Mobile Matrix Carriers for High-Throughput Object Routing
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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, leading to increased costs and limited throughput in handling objects of varying sizes and weights.
Innovation Solution
The system employs a network of track sections with remotely controllable carriers that can move in orthogonal directions without rotating, allowing for flexible and efficient transportation of objects between multiple points within a grid-like track system, reducing the need for multiple bins and minimizing mechanical complexity.
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 object types and destinations, but the physical space, capital costs, and operating costs increase significantly
Solution Approach 1:
The system replaces static collection bins with dynamic, mobile robots that can move throughout the workspace. Instead of having fixed destinations for each object type, robots dynamically transport objects to appropriate locations based on real-time requirements, eliminating the need for dedicated space for each object category.
Solution Approach 2:
Mobile robots serve multiple functions: they transport objects, navigate autonomously, interact with conveyors, and adapt to different object types. A single robot can handle various object categories and deliver to multiple destinations, replacing the need for specialized collection bins for each object type.
2Adaptability or versatility
If human workers manually sort objects to collection bins, then the system can handle diverse object types, but the throughput is limited by worker speed and the number of diverts is constrained by worker reach
Solution Approach 1:
The system replaces human workers with autonomous mobile robots equipped with sensors and navigation systems. These robots can process objects at higher speeds without fatigue and access any location within the workspace, eliminating the reach limitations of human workers while maintaining high throughput.
Solution Approach 2:
Mobile robots autonomously navigate, identify objects, determine destinations, and transport items without human intervention. The system self-manages the sortation process through automated decision-making and execution, eliminating dependency on human worker availability and speed.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput increases, but the mechanical complexity and cost per divert increase due to requiring an actuator for every divert
Solution Approach 1:
The system extracts the actuation function from fixed conveyor locations and relocates it to mobile robots. Instead of having actuators embedded in the conveyor structure at each divert point, the robots carry their own propulsion and manipulation mechanisms, eliminating the need for complex fixed infrastructure.
Solution Approach 2:
Mobile robots serve as intermediaries between the induction conveyor and final destinations. They receive objects from the conveyor and autonomously transport them to target locations, replacing the need for complex mechanical divert mechanisms at each potential destination point.
4Device complexity
If the system uses fixed sequences of operations with inflexible routing, then the control logic is simpler, but the system cannot accommodate dynamic environments or varied object processing requirements
Solution Approach 1:
The system uses dynamic routing where mobile robots can change their paths and destinations in real-time based on object characteristics, destination availability, and system state. This replaces fixed operational sequences with adaptive, flexible routing logic that responds to current conditions.
Solution Approach 2:
The system performs preliminary object identification and destination determination using sensors and vision systems before physical transport begins. This allows the control system to plan optimal routes and coordinate robot movements in advance, managing complexity through proactive decision-making rather than reactive adjustments.
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.