Discontinuous Grid Carrier With Pivoting Wheels for Object Routing
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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 large numbers of collection bins and high mechanical complexity, which increase costs and limit throughput and flexibility in handling objects of varying sizes and weights.
Innovation Solution
An automated carrier system with pivotable wheel assemblies that move along discontinuous track sections, allowing for orthogonal direction changes without rotating the carrier, enabling efficient movement and sorting of objects across a grid of track sections.
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:
The patent merges multiple discrete tilt trays into a single continuous belt structure, eliminating the need for individual actuators at each divert location. The continuous belt is controlled by a single actuator that tilts the entire belt, thereby reducing mechanical complexity while maintaining automated sortation functionality.
Solution Approach 2:
The single continuous belt serves multiple functions: it acts as both the conveying surface and the tilting mechanism for all divert locations along its length. This universal structure replaces the need for specialized actuators at each individual divert point, reducing overall system complexity.
2Adaptability or versatility
If a large number of collection bins are deployed to handle diverse objects, then adaptability is improved, but area occupied increases significantly
Solution Approach 1:
The patent transitions from a discrete array of collection bins occupying horizontal space to a continuous linear belt system where divert locations are distributed along the length of the belt. This dimensional reorganization allows for numerous divert points without proportionally increasing the area occupied, as objects are diverted sequentially along the belt's path rather than requiring simultaneous access to multiple bins.
Solution Approach 2:
The system uses a dynamic continuous belt that can be tilted at any position along its length, replacing static collection bins. This dynamic approach allows the same physical space to serve multiple divert functions at different times, effectively increasing adaptability without proportionally increasing the occupied area.
3Adaptability or versatility
If discrete trays with actuators are used for each divert location, then number of diverts is improved, but manufacturing cost increases due to high cost per divert
Solution Approach 1:
The patent combines multiple individual actuator mechanisms into a single actuator that controls the entire continuous belt. This merging reduces the number of components required, lowering manufacturing costs while maintaining the capability to divert at multiple locations along the belt's length.
Solution Approach 2:
Instead of replicating expensive actuator mechanisms at each divert location, the system uses a single actuator design that controls a continuous belt serving all divert points. This eliminates the need to manufacture and install multiple copies of complex actuator assemblies, significantly reducing the cost per divert.
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.