Mobile Matrix Carriers for High-Divert Object Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current object processing systems, such as sortation and storage systems, face inefficiencies and inflexibilities due to the need for a large number of collection bins and high mechanical complexity, which increases costs and limits throughput and divert capabilities.
Innovation Solution
The system employs a network of track sections with remotely actuatable carriers that can move in orthogonal directions without rotating, allowing for flexible and efficient movement of objects between multiple track sections, reducing the need for multiple bins and divert mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then the system can accommodate more diverts and object types, but the physical space, capital costs, and operating costs increase significantly
Solution Approach 1:
The patent implements a dynamic recirculating conveyor system where collection bins are reused across multiple cycles. Objects that miss their destination on one pass continue circulating and are diverted on subsequent passes. This transforms static collection bins into dynamic, multi-purpose receptacles that serve different destinations at different times, eliminating the need for dedicated bins for each destination.
Solution Approach 2:
The system employs periodic action by cycling objects through the conveyor loop multiple times. Collection bins are periodically assigned to different destinations based on the current batch of objects being sorted. This periodic reassignment allows the same physical infrastructure to handle a much larger number of destinations without requiring proportional increases in physical space.
2Reliability
If discrete actuators are installed at every divert location in recirculating conveyor systems, then precise object routing is achieved, but the mechanical complexity and cost per divert increase significantly
Solution Approach 1:
The patent implements a single actuator that serves multiple divert locations sequentially as objects circulate through the conveyor loop. This universal actuator is periodically positioned at different divert points to route objects to various destinations, replacing the need for dedicated actuators at each location. The same mechanical component performs multiple functions across different spatial and temporal contexts.
Solution Approach 2:
The system uses a single actuator mechanism that is repeatedly deployed to different locations through the recirculating conveyor system. Rather than having multiple physical actuators, the same actuator is effectively 'copied' across space and time by positioning it at different divert points during different cycles, achieving the routing capability of multiple actuators with a single physical component.
3Adaptability or versatility
If human workers perform manual sortation, then flexibility in handling various object types is maintained, but the system throughput is limited by worker speed
Solution Approach 1:
The patent implements an automated system where objects are self-identified through scanning and self-routed through the recirculating conveyor based on their destination requirements. The system autonomously determines routing decisions and executes divert actions without human intervention, allowing continuous operation at high speeds while maintaining flexibility through programmable routing logic that can adapt to different object types and destinations.
Data Source
AI summary
An object processing system is disclosed that includes a plurality of track sections, and a plurality of remotely actuatable carriers for controlled movement along at least portions of the plurality of track sections, wherein each of the remotely controllable carriers is adapted to support and transport an object processing bin.