Mobile Matrix Carrier Maintenance on Discontinuous Track Sections
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Solution Overview
Problem
Current object processing systems are inefficient and inflexible, requiring large numbers of collection bins and human labor, leading to high costs and limited throughput, and existing automated systems are mechanically complex and costly due to the need for multiple actuators for diverting objects.
Innovation Solution
A maintenance system utilizing automated carriers with swivel-mounted wheels that can pivot 90 degrees to move on an array of discontinuous track sections, allowing bidirectional movement without rotating the carrier, and featuring mechanisms for loading and unloading bins or objects onto racks, with integrated sensors for tracking and realignment, enabling efficient and flexible object processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then automation extent is improved, but device complexity increases due to actuators required for each divert
Solution Approach 1:
A single robotic arm performs the function of multiple discrete divert actuators by dynamically selecting and placing objects into different collection bins based on real-time destination requirements. The robotic arm serves as a universal sorting mechanism that replaces numerous specialized actuators, thereby reducing mechanical complexity while maintaining high automation levels.
Solution Approach 2:
The system uses dynamic bin assignment where collection bins are reassigned to different destinations based on current sorting needs rather than having fixed assignments. This dynamic reconfiguration allows a smaller number of bins to handle a larger number of destinations over time, reducing the need for numerous permanent divert locations and their associated actuators.
2Adaptability or versatility
If a large number of collection bins are used to handle diverse object types, then adaptability is improved, but area occupied increases
Solution Approach 1:
Collection bins are dynamically reassigned to different destinations based on the current mix of objects being sorted. Instead of having a static one-to-one mapping between bins and destinations, the system reconfigures bin assignments in real-time, allowing a smaller number of bins to serve a larger number of destinations through multiple sorting passes and recirculation.
Solution Approach 2:
The system maintains continuous sorting operation by recirculating objects that cannot be sorted in the current pass back into the input stream. This allows the sorting process to continue without interruption while bins are dynamically reassigned, ensuring that the limited number of bins is fully utilized across multiple cycles rather than requiring additional bins for simultaneous sorting of all destinations.
3Adaptability or versatility
If discrete tilt trays with actuators are used for each divert location, then number of diverts is improved, but manufacturing cost increases
Solution Approach 1:
A single robotic arm with multi-axis movement capability replaces the function of multiple discrete tilt tray actuators. This universal sorting mechanism can reach multiple collection bins and perform all divert operations from a central location, eliminating the need for expensive actuators at each divert point while maintaining the ability to handle numerous destinations.
Solution Approach 2:
The system uses vision systems and sensors to create digital representations of objects and their destinations, allowing the control system to plan and execute sorting operations without physical prototypes or manual setup for each divert location. This digital modeling approach reduces manufacturing and setup costs for handling diverse object types.
Data Source
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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.