Mobile Matrix Carriers for Flexible High-Throughput 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 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 a network of track sections with remotely actuatable carriers that can move along these sections in a controlled manner, allowing for the movement of objects to specific destinations with reduced mechanical complexity and increased flexibility, using pivotable wheels to navigate orthogonal directions without rotating the carrier, and actuatable paddles to manage bin placement and retrieval.
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:
The patent removes the complex actuator mechanisms from each divert location and extracts only the essential function of directing objects to collection bins. Instead of active tilt trays with motors, the system uses passive gravity-fed chutes and simple gates that redirect objects based on their destination, eliminating the need for powered actuators at each sortation point.
Solution Approach 2:
The patent replaces the mechanical actuator-based tilt tray system with a gravity-based passive diversion system. Objects are directed to collection bins using gravity-fed pathways and simple mechanical gates rather than powered tilting mechanisms, substituting complex mechanical actuation with simpler gravitational forces.
2Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then adaptability is improved, but area occupied increases significantly
Solution Approach 1:
The patent transitions from a horizontal arrangement of numerous collection bins occupying large floor space to a vertical stacking configuration. Collection bins are arranged in multiple levels or tiers, allowing the system to handle diverse object types with high adaptability while utilizing vertical space instead of horizontal space, thereby reducing the footprint area significantly.
Solution Approach 2:
The patent implements a nested arrangement where collection bins are stacked or nested within each other in vertical layers. This nested configuration allows multiple bin locations to be compacted into a smaller vertical envelope, reducing the horizontal area occupied while maintaining the ability to direct objects to many different destinations.
3Device complexity
If human workers perform manual sortation, then device complexity is reduced, but productivity is limited by worker speed
Solution Approach 1:
The patent implements preliminary identification and routing decisions using automated scanning and control systems. Objects are scanned and their destinations determined before reaching the sortation point, allowing automated gates to direct them appropriately. This preliminary automated processing enables higher throughput while keeping the physical sortation mechanism relatively simple.
Solution Approach 2:
The patent enables objects to be automatically directed to their correct collection bins through automated identification and routing systems without requiring manual intervention. The system serves itself by using scanners, controllers, and automated gates to perform sortation, thereby increasing productivity beyond human worker capabilities while maintaining reasonable system simplicity.
4Adaptability or versatility
If bomb-bay style recirculating conveyors with open doors are used, then adaptability is improved, but device complexity increases due to actuator requirements
Solution Approach 1:
The patent removes the complex bomb-bay style actuator mechanisms that open doors on trays and extracts only the essential function of releasing objects at the correct location. Instead of powered door-opening mechanisms, the system uses passive gravity-fed pathways with simple gates that allow objects to be directed to collection bins without complex actuation.
Solution Approach 2:
The patent replaces the mechanical bomb-bay actuator system with a gravity-based passive diversion system. Objects are directed to collection bins using gravity-fed pathways and simple mechanical gates rather than powered door-opening mechanisms, substituting complex mechanical actuation with simpler gravitational forces and passive structures.
Data Source
AI summary
An object processing system is disclosed that includes a plurality of track sections, and a plurality of remotely actuatable carriers for controlled movement along at least portions of the plurality of track sections, each of the actuatable carriers being instructed at any time to move a limited number of track section only.