Mobile Bin Carrier Sortation for High-Capacity Multi-Pass Processing
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Solution Overview
Problem
Current object processing systems, particularly in distribution centers, face inefficiencies and inflexibilities due to the need for a large number of collection bins, which increases physical space, capital, and operating costs. These systems struggle to efficiently sort and process a variety of objects of different sizes and weights.
Innovation Solution
The proposed solution is a bin exchange system that utilizes automated carriers moving on an array of track sections. This system includes input, processing, and output stations for bin exchange, allowing for remote movement and efficient processing of objects between bins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to sort all objects to all destinations at once, then the sortation capacity and number of diverts increase, but the physical space requirements, capital costs, and operating costs increase significantly
Solution Approach 1:
The sortation process is divided into multiple passes, with each pass handling a subset of destinations. Objects are sorted in stages rather than all at once, allowing the system to achieve high sortation capacity with a limited number of physical bins at any given time.
Solution Approach 2:
The system dynamically reconfigures bin assignments between passes. Collection bins are reassigned to different destination groups in subsequent passes, allowing the same physical bins to serve multiple destinations over time, thereby reducing the total number of bins needed.
2Ease of operation
If human workers manually sort objects to collection bins, then labor flexibility is maintained, but system throughput is limited by worker speed
Solution Approach 1:
The system uses automated scanning and identification to determine object destinations, with objects being automatically directed to the correct bins. This reduces reliance on human decision-making speed while maintaining operational simplicity, thereby increasing throughput without sacrificing ease of operation.
Solution Approach 2:
An automated control system acts as an intermediary between object identification and physical sortation. The control system processes destination information and directs sortation actions, enabling faster throughput while keeping the physical sortation process simple and maintainable.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput increases, but the system complexity and mechanical costs increase
Solution Approach 1:
The patent extracts the complex tilt tray mechanism from the sortation system and replaces it with simpler divert mechanisms. Objects are moved along a conveyor and diverted to stationary bins using less complex mechanical means, maintaining throughput while reducing system complexity and cost.
Solution Approach 2:
Instead of using expensive recirculating tilt tray systems, the patent employs multiple simpler conveyor segments that replicate basic transport and divert functions. This achieves similar throughput using less complex, more cost-effective components.
4Ease of operation
If bins are arranged within efficient reach of human workers, then ease of operation is maintained, but the number of diverts is limited
Solution Approach 1:
Collection bins serve multiple destinations across different passes rather than being dedicated to single destinations. Each bin is reassigned to different destination groups in subsequent passes, allowing a small number of accessible bins to handle a large total number of diverts through multi-functional use.
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.