Maintenance Carrier Layout for Discontinuous Track Sortation
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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, which increase costs and limit throughput and the number of divert locations.
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 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 number of diverts increases, but the system area and capital costs increase significantly
Solution Approach 1:
The system replaces static collection bins with dynamic autonomous carriers that can change their destination assignments in real-time. Carriers are dynamically routed based on current sortation needs rather than being fixed to specific destinations, allowing the system to handle diverse object types without increasing physical footprint.
Solution Approach 2:
Each autonomous carrier body serves as a universal collection point that can be assigned to any destination. The carriers are multi-functional units that can handle different object types and be routed to different locations, replacing the need for dedicated collection bins for each destination type.
2Ease of operation
If human workers perform sortation manually, then operational flexibility is maintained, but system throughput is limited by worker speed
Solution Approach 1:
The autonomous carriers are self-propelled and self-navigating units that automatically transport objects to their assigned destinations without requiring manual handling. The carriers independently follow track sections and execute routing decisions, eliminating the need for human workers to physically move objects while maintaining system flexibility through programmable control.
Solution Approach 2:
The system replaces manual human labor with an automated control system that uses sensors, processors, and communication networks to manage carrier routing. The mechanical action of workers sorting objects is substituted with electronic control signals that direct autonomous carriers to appropriate destinations.
3Productivity
If recirculating conveyors with tilt trays are used for automation, then throughput increases, but mechanical complexity and operating costs increase
Solution Approach 1:
The patent extracts the diverting function from complex mechanical mechanisms and transfers it to the routing logic of autonomous carriers. Instead of using tilt trays or bomb-bay doors to divert objects at fixed points, the system allows carriers themselves to navigate to different destinations, eliminating the need for mechanical diverting devices at each collection point.
Solution Approach 2:
The autonomous carrier acts as an intermediary between the induction conveyor and the final destination. Rather than using complex mechanical systems to transfer objects directly from conveyor to collection bin, the carrier serves as a mobile intermediate platform that simplifies the transfer mechanism while enabling flexible routing.
4Device complexity
If the system uses fixed sequence operations with inflexible routing, then system simplicity is maintained, but adaptability to varying object types is reduced
Solution Approach 1:
The system uses dynamic routing where carrier destinations and paths are determined in real-time based on object characteristics and system state. Rather than following fixed predetermined sequences, carriers receive dynamic routing instructions that adapt to current sortation requirements, maintaining simple physical infrastructure while achieving operational flexibility.
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.