Automated Distribution Station Layout for Space-Efficient Object Sorting
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Solution Overview
Problem
Existing object distribution systems are inefficient and costly, requiring large numbers of collection bins and human labor, with limited throughput and flexibility, and existing automated systems are mechanically complex and expensive.
Innovation Solution
A space-efficient automated processing system with an input conveyance, perception, primary transport, and secondary transport systems, utilizing a programmable motion device and perception systems to identify and divert objects to appropriate destinations, optimizing grasp points and reducing mechanical complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated systems use traditional conveyor-based sorting with multiple collection bins, then object distribution can be achieved, but the system requires large physical space and high device complexity
Solution Approach 1:
The system transitions from horizontal conveyor-based sorting to vertical stacking operations. Objects are conveyed horizontally to a positioning station, then stacked vertically in layers within collection bins. This dimensional change allows multiple objects to be stored in the same horizontal footprint, dramatically reducing the space required for collection bins while maintaining automated operation.
Solution Approach 2:
The system implements nested stacking where objects are placed inside collection bins in a hierarchical manner. Multiple layers of objects are stacked within each bin, with each layer containing multiple objects arranged in columns. This nesting approach maximizes the utilization of vertical space within each bin, reducing the total number of bins needed and thereby reducing overall physical space requirements.
2Productivity
If human workers manually sort objects, then flexibility in handling various object types is maintained, but throughput is limited and labor costs increase
Solution Approach 1:
The system employs vision-guided automated positioning where cameras and sensors automatically detect object characteristics, determine optimal stacking positions, and guide the robotic arm for placement. The system self-adjusts based on real-time feedback from sensors, eliminating the need for complex manual programming while achieving high throughput. This self-service capability allows the system to handle various object types autonomously, increasing productivity without proportionally increasing device complexity.
Solution Approach 2:
The robotic arm and positioning system are designed to be dynamically adjustable, allowing real-time modification of stacking patterns, speeds, and configurations based on object characteristics and bin status. This dynamic adaptability enables the system to optimize throughput for different object types without requiring complex reconfiguration, balancing automation capability with system simplicity.
3Area of stationary object
If collection bins are densely packed to reduce space, then physical footprint is reduced, but access and retrieval operations become more difficult
Solution Approach 1:
The system segments the bin access operation into distinct phases: the robotic arm approaches the bin from the front, uses vision guidance to locate the specific object, and retrieves it through controlled manipulation. This segmentation allows dense bin packing while maintaining ease of operation, as each bin can be independently accessed without interfering with adjacent bins. The modular nature of individual bin access simplifies the overall operation despite high density.
Solution Approach 2:
The robotic arm acts as an intermediary between the control system and the objects within densely packed bins. It provides the necessary dexterity and precision to access objects in tightly arranged bins without requiring manual intervention. The gripper mechanism serves as another intermediary, enabling safe and precise object retrieval from confined spaces, thereby maintaining ease of operation even when bins are densely packed to reduce facility footprint.
Data Source
AI summary
A space efficient automated processing system for processing objects is disclosed. The processing system includes an input conveyance system for moving objects from an input area in at least an input conveyance vector that includes an input conveyance horizontal direction component and an input conveyance vertical direction component, a perception system for receiving objects from the input conveyance system and for providing perception data regarding an object, a primary transport system for receiving the object from the perception system and for providing transport of the object along at least a primary transport vector including an primary transport horizontal component and a primary transport vertical component that is generally opposite the input conveyance horizontal direction component, and at least two secondary transport systems, each of which receives the object from the primary transport system and moves the object in either of reciprocal directions.