Mobile Carrier Payload Positioning for Flexible Object Sortation
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Solution Overview
Problem
Current object processing systems are inefficient and inflexible, requiring large numbers of collection bins and human labor, with high mechanical complexity and cost per divert, and limited throughput and divert capabilities, especially when handling varied object sizes and weights.
Innovation Solution
An object processing system utilizing remotely actuatable carriers that move in multiple directions, including a base with independently actuatable wheels and a payload portion capable of elevation and rotation, allowing precise placement of objects onto protrusions and conveyors, with integrated detection units for precise positioning and identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then objects can be automatically routed to predefined locations, but mechanical complexity increases due to actuators required for each divert
Solution Approach 1:
The system divides the sortation function into two independent parts: (1) a single actuator that controls carrier orientation, and (2) passive gravity-based object release at multiple divert locations. This segmentation eliminates the need for actuators at each divert point, reducing mechanical complexity while maintaining automated sortation.
Solution Approach 2:
The carrier acts as an intermediary between the single actuator and multiple divert locations. The actuator controls the carrier's tilt angle, and this intermediate carrier then passively directs objects to different destinations based on its orientation, eliminating the need for direct actuation at each divert point.
2Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then sortation capability increases, but physical space requirements and capital costs increase
Solution Approach 1:
The system uses dynamically adjustable carrier tilt angles to route objects to different divert locations. By changing the carrier orientation dynamically, the same carrier can serve multiple destinations without requiring dedicated collection bins for each object type, reducing physical space requirements.
Solution Approach 2:
The carrier is designed as a multi-functional element that can route objects to multiple different destinations by adjusting its tilt angle. This universal carrier replaces the need for multiple specialized collection bins, reducing both physical space and capital costs while maintaining high sortation capability.
3Measurement precision
If discrete trays with actuators are used for each divert location, then precise object routing is achieved, but cost per divert becomes very high
Solution Approach 1:
The system merges multiple divert control functions into a single actuator that controls the carrier's tilt angle. This single actuator serves multiple divert locations simultaneously, dramatically reducing the cost per divert while maintaining precise object routing through controlled carrier orientation.
Solution Approach 2:
The system replaces the mechanical actuator-at-each-divert approach with a gravity-based passive release mechanism. The single actuator controls carrier tilt, and gravity naturally directs the object to the appropriate divert location, eliminating expensive mechanical actuators at each divert point while maintaining routing precision.
Data Source
AI summary
An object processing system is disclosed that includes a plurality of remotely actuatable carriers for controlled movement in at least two mutually orthogonal directions, each carrier including a base and a payload portion for receiving a container, each the payload portion being adapted to move in an elevational direction and a rotational direction about a rotational axis that is substantially parallel with the elevational direction.