Multi-Robot Parcel Singulation for Higher Conveyor Throughput
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Solution Overview
Problem
Conveyor systems with a single robot singulator struggle to handle large parcel volumes efficiently due to cycle time limitations, leading to non-singulated parcels that interfere with subsequent processing.
Innovation Solution
A conveyor system with multiple robot singulators and a vision and control subsystem that communicates instructions to control the robots, allowing simultaneous parcel transfer and indexing, reducing downtime through a robot selection subroutine and selective image acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single robot singulator is used to transfer parcels from bulk flow to singulated stream, then the system structure is simple, but the productivity is insufficient to handle large parcel volumes
Solution Approach 1:
The system divides the single robot singulator into multiple parallel robot singulators (first robot singulator and second robot singulator), each handling a portion of the parcel flow. This segmentation increases the overall parcel throughput rate while maintaining manageable complexity through modular architecture
Solution Approach 2:
Multiple robot singulators perform the same function of transferring parcels from bulk flow to singulated stream simultaneously. This multi-functionality approach increases productivity by parallelizing the parcel transfer operation without requiring fundamentally different system components
2Productivity
If mechanical singulation systems are used to handle bulk flow, then the system can process parcels, but the system becomes overwhelmed during parcel volume surges and fails to fully singulate parcels
Solution Approach 1:
The system dynamically adapts to varying parcel volumes by utilizing multiple robot singulators that can operate in parallel. When parcel volume surges occur, the additional robots provide the necessary processing capacity to maintain complete singulation, preventing non-singulated parcels from interfering with downstream processing
3Productivity
If a single robot singulator operates with fixed cycle time, then the operation is simple to control, but the system experiences downtime that reduces overall throughput
Solution Approach 1:
Multiple robot singulators operate in parallel to eliminate idle time. While one robot is performing transfer operations, another can be positioned or preparing for the next parcel, ensuring continuous useful action and reducing system downtime that would otherwise reduce overall throughput
Data Source
AI summary
A conveyor system includes a first robot singulator, a second robot singulator, and a picking area from which parcels of a bulk flow of parcels can be engaged and transferred by the first robot singulator or the second robot singulator. The conveyor system further includes a first place conveyor positioned downstream of the picking area and configured to receive parcels transferred by the first robot singulator. The conveyor system further includes a second place conveyor positioned downstream of the picking area and the first place conveyor, the second place conveyor configured to receive parcels transferred by the second robot singulator and to receive parcels from the first place conveyor. In some embodiments, a buffering conveyor is positioned between the first place conveyor and the second place conveyor for regulating a rate at which parcels offloaded by the first place conveyor are transferred to the second place conveyor.