Mobile Carrier Sortation With Dynamic Bin Assignment
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Solution Overview
Problem
Current object sortation and distribution systems are inefficient and inflexible, requiring large numbers of collection bins, significant human labor, and limited throughput due to the need for manual scanning and sorting of objects, which leads to high operational and capital costs and limitations in handling objects of varying sizes and weights.
Innovation Solution
A programmable motion device system that identifies objects using perception units and directs them to specific processing locations via automated mobile carriers, optimizing the sorting process by learning grasp points and routes to improve efficiency and reduce manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual scanning and sorting is used, then flexibility in handling various objects is maintained, but throughput and productivity are limited
Solution Approach 1:
The patent replaces manual mechanical scanning and sorting operations with an automated system using vision sensors, programmable motion devices, and mobile carriers. The vision sensors automatically identify objects and their destinations, while programmable motion devices and mobile carriers automatically transport objects to correct locations, eliminating the need for manual intervention and significantly increasing throughput.
Solution Approach 2:
The system enables objects to be automatically identified and routed based on their inherent identification features (barcodes, RFID tags, or visual characteristics). The programmable motion devices autonomously determine optimal paths and grasp points, and mobile carriers self-navigate to destination bins, creating a self-service automated sorting system that operates without human intervention.
2Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then sortation capability is improved, but device complexity and capital costs increase
Solution Approach 1:
The patent implements dynamic bin assignment where the correspondence between sorter outputs and destination bins is not fixed but changes during operation. The system dynamically determines which bin receives which object based on real-time conditions, allowing the same physical bin to serve multiple destinations at different times. This dynamic approach reduces the total number of bins needed while maintaining high sortation capability for diverse objects.
Solution Approach 2:
The system adds the time dimension to the sorting process by allowing bins to be reassigned to different destinations across different time periods. Instead of requiring simultaneous access to multiple fixed bins for different destinations, the system sequences object routing so that a single bin can serve multiple destinations sequentially, effectively using the time dimension to reduce spatial requirements.
3Adaptability or versatility
If fixed sortation sequences are used, then system simplicity is maintained, but adaptability to varying object types and destinations is reduced
Solution Approach 1:
The patent implements dynamic routing where the system determines optimal paths and bin assignments in real-time based on object characteristics, destination requirements, and current system state. The programmable motion devices and control system continuously adapt routing decisions, allowing the same physical system to handle various object types and destination configurations without requiring fixed predetermined sequences.
Solution Approach 2:
The system changes operational parameters dynamically, including bin assignments, routing paths, and grasp points, based on real-time conditions. The control system adjusts these parameters adaptively to handle different object types, sizes, weights, and destination requirements, providing flexibility without requiring physical reconfiguration of the system architecture.
4Loss of time
If human workers perform sortation, then adaptability to different objects is maintained, but operational costs and time consumption increase
Solution Approach 1:
The patent replaces human workers with an automated system comprising vision sensors for object identification, programmable motion devices for grasping and lifting, and mobile carriers for transport. This mechanical substitution eliminates human labor from the sortation process, significantly reducing processing time while maintaining the ability to handle various object types through programmable control and adaptive algorithms.
Data Source
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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, and 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. The programmable motion device is adapted for assisting in the delivery of the object to an identified processing location. The identified processing location is associated with the identifying indicia and the identified processing location is provided as one of a plurality of processing locations. The system also includes a delivery system for receiving the object in a carrier and for delivering the object toward the identified processing location.