Automated Mobile Matrix Bins for High-Throughput 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 limited throughput due to the need for manual sorting and bin management, especially in environments where objects of varying sizes and weights need to be processed.
Innovation Solution
A programmable motion control system with a perception unit, acquisition system, and delivery system that automates the identification and conveyance of objects to specific bins using a programmable motion device, including an articulated arm with an end effector and mobile carriers, which can learn optimal grasp points through machine learning and adapt to various object configurations.
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 the system can handle objects of varying sizes and weights with simple equipment, but the throughput is limited and labor requirements are high
Solution Approach 1:
The system enables self-service automation where the robotic device independently identifies objects, determines their destinations, and places them in collection bins without continuous human intervention. The perception unit automatically scans objects and the control system autonomously directs the robotic device to sort items into appropriate bins based on identified characteristics.
Solution Approach 2:
The patent replaces manual mechanical sorting operations with an automated robotic system. The robotic device with end effector substitutes human workers' hands, while the perception unit and control system replace human decision-making processes. This mechanical substitution dramatically increases throughput while reducing labor requirements.
2Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then the system can accommodate various object types and destinations, but the system complexity and space requirements increase
Solution Approach 1:
The system implements dynamic bin assignment where collection bins are not permanently dedicated to specific object types but are temporarily assigned based on real-time sorting needs. The control system dynamically reconfigures which bin receives which object type, allowing the same physical bin to serve multiple destinations sequentially. This dynamic approach maintains high adaptability while reducing the total number of bins required.
3Productivity
If fixed or handheld barcode scanners are used for object identification, then the system can identify objects with simple scanning equipment, but the scanning process requires manual positioning and is time-consuming
Solution Approach 1:
The perception unit replaces manual handheld scanning operations with an automated optical scanning system. The robotic device positions the perception unit automatically, eliminating the need for manual positioning. The perception unit can scan multiple objects simultaneously or in rapid succession as they move along the conveyor, dramatically increasing scanning speed while removing manual operation requirements.
4Productivity
If the robotic device processes objects one at a time in a linear sequence, then the system is simple to control, but the throughput is limited by the sequential processing speed
Solution Approach 1:
The system transitions from one-dimensional sequential processing to multi-dimensional parallel processing. Multiple objects are processed simultaneously at different positions along the conveyor, with the robotic device able to service multiple collection bins in different spatial locations. This spatial dimensionality allows parallel processing of multiple objects, dramatically increasing throughput while maintaining manageable control complexity through modular architecture.
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, 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.