Mobile Carrier Alignment for Precise Container Transfer
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Solution Overview
Problem
Current object processing systems are inflexible, inefficient, and costly, requiring large numbers of collection bins and human labor, with limitations in throughput, divert capabilities, and mechanical complexity, especially when handling varied object sizes and weights.
Innovation Solution
A system utilizing remotely actuatable carriers with support ridges and sensors for precise alignment with container support structures, enabling efficient transfer and sorting of objects into appropriate collection bins or trays, using automated mobile carriers with multi-functional payloads and integrated detection units for real-time monitoring and alignment.
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 extracts the actuator mechanism from each individual divert location and replaces it with passive gravity-fed chutes. Objects are diverted by their physical trajectory and gravity rather than active mechanical tilting at each station, eliminating the need for numerous actuators while maintaining automated sortation capability
Solution Approach 2:
The patent replaces the mechanical tilt-tray actuation system with a gravity-based passive sortation system. Instead of using motorized actuators to tilt trays at each divert location, objects are routed through gravity-fed pathways and deposited into collection bins using gravitational force alone
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 transitions from a horizontal arrangement of numerous collection bins to a vertical stacking configuration. Collection bins are arranged in multiple levels and tiers, allowing the system to handle a large number of different object types (high adaptability) while utilizing vertical space rather than horizontal footprint, thereby reducing the area occupied
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 implements an automated system where objects self-sort through gravity-fed pathways and passive routing mechanisms. The system serves itself by using the objects' own movement and gravitational force to direct them to appropriate collection bins without requiring human physical intervention at each sortation point, thereby achieving high throughput while maintaining relatively simple system architecture
Data Source
AI summary
A method of providing transfer between a remotely actuatable carrier and a container support structure is disclosed, the method including providing a remotely actuatable carrier including a plurality of support ridges proximate the support structure and providing sensor output information regarding alignment of the remotely actuatable carrier and the container support structure, the container support structure including a plurality of support structure protrusions; and passing the plurality of support ridges of the remotely actuatable carrier between the plurality of support structure protrusions responsive to the sensor output information.