Mobile Matrix Carriers for Flexible Robotic Object Sorting
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Solution Overview
Problem
Existing object distribution systems are inefficient and inflexible, requiring large numbers of collection bins, significant human labor, and high operational costs, especially when handling objects of varying sizes and weights.
Innovation Solution
A programmable motion device-based processing system that includes a perception unit for identifying objects, an acquisition system for retrieving objects, and a delivery system with movable carriers to efficiently direct objects to their designated processing locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sorting is used with human workers scanning objects and placing them in collection bins, then flexibility in handling various objects is maintained, but productivity is low and operational costs are high
Solution Approach 1:
The patent replaces manual mechanical sorting operations with an automated robotic system. A robotic arm with gripper mechanically retrieves objects from input conveyance and places them in mobile carriers, substituting human workers entirely. The system uses vision systems and automated control to identify objects and determine destinations, eliminating the need for human scanning and decision-making while dramatically increasing sorting throughput.
Solution Approach 2:
The system enables objects to be automatically identified and routed without human intervention. The vision system autonomously detects objects and their identification features, the control system automatically determines destination locations, and the robotic arm automatically retrieves and transports objects to correct carriers, creating a self-service automated sorting process.
2Productivity
If a large number of collection bins are used to handle diverse objects, then all object types can be sorted simultaneously, but device complexity and space requirements increase
Solution Approach 1:
The patent replaces static collection bins with dynamic mobile carriers that move along a conveyor system. Carriers are dynamically assigned to different destinations based on real-time sorting needs, and their positions are continuously adjusted. This dynamic allocation allows the same physical infrastructure to handle diverse object types without requiring a fixed large array of collection bins, reducing system complexity while maintaining concurrent sorting capacity.
Solution Approach 2:
The system transitions from a two-dimensional array of collection bins on the floor to a three-dimensional mobile carrier system moving along elevated conveyors. Objects are sorted into carriers that travel through vertical and horizontal spaces, utilizing unused spatial dimensions. This approach handles diverse object types without proportionally increasing ground space requirements or system complexity.
3Measurement precision
If fixed scanners are used to identify objects, then code detection is reliable, but the system requires inflexible sequencing and objects must be oriented correctly
Solution Approach 1:
The patent employs vision systems with cameras and image processing algorithms that can identify objects from multiple angles and orientations simultaneously. Unlike fixed scanners that require specific positioning, the vision system captures images from various perspectives and uses computational algorithms to recognize identification features regardless of object orientation, enabling flexible retrieval sequences without compromising identification accuracy.
Solution Approach 2:
The system changes the identification approach from optical scanning requiring specific geometric parameters (fixed angles, distances, orientations) to vision-based recognition that processes images with varying parameters. The vision system adjusts focus, exposure, and image processing parameters dynamically based on object characteristics, allowing accurate identification while accommodating flexible object positioning and retrieval sequences.
4Productivity
If automated robotic arms are used to retrieve objects, then productivity increases, but the system requires precise control and coordination complexity increases
Solution Approach 1:
The patent incorporates vision systems that continuously monitor object positions, orientations, and identification features in real-time. This visual feedback is fed to the control system, which adjusts the robotic arm's motion parameters dynamically. The system also tracks carrier positions and coordinates retrievals based on real-time system state, reducing control complexity through continuous feedback while maintaining high productivity.
Solution Approach 2:
The vision system performs preliminary identification and classification of objects before retrieval begins. The control system pre-plans retrieval sequences and coordinates carrier assignments in advance based on predicted sorting needs. This preliminary action reduces real-time control complexity by resolving decision-making beforehand, allowing the robotic arm to execute predetermined high-speed retrieval operations with simpler real-time adjustments.
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, 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.