Horizontal Gantry Parcel Sortation for Scalable Multi-Tote Output
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Solution Overview
Problem
Existing automated parcel sortation systems face challenges with scalability, cost, and space requirements, particularly when dealing with a large number of outputs, as linear sorters become impractical and robotic sorting is limited by reachability.
Innovation Solution
A modular and expandable robotic horizontal sortation system using an item selection unit and a secondary sortation unit that integrates a robotic parcel processing system, utilizing a robotic pick-and-place machine for singulation and a horizontal gantry system for depositing items into multiple output locations, enabling efficient sorting of items into a large number of groups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conveyor-based sortation method is used to increase the number of outputs, then the number of output locations increases, but the system becomes massive and costly
Solution Approach 1:
The sortation system is divided into multiple independent robotic cells, each capable of performing pick-and-place operations. This segmentation allows the system to scale by adding modular units rather than building a single massive conveyor system, reducing overall complexity while increasing output capacity
Solution Approach 2:
Traditional mechanical conveyor-based sortation is replaced with robotic automation. The robotic system uses end-effectors to grasp and transport items, eliminating the need for complex mechanical conveyor infrastructure and reducing system cost and size while maintaining high throughput
2Device complexity
If a robotic sorter is used to reduce system size, then the space requirement decreases, but the robot's reachability limits the number of outputs
Solution Approach 1:
The robotic system incorporates vertical movement capability, transitioning from two-dimensional horizontal reach to three-dimensional workspace. This allows the robot to access output locations both horizontally and vertically, effectively increasing the number of accessible outputs without proportionally increasing system footprint
Solution Approach 2:
The robotic end-effectors feature dynamic, adjustable gripper configurations that can adapt to different item sizes and shapes. This dynamic capability allows a single robot to handle diverse sortation requirements and access various output locations efficiently, maximizing versatility without expanding physical dimensions
3Productivity
If linear sorters are used to sort parcels by route, then the sortation function is achieved, but the cost and complexity become untenable as the number of outputs increases
Solution Approach 1:
The robotic end-effectors are designed as universal, multi-functional components that can handle various item types and sortation configurations. A single robotic system can perform multiple sortation functions by reconfiguring end-effectors, eliminating the need for specialized linear sorter equipment for each route and reducing overall system cost and complexity
Data Source
AI summary
A system and method for item sorting that can include an item selection unit with a robotic pick-and-place machine positioned adjacent to a defined input item region; an item sortation unit comprising a horizontal multi-degree-of-freedom gantry system and an item tote array, wherein the horizontal gantry system is positioned above the item tote array; wherein the item sortation unit further comprises an item holding and depositing system that is coupled to and actuated by the gantry system. The system and method can singulate an item from a collection of items and sort into one of a set of item totes.