Mobile Matrix Carriers With Orthogonal Routing for Object Sortation
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Solution Overview
Problem
Current object processing systems, such as sortation and automated storage and retrieval 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 the number of divert locations.
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
1Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then automation extent is improved, but device complexity increases due to actuators required for every divert location
Solution Approach 1:
A single robotic manipulator with vision guidance performs sortation to multiple collection bins, replacing the need for dedicated actuators at each divert location. The robot can service many bins sequentially, making one device perform multiple sortation functions that previously required many separate actuators.
Solution Approach 2:
The system uses vision systems (cameras and scanners) to capture optical information about objects, creating a digital representation that guides the robotic manipulator. This allows the system to identify and sort objects based on their visual characteristics without physical contact during identification.
2Adaptability or versatility
If a large number of collection bins are deployed to handle diverse object types, then adaptability is improved, but area occupied increases significantly
Solution Approach 1:
The system arranges collection bins in a three-dimensional workspace around the robotic manipulator, utilizing vertical space and radial positioning rather than only linear horizontal arrangement. This allows more bins to be accessed within a compact footprint by the robot's multi-axis movement capability.
Solution Approach 2:
The system uses software-configurable bin assignments that can be dynamically changed without physical reconfiguration. The robotic manipulator can adapt its motion paths and sorting logic in real-time based on changing sortation requirements, providing flexibility without adding physical infrastructure.
3Device complexity
If human workers perform manual sortation, then device complexity is reduced, but productivity is limited by human sorting speed
Solution Approach 1:
The system replaces human manual sortation with an automated robotic manipulator guided by vision systems and control software. This substitution eliminates human speed limitations while maintaining relatively simple mechanical components, achieving high throughput through automation rather than complex mechanical sortation devices.
Solution Approach 2:
The robotic system autonomously identifies objects using vision sensors, determines their destinations based on programmed logic, and executes sortation without continuous human intervention. The system serves itself by making independent decisions about object routing, freeing operators from repetitive manual sorting tasks.
4Extent of automation
If bomb-bay style recirculating conveyors with tray door mechanisms are used, then automation is improved, but device complexity increases due to actuator requirements at each divert
Solution Approach 1:
The patent removes the complex actuator mechanisms from each divert location and extracts the sortation decision-making function to a centralized vision and control system. The robotic manipulator uses its end effector to directly place objects into bins, eliminating the need for intermediate tray door mechanisms and their associated actuators.
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.