Automated Mobile Matrix Bins for Flexible Object Sortation
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Solution Overview
Problem
Current object distribution systems rely heavily on human labor, are inefficient in handling varying object sizes and weights, and require a large number of collection bins, leading to high operational and capital costs, as well as inflexibility in processing diverse objects.
Innovation Solution
A programmable motion control system that includes a perception unit for identifying objects, an acquisition system to grasp objects using an end effector, and a delivery system with automated mobile carriers to efficiently route objects to specific bins, optimizing throughput, reducing the need for multiple bins, and enhancing processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human workers manually sort objects to collection bins, then flexibility in handling varying object sizes and weights is maintained, but processing efficiency is low and labor costs are high
Solution Approach 1:
The system uses vision systems and sensors to automatically identify objects, determine their destinations, and guide their placement without human intervention. The robotic arms and conveyors autonomously perform sortation tasks based on real-time object characteristics and destination requirements
Solution Approach 2:
Manual mechanical sortation by human workers is replaced with automated robotic systems including robotic arms, automated conveyors, and computer-controlled placement mechanisms that can handle varying object sizes and weights through programmable motion control
2Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then all object types can be sorted simultaneously, but capital costs and operational complexity increase
Solution Approach 1:
The system uses dynamically adjustable conveyors and movable bin positions that can be reconfigured based on the mix of objects being sorted. Collection bins can be moved, added, or removed from the system dynamically, and conveyor paths can be reprogrammed to route objects to different destinations without physical reconfiguration
Solution Approach 2:
A smaller number of multi-functional collection bins are used that can serve multiple destinations through automated transfer mechanisms. The system can consolidate objects from multiple sources into fewer bins and then redistribute them, reducing the total number of bins required while maintaining the ability to handle diverse object types
3Measurement precision
If fixed or handheld barcode scanners are used for object identification, then code detection is reliable, but processing speed is limited by manual operation
Solution Approach 1:
Manual or handheld barcode scanning is replaced with fixed automated barcode scanners and vision systems that continuously scan objects as they move along conveyors. Multiple scanners can operate in parallel, and the system can read multiple codes simultaneously, dramatically increasing processing speed while maintaining detection reliability through automated image processing and code verification algorithms
4Measurement precision
If objects are singulated and oriented for scanner detection, then identification accuracy improves, but system inflexibility increases for handling varying object sizes and weights
Solution Approach 1:
The singulation and orientation mechanisms are made dynamically adjustable with variable speed conveyors, adjustable guide rails, and programmable positioning systems that can adapt to different object sizes, shapes, and weights. The system can modify the singulation process in real-time based on object characteristics detected by vision systems
Solution Approach 2:
The system changes operational parameters such as conveyor speed, guide rail positioning, and orientation angles based on the specific object being processed. By adjusting these parameters dynamically, the system maintains high identification accuracy while accommodating a wide variety of object types with different dimensions and physical properties
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, 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, wherein the programmable motion device is adapted for assisting in the delivery of the object to an identified processing bin, and the identified processing bin is associated with the identifying indicia and said identified processing location is provided as one of a plurality of processing bins, and a delivery system for bringing the identified processing bin toward the object, where the delivery system includes a carrier for carrying the identified processing bin toward the object.