Maintenance Carrier Layout for Discontinuous Track Sortation Grids
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Solution Overview
Problem
Current object processing systems, particularly in distribution centers, face inefficiencies and inflexibilities due to the need for a large number of collection bins, which increases physical space, capital, and operating costs. These systems struggle to efficiently sort and process a variety of objects of different sizes and weights.
Innovation Solution
The development of a maintenance system for automated carrier systems that utilize a network of discontinuous standard track sections. This system includes automated carriers and a maintenance carrier that can move on these track sections, providing maintenance and improving the efficiency of object processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to sort all objects to all destinations at once, then the sortation capacity and number of diverts increase, but the physical space requirements, capital costs, and operating costs increase significantly
Solution Approach 1:
The sortation process is divided into multiple passes, with each pass handling a subset of destinations. Objects are sorted in stages rather than all at once, allowing the system to achieve high sortation capacity with a limited number of physical bins at any given time.
Solution Approach 2:
The system dynamically reconfigures bin assignments between passes. Collection bins are reassigned to different destination groups in subsequent passes, allowing the same physical bins to serve multiple destinations over time, thereby reducing the total number of bins needed.
2Ease of operation
If human workers manually sort objects to collection bins, then labor flexibility is maintained, but system throughput is limited by worker speed
Solution Approach 1:
The system combines automated scanning and identification with manual sortation. Automated systems handle object identification and routing decisions, while human workers handle physical movement, creating a hybrid system that achieves both high throughput and operational flexibility.
Solution Approach 2:
A control system acts as an intermediary between automated scanning and manual sortation. The control system processes object data, determines optimal bin assignments, and provides real-time guidance to workers, enabling them to sort at higher speeds without sacrificing flexibility.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput increases, but the system complexity and capital costs increase
Solution Approach 1:
The patent extracts the complex tilt tray mechanism from the sortation system and replaces it with simpler divert mechanisms. Objects are moved along a conveyor and diverted to stationary bins using less complex mechanical means, maintaining throughput while reducing system complexity and capital costs.
Solution Approach 2:
Instead of using expensive recirculating tilt tray systems, the patent employs multiple simpler conveyor segments that replicate basic transport and divert functions. This achieves similar throughput using less complex, more cost-effective components.
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.