Mobile Bin Carrier Grid for High-Divert 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, which increases costs and limits throughput and the number of divert locations.
Innovation Solution
A bin exchange system with remotely movable automated carriers on track sections, allowing for efficient movement and processing of objects between bins, including input, processing, and output stations, using pivotable wheels and actuable paddles for bin handling and realignment on a grid system.
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 patent implements a dynamic bin assignment system where collection bins are not permanently dedicated to specific destinations but are temporarily assigned based on real-time sortation needs. The system controller dynamically reconfigures which bin receives objects for which destination, allowing the same physical bin to serve multiple diverts sequentially. This dynamic approach enables a limited number of bins to handle a much larger number of diverts without requiring proportional physical space expansion.
Solution Approach 2:
The system adds the time dimension to the sortation process by implementing multi-pass sortation. Instead of requiring all diverts to be simultaneously accessible (spatial dimension only), objects can be sorted in multiple passes where different destination sets are active at different times. This temporal dimension allows the system to handle more diverts than the number of physical bins by cycling through different destination configurations.
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 system creates a hybrid sortation approach where automated components (scanners, controllers, indicators) handle identification and routing decisions, while human workers handle physical object manipulation. This multi-functional system leverages the speed and accuracy of automation for decision-making while utilizing human dexterity and adaptability for handling diverse object types, achieving both high throughput and operational flexibility.
Solution Approach 2:
The system introduces an intermediary control system that acts as a mediator between automated identification and human sortation actions. The controller receives object identification data, determines optimal bin assignments, and provides real-time guidance to workers through indicators (lights, displays). This intermediary layer enables workers to operate at higher speeds by eliminating decision-making delays while maintaining the flexibility of manual handling.
3Productivity
If recirculating conveyors with tilt trays are used for automation, then throughput increases, but the number of diverts is limited by physical tray constraints
Solution Approach 1:
The system implements dynamic bin assignment where collection bins are reassigned to different destinations based on current sortation requirements rather than having fixed assignments. This allows the system to handle more diverts than the number of physical bins by cycling through different destination configurations over time, increasing versatility without adding more bins.
Solution Approach 2:
The system maintains continuous sortation operation by implementing multi-pass processing and dynamic bin utilization. While objects are being sorted to current active destinations, bins are prepared for upcoming destinations, ensuring continuous useful action without idle time. This continuous operation maximizes throughput while the dynamic reassignment enables handling of more divert types than physical bins.
Data Source
AI summary
A bin exchange system is disclosed that includes a plurality of automated carriers, each of which is adapted to be remotely movable on an array of track sections, at least one input station by which bins may be introduced to the array of track sections, at least one processing station in communication with the array of track sections wherein objects may be moved between bins, and at least one output station by which bins may be removed from the array of track sections.