Automated Linear Processing Stations for Flexible Object Routing

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Solution Overview

Problem

Existing object distribution systems are inefficient and inflexible, requiring large numbers of collection bins, significant human labor, and are limited by throughput and divert capabilities, especially in handling objects of varying sizes and weights.

Innovation Solution

A programmable motion device is used to identify and direct objects to specific processing locations using an end effector, with a perception unit and central control system to manage the distribution, optimizing the system's throughput, number of diverts, and reducing the need for physical space and labor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual sorting is used with human workers scanning objects and placing them at assigned locations, then flexibility in handling various objects is maintained, but productivity and efficiency are limited

Engineering Contradiction:

Improveflexibility in handling various objectsVSAvoidproductivity and efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system enables objects to be automatically identified and routed without human intervention. Barcode scanners automatically detect codes on objects, the control system processes this information, and conveyance systems automatically transport objects to correct destinations, replacing manual scanning and sorting operations

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical sorting operations with an automated control system that uses optical scanning (barcode readers), electronic processing (control system), and automated conveyance mechanisms to identify and route objects, thereby increasing productivity while maintaining flexibility

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If fixed barcode scanner systems are used at point-of-sale, then continuous scanning capability is provided, but the operator must manually position objects and the system lacks automation

Engineering Contradiction:

Improvecontinuous scanning capabilityVSAvoidautomation level

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The system transitions from a static fixed scanner requiring manual object positioning to a dynamic automated system where conveyance mechanisms actively transport objects through the scanning zone, enabling continuous operation without human intervention while maintaining reliable scanning capability

Inventive Principle:

Principle #15Dynamics

3Productivity

If conventional distribution systems use large numbers of collection bins to handle various object types, then all objects can be sorted simultaneously, but significant physical space and device complexity are required

Engineering Contradiction:

Improvesimultaneous sorting capabilityVSAvoidnumber of collection bins and physical space

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system segments the sorting process into discrete stages: identification (barcode scanning), processing (control system decision-making), and conveyance (automated transport to destinations). This segmentation allows efficient routing through a streamlined system rather than requiring all objects to be simultaneously distributed to numerous collection bins

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a temporal dimension to the sorting process by using sequential processing and automated conveyance, where objects are sorted over time through a controlled flow system rather than requiring simultaneous spatial distribution to multiple bins, thereby reducing physical space requirements

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Device complexity

If inflexible sequence of operation is used in conventional systems, then simple control is maintained, but the system cannot adapt to varying object sizes and weights

Engineering Contradiction:

Improvecontrol simplicityVSAvoidadaptability to varying object sizes and weights

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The control system dynamically adjusts operational parameters based on object characteristics. The system reads barcode information to identify object type, then modifies conveyance speed, routing decisions, and destination assignments according to the specific size and weight requirements of each object, enabling adaptability while maintaining controlled operation

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250236464A1Systems and methods for processing objects, including automated linear processing stations

Publication Date: 2025.07.24 BERKSHIRE GREY OPERATING CO INC

AI summary

A method of processing objects using a programmable motion device is disclosed. The method includes the steps of perceiving identifying indicia representative of an identity of a plurality of objects and directing the plurality of objects toward an input area from at least one input conveyance system, acquiring an object from the plurality of objects at the input area using an end effector of the programmable motion device, and moving the acquired object toward an identified processing location using the programmable motion device. The identified processing location is associated with the identifying indicia and the identified processing location is provided as one of a plurality of processing locations along a first direction. The step of moving the acquired object includes moving the programmable motion device along a second direction that is substantially parallel with the first direction.