Parcel Processing With Dynamic Bin Assignment and Robotic Sorting
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Solution Overview
Problem
Existing parcel sortation systems are inefficient and costly, requiring significant human labor, large numbers of collection bins, and inflexible operation, with mechanical complexity and high costs per divert, and are unable to handle varying parcel sizes and weights effectively.
Innovation Solution
A processing system that includes a perception system for identifying parcels and a primary transport system to direct them to specific processing locations based on perception data, using a robotic arm and conveyors to automate the sorting process, allowing dynamic assignment of parcels to bins and reducing the need for fixed collection bins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual sorting with human workers is used, then flexibility in handling various parcel types is maintained, but labor costs and processing time increase significantly
Solution Approach 1:
The patent replaces manual mechanical sorting operations with an automated robotic system that uses computer vision (perception system) to identify parcels and a robotic arm to manipulate them. This substitution maintains flexibility in handling various parcel types while dramatically increasing processing speed and reducing labor costs.
Solution Approach 2:
The system enables parcels to be automatically identified and routed without human intervention. The perception system autonomously detects parcel characteristics, determines destination bins, and the robotic arm autonomously places parcels, creating a self-service sorting mechanism that improves both efficiency and flexibility.
2Productivity
If a large number of fixed collection bins are used to handle all parcel types, then all parcels can be sorted simultaneously, but space requirements and system complexity increase
Solution Approach 1:
The patent implements dynamic bin assignment where the destination bin for each parcel is determined in real-time based on perception data about the parcel's destination. Instead of having fixed, predetermined bin assignments, the system dynamically routes parcels to appropriate bins, reducing the total number of bins needed while maintaining simultaneous sorting capability.
Solution Approach 2:
The robotic arm and perception system serve multiple functions: identifying parcels, determining destinations, manipulating parcels of various sizes and weights, and routing them to different bins. This multi-functionality allows the system to handle diverse parcel types with fewer specialized components, reducing overall system complexity.
3Ease of operation
If fixed collection bins are used for each destination, then parcel routing is simplified, but space usage efficiency decreases
Solution Approach 1:
The system uses dynamic bin assignment where the same physical bin can serve multiple destinations at different times. The perception system identifies parcel destinations and the control system dynamically assigns bins based on current workload and destination requirements, simplifying routing logic while maximizing space utilization.
Solution Approach 2:
The system changes the operational parameters of bins dynamically - a bin's assigned destination is not fixed but can change based on real-time conditions. This parameter change allows the same physical space to serve multiple purposes, improving space efficiency while maintaining simple parcel routing through software-based destination assignment.
4Reliability
If conventional sortation systems are used, then infrastructure requirements are met, but capital and operating costs remain high
Solution Approach 1:
The patent replaces expensive mechanical sortation infrastructure with a more cost-effective robotic system. Instead of dedicated mechanical conveyors and divert mechanisms for each destination, the system uses a single robotic arm with perception capabilities to handle sorting, significantly reducing capital costs and operating expenses per divert.
Solution Approach 2:
The robotic arm serves as a universal sorting mechanism that can handle multiple destinations and parcel types with a single device. This multi-functional approach eliminates the need for multiple specialized mechanical sortation systems, reducing both capital investment and per-unit operating costs while maintaining reliable infrastructure capability.
Data Source
AI summary
A processing system is disclosed for processing objects. The processing system includes a perception system for providing perception data regarding an object, and a primary transport system for providing transport of the object along a primary direction toward a processing location that is identified based on the perception data.