Automated Mobile Bin Sortation for Flexible Object Handling
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Solution Overview
Problem
Current object distribution systems rely heavily on human labor, are inefficient in handling varying object sizes and weights, and require a large number of collection bins, leading to high operational and capital costs, as well as limitations in throughput and flexibility.
Innovation Solution
A programmable motion device system that includes a perception unit for identifying objects, an acquisition system for grasping objects using an end effector, and a delivery system with a carrier to move identified processing bins towards the objects, optimizing the delivery process by automating the identification and conveyance of objects to specific destinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If human workers manually sort objects to collection bins, then flexibility in handling various object types is maintained, but productivity and operational efficiency deteriorate
Solution Approach 1:
The system enables self-service automation where the robotic device independently identifies objects, determines destinations, and places objects in collection bins without continuous human intervention. The perception unit automatically scans objects, the control system autonomously decides routing, and the robotic device executes placement, creating a self-managing sortation system that maintains flexibility while dramatically improving productivity
Solution Approach 2:
The patent replaces manual human sorting with an automated robotic system comprising a robotic device with perception units, control systems, and automated placement mechanisms. This mechanical substitution eliminates manual labor while maintaining adaptability through programmable control, resolving the contradiction between human flexibility and automated productivity
2Adaptability or versatility
If a large number of collection bins are deployed to handle diverse objects, then adaptability to different object types improves, but device complexity and capital costs worsen
Solution Approach 1:
The system implements dynamic destination assignment where collection bin assignments are not fixed but can be reconfigured based on current sorting needs. The control system can dynamically adjust which objects go to which bins, allowing the same physical infrastructure to handle diverse object types without requiring a separate bin for every possible object category, thus reducing overall system complexity while maintaining adaptability
Solution Approach 2:
Collection bins serve multiple functions and multiple object types rather than being dedicated to single object categories. The universal bin design allows any bin to receive any object type based on real-time routing decisions, eliminating the need for specialized bins for each object category and significantly reducing the total number of bins required in the system
3Measurement precision
If fixed or handheld barcode scanners are used for object identification, then measurement capability is provided, but ease of operation and automation level worsen
Solution Approach 1:
The perception unit mounted on the robotic device performs automated object identification without requiring manual scanning operations. The system autonomously scans, identifies, and processes object information as part of its self-service operation cycle, eliminating the need for operators to manually position and scan barcodes while maintaining accurate object identification
Solution Approach 2:
Object identification is performed as a preliminary automated step before the robotic device proceeds with manipulation and placement. The perception unit continuously or periodically scans objects in its field of view, pre-identifying them before the robot needs to interact with them, thereby eliminating manual scanning operations and enabling seamless automated operation
4Device complexity
If objects are processed in arrival order with rigid sortation sequences, then system simplicity is maintained, but productivity and throughput deteriorate
Solution Approach 1:
The control system implements dynamic sortation sequencing that adapts to real-time system conditions, object characteristics, and destination requirements. Rather than following a fixed arrival-order sequence, the system can dynamically prioritize and route objects based on multiple factors including bin capacity, object type, and destination urgency, thereby improving throughput without requiring overly complex predetermined sequences
Data Source
AI summary
A processing system for processing objects using a programmable motion device is disclosed. The processing system includes a perception unit for perceiving identifying indicia representative of an identity of a plurality of objects received from an input conveyance system, an acquisition system for acquiring an object from the plurality of objects at an input area using an end effector of the programmable motion device, wherein the programmable motion device is adapted for assisting in the delivery of the object to an identified processing bin, and the identified processing bin is associated with the identifying indicia and said identified processing location is provided as one of a plurality of processing bins, and a delivery system for bringing the identified processing bin toward the object, where the delivery system includes a carrier for carrying the identified processing bin toward the object.