Multi-Arm Parcel Conveyor Layout for Accurate High-Throughput Induction
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Solution Overview
Problem
Dual arm robotic induction systems face challenges with poor placement accuracy, difficulty in configuring verification systems, and inadequate handling of exceptions due to structural and cost-related constraints, limiting their effectiveness in handling larger items and managing exceptions efficiently.
Innovation Solution
An automated robotic conveyance system with serialized conveyor belts and an exceptions handling area, where manipulators can work independently, identify exceptions, and verify placement accuracy, allowing for larger items to be handled within a smaller footprint by avoiding exceptions and ensuring high throughput and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dual arm induction systems are used to speed up workflow, then throughput is improved, but placement accuracy deteriorates
Solution Approach 1:
The system divides the induction workflow into separate pick and place areas for each robotic arm, with dedicated conveyors for each arm. This segmentation allows each arm to operate independently in its own zone, eliminating interference between arms and improving placement accuracy while maintaining high throughput through parallel operations.
2Device complexity
If dual arm induction systems are configured with single manual lane, then system complexity is reduced, but exception handling capability deteriorates
Solution Approach 1:
The system extracts exception handling from the robotic manipulation process by providing a dedicated exceptions area where items can be diverted without requiring manipulator intervention. This separates the exception handling function from the primary pick-and-place operation, allowing the system to maintain simplicity while improving adaptability to various exception scenarios.
3Productivity
If parallel flow systems with divided lanes are used, then throughput is improved, but footprint size increases
Solution Approach 1:
The system merges the pick and place operations into a more compact integrated layout where pick conveyors and place conveyors are closely coupled for each robotic arm. This consolidation reduces the overall footprint compared to fully parallel flow systems while maintaining high throughput through efficient space utilization and coordinated arm operations.
Data Source
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AI summary
A conveyance system includes an in-feed conveyor for conveying a high density flow of a plurality of parcels. The system further includes a first pick conveyor configured for being selectively activated and deactivated in order to space out the plurality of parcels and turn the high density flow into a low density flow of parcels. A second pick conveyor is in series with and downstream of the first pick conveyor. The system further includes a first place conveyor and a second place conveyor in series with and downstream of the first place conveyor. A first robot is configured for transferring parcels from the first pick conveyor to the first place conveyor. A second robot is configured for transferring parcels from the second pick conveyor to the second place conveyor. As such, robots each have their own dedicated workspace and do not interfere with each other.