Maintenance Carrier Layout for Discontinuous Track Matrix Systems
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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 a large number 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 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, enabling efficient object processing and bin management through a network of track modules and sensors.
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 a dynamic recirculating conveyor system where collection bins are reused across multiple cycles. Objects that miss their destination on one pass continue circulating and are diverted on subsequent passes. This transforms static collection bins into dynamic, multi-purpose receptacles that serve different destinations at different times, eliminating the need for dedicated bins for each destination.
Solution Approach 2:
The system employs periodic action by cycling objects through the conveyor loop multiple times. Collection bins are periodically assigned to different destinations based on the current batch of objects being sorted. This periodic reassignment allows the same physical infrastructure to handle a much larger variety of destinations without requiring proportional increases in physical space.
2Adaptability or versatility
If human workers manually sort objects to collection bins, then the system is flexible in handling various object types, but the throughput is limited by worker speed
Solution Approach 1:
The patent replaces manual human sorting with an automated system combining computer vision technology and automated conveyor mechanisms. Scanners and sensors automatically identify objects and their destinations, while the control system manages the recirculating conveyor and divert mechanisms. This substitution eliminates human speed limitations while maintaining the flexibility to handle diverse object types through programmable logic.
Solution Approach 2:
The system implements self-service through automated object identification and routing. Scanners automatically read object identifiers, the control system determines optimal destinations, and divert mechanisms automatically route objects without human intervention. This self-service automation maintains adaptability while dramatically increasing throughput beyond human capabilities.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput 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 recirculating conveyor loop that serves multiple diversion points along its path. Instead of dedicated actuators at every possible destination point, the system uses the circulating loop to bring objects to different locations sequentially. A single divert mechanism at each station handles multiple destinations over time, making each divert mechanism universal rather than specialized for a single destination.
Solution Approach 2:
The system dynamically assigns collection bins to different destinations based on real-time needs. Rather than having fixed, dedicated divert points for each destination, the recirculating nature allows the same physical divert location to serve multiple destinations at different times. This dynamic assignment reduces the total number of divert mechanisms required while maintaining high throughput capability.
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.