Multi-Object Shuttle Carrier for Automated Object Sortation
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Solution Overview
Problem
Current object processing systems are inefficient and labor-intensive, struggling to handle a variety of object sizes, weights, and shapes while maintaining high throughput and cost-effectiveness.
Innovation Solution
A carrier system with a carrier body having multiple containment areas, a motion actuator for movement, and an ejection actuation system to deposit objects into specific destination locations, controlled by a computer processing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional AS/RS with totes are used, then objects can be stored and retrieved, but the system requires human workers to pick items manually and re-induct totes, limiting throughput and efficiency
Solution Approach 1:
The robotic system performs pick-and-place operations autonomously without human intervention. The robot retrieves totes, picks items, places them in destination bins, and returns totes to the AS/RS automatically, making the system self-sufficient and eliminating manual labor bottlenecks
Solution Approach 2:
Manual mechanical operations by human workers are replaced with an automated robotic system. The robot manipulates totes and items through programmed sequences, substituting human physical labor with automated mechanical control to increase throughput and consistency
2Adaptability or versatility
If human workers perform sortation manually, then objects can be routed to collection bins, but the system has limits on throughput and number of diverts within efficient reach
Solution Approach 1:
The system transitions from horizontal reach constraints to vertical stacking capability. Multiple layers of collection bins can be accessed vertically by the robotic arm, dramatically increasing the number of diverts without expanding horizontal workspace, thereby improving both adaptability and throughput
3Ease of operation
If bins are arranged within efficient reach of human workers, then sortation can be performed manually, but the number of diverts is limited and throughput cannot be increased
Solution Approach 1:
Collection bins are arranged in vertical stacks that the robotic system can access through vertical movement. This multi-layer configuration expands the number of diverts from a limited horizontal reach to numerous vertical positions, maintaining ease of automated operation while dramatically increasing system capacity
4Measurement precision
If a disorganized stream of input objects is singulated into isolated objects, then each object can be identified and routed, but the sequence of operations is inflexible and reduces efficiency
Solution Approach 1:
The system dynamically adapts its processing sequence based on real-time identification results and destination requirements. Rather than following a fixed singulation sequence, the robot can adjust pick order, tote selection, and placement timing to optimize throughput while maintaining accurate object identification and routing
Data Source
AI summary
A carrier system is disclosed for use in an object processing system. The carrier system includes a carrier body including a plurality of containment areas for respectively receiving a plurality of objects at a loading station, a motion actuator for moving the carrier body from the loading station to a distribution area, and an ejection actuation system for actuating the carrier body to deposit each of the plurality of objects into different destination locations.