Mobile Bin Carrier Grid for High-Divert Object Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current object processing systems, such as sortation and storage 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 divert capabilities.
Innovation Solution
A bin exchange system with remotely movable automated carriers on track sections, allowing for efficient movement and processing of objects between bins, including input, processing, and output stations, using pivotable wheels and actuable paddles for bin handling and realignment on a grid system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then the system can accommodate more diverts and object types, but the physical space, capital costs, and operating costs increase significantly
Solution Approach 1:
The patent implements a dynamic bin assignment system where collection bins are not permanently dedicated to specific destinations but are temporarily assigned based on real-time sortation needs. The system controller dynamically reconfigures which bin receives objects for which destination, allowing the same physical bin to serve multiple diverts sequentially. This dynamic approach enables a limited number of bins to handle a much larger number of diverts without requiring proportional physical space expansion.
Solution Approach 2:
The system adds the time dimension to the sortation process by implementing multi-pass sortation. Instead of requiring all destinations to be simultaneously accessible (spatial dimension only), objects can be sorted in multiple passes where different destination sets are active at different times. This temporal dimension allows the system to handle more diverts than the number of physical bins by cycling through different destination configurations.
2Adaptability or versatility
If human workers manually sort objects to collection bins, then the system is flexible in handling various object types, but the throughput is limited by worker speed
Solution Approach 1:
The system implements automated object presentation where robots or automated mechanisms present objects to workers in an optimized sequence and orientation, reducing the cognitive and physical effort required for sortation. The system self-manages object identification, positioning, and presentation timing, allowing workers to focus primarily on the sorting decision and placement action, thereby increasing throughput while maintaining flexibility.
Solution Approach 2:
Objects are pre-scaned, identified, and routed decisions are made before objects reach the sortation point. The system prepares sortation instructions in advance and pre-positions objects for optimal worker access. This preliminary processing reduces on-the-spot decision time and enables faster sortation rates while maintaining the ability to handle diverse object types.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput increases, but the mechanical complexity and cost per divert increase due to required actuators
Solution Approach 1:
The patent extracts the actuator mechanism from each individual divert location and replaces it with passive gravity-fed chutes and guided channels. Objects are diverted by their physical trajectory and gravity rather than active mechanical tilting at each station. This elimination of numerous actuators dramatically reduces mechanical complexity and cost while maintaining automated sortation capability through intelligent object routing and timing.
Solution Approach 2:
The system replaces active mechanical tilt-tray actuators with a passive gravity-based sortation approach. Instead of using motorized tilting mechanisms to drop objects, the system uses gravity-fed conveyors, angled chutes, and strategically positioned guides to direct objects into collection bins. This substitution eliminates complex mechanical actuation systems while maintaining automated control through software-managed object flow and timing.
4Ease of operation
If bins are arranged within efficient reach of human workers, then ease of operation is maintained, but the number of diverts is limited by the physical reach constraint
Solution Approach 1:
The system implements dynamic bin repositioning where collection bins are moved to different locations based on the current sortation task. Bins that are currently active for a destination are positioned within worker reach, while inactive bins are stored elsewhere. This dynamic reconfiguration allows a small number of bins to serve many more diverts by ensuring that only the necessary bins are within worker reach at any given time.
Solution Approach 2:
The system pre-positions collection bins to their optimal locations before sortation begins. Bins are brought to within worker reach in advance of when they are needed, and removed or repositioned after use. This preliminary positioning ensures that workers never need to reach for bins that are not currently active for the sortation task, maintaining ease of operation while enabling support for many more diverts through sequential bin usage.
Data Source
AI summary
A bin exchange system is disclosed that includes a plurality of automated carriers, each of which is adapted to be remotely movable on an array of track sections, at least one input station by which bins may be introduced to the array of track sections, at least one processing station in communication with the array of track sections wherein objects may be moved between bins, and at least one output station by which bins may be removed from the array of track sections.