Automated Linear Processing Stations for High-Throughput Object Sorting
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Solution Overview
Problem
Current object processing systems are inefficient and inflexible, requiring large numbers of collection bins and relying heavily on human labor for sorting and distribution, which limits throughput and increases costs.
Innovation Solution
A programmable motion device is used to perceive identifying indicia on objects and direct them to specific processing locations, automating the identification and conveyance of objects using a perception unit, acquisition system, and programmable motion device that moves objects along parallel directions to designated processing locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human workers manually sort objects to collection bins, then flexibility in handling various object types is maintained, but system throughput is limited and labor costs increase
Solution Approach 1:
The system enables objects to be automatically identified and routed without human intervention. Barcode scanners automatically detect object identifiers, the control system determines destination bins, and conveyors automatically transport objects to the correct locations, creating a self-service automated sorting system that eliminates manual labor while maintaining high throughput
Solution Approach 2:
The patent replaces the mechanical manual sorting system with an automated system using barcode scanning technology, computer control systems, and automated conveyor mechanisms. This substitution of mechanical human labor with automated technological systems achieves both high throughput and reduced labor requirements
2Adaptability or versatility
If a large number of collection bins are used to handle diverse object types, then sorting capacity increases, but system complexity and space requirements increase
Solution Approach 1:
The control system serves multiple functions: it identifies objects via barcode scanning, determines destination bins based on object type, manages conveyor routing, and tracks inventory levels across all bins. This universal control system handles diverse object sorting capabilities without requiring proportional increases in physical bin infrastructure, as the same control system manages all sorting operations efficiently
Solution Approach 2:
The system adds the dimension of automated identification and control by introducing barcode scanning and computer management layers. Instead of simply adding more bins linearly, the system uses informational dimensions (barcode data, control algorithms) to manage sorting complexity, allowing diverse object handling without proportional increases in physical bin complexity
3Measurement precision
If fixed or handheld barcode scanners are used, then code identification is achieved, but processing speed and automation capability are limited
Solution Approach 1:
The patent replaces manual or semi-automated barcode scanning with fully automated optical scanning systems integrated on the conveyor. These scanners continuously and automatically read barcodes on passing objects without requiring manual positioning or intervention, thereby maintaining accurate code detection while dramatically increasing processing speed through continuous automated operation
Solution Approach 2:
The barcode scanning system operates continuously as objects move along the conveyor belt, rather than requiring discrete manual scanning actions. This continuous automated scanning maintains high detection accuracy while maximizing processing speed by eliminating interruptions and manual operation delays between scans
Data Source
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.