Mobile Matrix Carriers With Pivoting Wheels for Orthogonal Sortation
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Solution Overview
Problem
Current object processing systems, such as sortation and storage systems, face inefficiencies and inflexibilities due to the need for large numbers of collection bins, high mechanical complexity, and labor-intensive operations, which increase costs and limit throughput and flexibility in handling objects of varying sizes and weights.
Innovation Solution
An automated carrier system with pivotally mounted wheels allows for orthogonal movement on a track system, enabling efficient routing and processing of objects without changing the carrier's orientation, and includes mechanisms for bin management and diversion to various destinations.
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. 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 invention replaces the mechanical actuator-based tilt tray system with a gravity-based passive diversion system. Objects are directed to collection bins using gravity flow paths 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 reorganizes the sortation system from a horizontal array of numerous collection bins to a multi-level vertical structure. Collection bins are stacked in layers and accessed via vertical conveyor paths, allowing the system to handle many more destinations (diverts) by utilizing the vertical dimension rather than spreading bins out horizontally across a large floor area.
Solution Approach 2:
The system employs recirculating conveyor loops that can serve multiple collection bins in sequence, allowing a single conveyor path to handle numerous destinations. The same conveyor infrastructure serves multiple functions: transporting objects to different levels, directing objects to various collection bins, and recycling empty carrier positions back to the induction area.
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 divides the sortation function into separate specialized components: an induction area for receiving and organizing objects, conveyor systems for transportation, scanner stations for identification, and collection bins for sorting. This segmentation allows each component to be optimized for its specific function, achieving high throughput through coordinated automation rather than relying on general-purpose manual labor.
Solution Approach 2:
The system introduces automated scanners and control systems as intermediaries between the physical objects and the sortation process. Scanners automatically identify objects and their destinations, and the control system coordinates conveyor movements and gate operations, replacing the need for human workers to visually inspect and manually direct each object while maintaining high processing speeds.
4Ease of operation
If fixed sequence operations are used in distribution centers, then ease of operation is improved, but adaptability worsens when handling varying object types
Solution Approach 1:
The patent implements a dynamic sortation system where the processing sequence is not fixed but adapts based on object characteristics. The scanner identifies each object's destination, and the control system dynamically adjusts conveyor routing and gate positions in real-time. This allows the system to handle diverse object types and destinations efficiently while maintaining smooth, continuous operation without rigid predetermined sequences.
Data Source
AI summary
An automated carrier system is disclosed for moving objects to be processed. The automated carrier system includes a base structure of a carrier on which an object may be supported, and at least two wheels mounted to at least two motors to provide at least two wheel assemblies, the at least two wheel assemblies being pivotally supported on the base structure for pivoting movement from a first position to a second position to effect a change in direction of movement of the carrier.