automation extent is improved, but device complexity increases due to actuators required for each divert
Solution Approach 1:
A single robotic arm performs the function of multiple divert actuators by dynamically selecting and placing objects into different collection bins based on real-time destination requirements. The robotic arm serves as a universal sorting mechanism that replaces numerous specialized actuators, thereby reducing mechanical complexity while maintaining high automation levels.
Solution Approach 2:
The system dynamically reconfigures collection bins and adjusts sorting sequences in real-time based on changing object streams and destination requirements. The robotic arm adapts its motion paths and placement targets dynamically, allowing the system to handle variable sorting configurations without requiring dedicated actuators for each possible destination.
2Adaptability or versatility
If a large number of collection bins are deployed to handle diverse object types, then adaptability is improved, but area occupied increases significantly
Solution Approach 1:
The system transitions from a horizontal arrangement of numerous collection bins to a vertical stacking configuration. Collection bins are arranged in multiple tiers or levels, allowing the robotic arm to access and deposit objects into bins at different heights and positions. This vertical dimension enables a high number of diverts within a compact footprint, significantly reducing the area occupied while maintaining high adaptability.
Solution Approach 2:
Collection bins are nested or stacked in a hierarchical arrangement where bins are positioned within or upon one another. This nested configuration allows multiple bins to occupy a reduced spatial envelope, enabling the system to accommodate a large number of diverts without proportionally increasing the physical space required.
3Adaptability or versatility
If discrete actuators are installed at every divert location, then number of diverts is improved, but manufacturing cost increases due to high cost per divert
Solution Approach 1:
A single robotic arm with multi-axis movement capability replaces the need for discrete actuators at each divert location. The robotic arm can reach and deposit objects into any collection bin within its workspace, providing a universal sorting mechanism that serves multiple destinations with one device. This eliminates the high per-divert cost associated with installing individual actuators while maintaining a high number of divert locations.
Solution Approach 2:
Instead of installing physical actuators at every possible divert point, the system uses a single robotic arm that can be programmed to replicate the sorting function across multiple destinations. The robotic arm's control system creates virtual copies of the sorting logic for each destination, allowing the system to handle numerous diverts without the proportional hardware investment required by traditional actuator-based systems.
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.