Maintenance Carrier Layout for Discontinuous Matrix Tracks
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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, leading to increased costs and limited throughput in handling objects of varying sizes and weights.
Innovation Solution
The system employs a network of automated carriers that move on discontinuous track sections, with pivotable wheels allowing bidirectional movement without rotating the carrier, and includes maintenance carriers that can span multiple track sections for efficient object processing and bin management.
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 object types and destinations, but the physical space, capital costs, and operating costs increase significantly
Solution Approach 1:
The patent implements dynamic bin assignment 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 destinations sequentially. This dynamic approach enables the system to handle a larger variety of destinations without proportionally increasing the number of physical bins, thereby reducing the physical footprint while maintaining high adaptability.
2Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then automation level increases, but the mechanical complexity and cost per divert increase due to requiring an actuator for every divert
Solution Approach 1:
The patent employs a single robotic manipulator that can service multiple collection bins, making the robot a universal sortation device. Instead of having dedicated actuators at each divert location, one robotic arm performs sortation to multiple bins by moving between them. This multi-functional approach consolidates the actuation function into a single device, dramatically reducing mechanical complexity while maintaining high automation levels. The robot can pick objects from the induction conveyor and place them in any assigned bin through programmed motion sequences.
Solution Approach 2:
The system uses vision systems and sensors to create digital representations of objects and their destinations, allowing the controller to plan sortation sequences without physical trial-and-error. The robotic system executes virtual sortation plans, copying the logic of human sortation decisions into automated code. This informational copying enables automation without requiring complex mechanical copying mechanisms at each divert point.
3Manufacturing precision
If discrete tilt trays with actuators are used for each divert location, then precise object routing is achieved, but the cost per divert becomes very high
Solution Approach 1:
The patent merges multiple sortation functions into a single robotic manipulator that services multiple bins. Instead of having separate actuator mechanisms at each divert location, the system combines the picking and placing functions into one robotic system. This consolidation reduces the total number of actuators from potentially dozens (one per divert) to just one or a few robotic joints, dramatically lowering the cost per divert while maintaining precise routing through advanced control algorithms and vision guidance.
Data Source
AI summary
A maintenance system is disclosed for assisting in maintaining an automated carrier system for moving objects to be processed. The maintenance system includes a plurality of automated carriers that are adapted to move on an array of discontinuous standard track sections, each said automated carrier including a carrier body that is no larger in either a length or width direction that a standard track section, and an automated maintenance carrier that is adapted to move on the array of discontinuous track sections, said automated maintenance system including a maintenance body that is larger in at least one of a length or width direction than the standard track section.