Drop Conveyor Sortation With Actuatable Doors and Bin Reuse
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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 outside system specifications.
Innovation Solution
A distribution system with an urging mechanism and actuatable doors directs objects to appropriate receiving stations, using perception units and actuatable doors to selectively drop objects into designated chutes, and an induction system filters out incompatible objects before processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If human workers or automated systems retrieve objects and sort each into collection bins based on heuristics, then objects can be sorted to multiple destinations, but a large number of collection bins are required which increases physical space, capital costs, and operating costs
Solution Approach 1:
The sortation process is divided into multiple passes, with each pass handling a subset of destinations. Objects are sorted in stages rather than all at once, allowing the system to serve many destinations using a limited number of bins at any given time.
Solution Approach 2:
Collection bins are reused across different passes. After one pass completes, bins are emptied and reassigned to different destination groups in subsequent passes. This periodic reuse of the same physical bins allows the system to handle more destinations than the number of physical bins available.
2Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then automation level increases, but mechanical complexity and costs increase due to required actuators for each divert
Solution Approach 1:
The complex actuation mechanism is extracted from the conveyor system and replaced with simple gravity-fed chutes. Objects are directed to different bins using passive gravitational flow paths rather than active mechanical tilting of each tray, eliminating the need for numerous actuators.
Solution Approach 2:
The mechanical tilt-tray actuation system is replaced with a gravity-based passive sortation system. Instead of using motors and actuators to tilt trays, the system uses gravity to naturally guide objects down chutes into the appropriate collection bins based on their destination.
3Device complexity
If conventional sortation systems process all objects through the same system, then processing is simplified, but objects outside system specifications can cause damage to robotic systems
Solution Approach 1:
An induction system performs preliminary filtering of objects before they enter the main sortation system. Incompatible objects are identified and diverted early in the process, preventing them from reaching and potentially damaging robotic components downstream.
Solution Approach 2:
The induction system acts as an intermediary between the incoming object stream and the main sortation system. It screens objects and selectively passes only compatible ones to the robotic system, while diverting incompatible objects to a separate handling path.
4Productivity
If a large number of collection bins are used to handle diverse objects, then all objects can be sorted simultaneously, but physical space requirements and capital costs increase
Solution Approach 1:
The destination set is segmented into multiple groups, with each group assigned to a subset of bins for a specific pass. This allows the system to handle a large total number of destinations using a smaller number of physical bins at any one time, reducing space requirements while maintaining throughput capability.
Solution Approach 2:
The system dynamically reconfigures bin assignments between passes. Bins are reassigned to different destination groups in subsequent passes, allowing the same physical bins to serve multiple destinations over time. This dynamic reuse increases effective throughput without requiring proportional increases in physical space.
Data Source
AI summary
A distribution system is disclosed for use with 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 a chute that includes at least one actuatable door for selectively dropping the object through the at least one actuable door, said chute leading to a first receiving station with a second receiving station being positioned below the at least one actuable door.