Parallel Robot Singulators for High-Throughput Parcel Conveying
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conveyor systems with single robot singulators face throughput limitations when handling large volumes of parcels, leading to incomplete singulation and interference with downstream processing.
Innovation Solution
A conveyor system utilizing multiple robot singulators and a vision and control subsystem that includes cameras and robots working in parallel to transfer parcels from a bulk flow to a singulated stream, allowing for simultaneous operation and improved throughput by selecting the most available robot and optimizing parcel transfer and indexing.
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 remains simple, but the throughput is limited and cannot handle large parcel volumes
Solution Approach 1:
The system divides the singulation task into multiple parallel robot singulators (first robot singulator and second robot singulator) that independently transfer parcels from the bulk flow to the singulated stream. This segmentation allows simultaneous operation of multiple robots, increasing overall throughput while each robot maintains relatively simple individual structure
Solution Approach 2:
Multiple robot singulators are merged into a single integrated system with shared conveyor infrastructure (pick conveyor and place conveyor) and coordinated control. The robots work in parallel but are unified under common system architecture, achieving high throughput without proportionally increasing overall system complexity
2Productivity
If mechanical singulation systems are used to handle bulk flow, then the system can process parcels, but during surge volumes the mechanical systems are overwhelmed and parcels are not fully singulated
Solution Approach 1:
The system employs dynamic robot control where the vision and control subsystem continuously monitors parcel positions and dynamically assigns tasks to available robots. This dynamic allocation allows the system to adapt to surge volumes by optimizing robot utilization and maintaining complete singulation even at high throughput rates
Solution Approach 2:
The vision and control subsystem provides real-time feedback on parcel locations and robot status, enabling continuous adjustment of transfer operations. This feedback mechanism ensures that all parcels are properly singulated by monitoring the bulk flow and directing robots to transfer parcels until the bulk flow is depleted, maintaining reliability during volume surges
3Productivity
If a single robot transfers parcels iteratively from pick conveyor to place conveyor, then the system structure is simple, but cycle time limitations prevent necessary throughput for large parcel volumes
Solution Approach 1:
Multiple robot singulators perform periodic transfer actions in parallel, with each robot operating on its own cycle while contributing to the overall throughput. The system coordinates these periodic actions to maximize parcel transfer rate, effectively reducing the time loss associated with iterative transfers by having multiple robots operate simultaneously
Data Source
AI summary
A conveyor system includes: a pick conveyor defining a picking area for a bulk flow of parcels; a place conveyor positioned downstream of the picking area; a first robot singulator and a second robot singulator, which work in parallel to transfer parcels within a picking area of the pick conveyor to the place conveyor; and a vision and control subsystem that communicates instructions to control operation of some or all of the foregoing components. The vision and control subsystem includes a target camera for acquiring one or more images of the picking area, which are processed within the system to determine the location of parcels positioned within the picking area. The vision and control subsystem can execute one or more routines or subroutines to reduce system downtime associated with image acquisition and processing, parcel transfer to the place conveyor, and/or parcel delivery to the picking area.