Mobile Container Transfer for High-Destination Sortation

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Solution Overview

Problem

Conventional unit sortation systems face inefficiencies due to their long perimeter, which increases the time human personnel spend waiting, walking, and making decisions to process items sorted into a large number of destinations.

Innovation Solution

An object processing system featuring a first support structure for containers, a second support structure for receiving containers, and an automated mobile transfer unit that selectively transfers containers from the first to the second support structure using elevatable belts, reducing the need for manual handling and processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the number of sort destinations is increased to improve sorting efficiency, then the sorting capacity increases, but the perimeter of the system increases and human personnel spend more time walking and processing items

Engineering Contradiction:

Improvesorting capacityVSAvoidtime for human personnel to walk and process items

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system enables self-service by implementing automated container transfer mechanisms that operate without human intervention. Mobile transfer units automatically transport containers between support structures, and discharge mechanisms automatically empty containers at destinations, eliminating the need for human personnel to manually walk and process items at each destination.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Mobile transfer units serve as intermediaries between the first and second support structures, automatically transporting containers along the system perimeter. This intermediary mechanism handles the transport function that would otherwise require human personnel to walk the entire perimeter, reducing their travel time and effort.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If automated transfer mechanisms are implemented to reduce manual handling, then labor efficiency improves, but device complexity increases

Engineering Contradiction:

Improvelabor efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system employs dynamic mobile transfer units that can move along the perimeter between different locations. These units transition from a stationary infrastructure to a dynamic, mobile system that adapts its position based on container discharge needs, providing automated functionality without requiring a completely complex fixed infrastructure throughout the entire perimeter.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Mobile transfer units perform multiple functions: they transport containers between support structures, position containers for discharge, and can serve multiple destinations along their route. This multi-functionality reduces the need for separate specialized mechanisms at each location, thereby managing system complexity while maintaining high labor efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system significantly reduces the time and effort required for human personnel to process sorted items by automating the transfer and handling of containers, thereby enhancing efficiency and reducing operational costs.

Implementation Method 1

a mobile chassis unit for moving the at least one automated mobile transfer unit in a first direction among the first support structure and the second support structure

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

a payload transfer system supported by the mobile chassis unit and adapted to transfer a selected container of the plurality of containers from the first support structure to the second support structure

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS20250091807A1Systems and methods for providing object processing using mobile transfer units

Publication Date: 2025.03.20 BERKSHIRE GREY OPERATING CO INC

AI summary

An object processing system is disclosed that includes a first support structure for supporting a plurality of containers that are positioned to receive a plurality of objects, a second support structure for receiving any of the plurality of containers when each of the plurality of containers is ready to be discharged from the first support structure, and an automated mobile transfer unit for selectively transferring a selected container from the first support structure to the second support structure, said automated mobile transfer unit including a mobile chassis unit for moving the at least one automated mobile transfer unit in a first direction among the first support structure and the second support structure, and a payload transfer system supported by the mobile chassis unit and adapted to transfer a selected container of the plurality of containers from the first support structure to the second support structure.