Mobile Bin Carrier Routing for High-Throughput Object Processing
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Solution Overview
Problem
Current object processing systems, such as sortation and storage systems, face inefficiencies due to the need for a large number of collection bins, high mechanical complexity, and high costs, especially when handling objects of varying sizes and weights, as they rely on human labor and discrete automated diverts which are costly and limited in throughput and flexibility.
Innovation Solution
A bin exchange system with remotely movable automated carriers on a track system, allowing for efficient movement and processing of bins between input, processing, and output stations, enabling flexible routing and reduced mechanical complexity by using pivotable wheels and actuatable paddles for bin handling and realignment on a grid of track sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If discrete automated diverts with actuators are used for each bin location, then sortation can be automated, but mechanical complexity and cost per divert become very high
Solution Approach 1:
The patent replaces the traditional mechanical tilt-tray actuator system with a mobile robotic unit that uses sensors, computer vision, and controlled movement to perform sortation. Instead of having mechanical actuators at every bin location, a single mobile robot travels along the conveyor and diverts objects using robotic manipulation, substituting complex distributed mechanical systems with a programmable mobile system.
Solution Approach 2:
The sortation system transitions from static divert mechanisms fixed at each location to a dynamic mobile robotic unit that moves along the conveyor. The robot's position, speed, and divert actions are dynamically adjusted based on real-time object identification and bin location requirements, enabling flexible automated sortation without fixed mechanical infrastructure at each divert point.
2Productivity
If a large number of collection bins are arranged within reach of workers, then all object types can be sorted simultaneously, but physical space requirements and capital costs increase significantly
Solution Approach 1:
The system replaces the static arrangement where all bins must be within worker reach with a dynamic mobile robot that travels along the conveyor to access bins distributed over a longer distance. This allows bins to be arranged linearly along the conveyor path rather than clustered in a compact area, reducing the footprint while maintaining high sortation capacity.
Solution Approach 2:
Instead of arranging bins in a two-dimensional array within arm's reach of a stationary worker, the system distributes bins along the one-dimensional conveyor path and uses the mobile robot's movement along this dimension to access them. This transforms the space utilization from a compact 2D workspace to an extended 1D linear arrangement, reducing overall facility space requirements.
3Extent of automation
If recirculating conveyors with tilt trays are used, then automated sortation is achieved, but the cost per divert increases due to required actuators at each location
Solution Approach 1:
The mobile robotic unit serves as a universal sortation mechanism that can divert objects to any bin location along the conveyor, replacing the need for dedicated actuators at each divert point. This single multi-functional robot performs the sortation function for all bins, significantly reducing the total number of actuators required and lowering the cost per divert.
Solution Approach 2:
Instead of having physical actuators at every bin location, the system uses a single mobile robot that sequentially visits different locations to perform divert actions. The robot effectively 'copies' the divert function across multiple locations through its movement and repeated actions, eliminating the need for expensive duplicate actuator hardware at each position.
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.