Parcel Processing With Dynamic Bin Reassignment for Flexible Sortation
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Solution Overview
Problem
Current parcel sortation systems are inefficient and costly due to reliance on human labor, require a large number of collection bins, and have limitations in handling objects of varying sizes and weights, with high mechanical complexity and costs associated with automated diverts.
Innovation Solution
An automated processing system that includes an input system, singulation system, and identification system, utilizing conveyors, sensors, and a robot arm to identify and sort parcels to specific destinations, with dynamic bin assignment and flexible conveyor systems to optimize throughput, space usage, and reduce capital and operating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If automated systems use a large number of collection bins to handle diverse objects, then sortation capability is improved, but space requirements and capital costs increase
Solution Approach 1:
The system dynamically reconfigures the number and assignment of collection bins based on real-time sortation needs. The controller can activate or deactivate bins and reassign destinations without physical reconfiguration, allowing the system to handle diverse object types with a reduced physical footprint of bins.
Solution Approach 2:
Collection bins serve multiple destinations and object types through dynamic reassignment. A single physical bin can be assigned to different destinations at different times, allowing the same hardware resource to fulfill multiple sortation functions, thereby reducing the total number of bins needed.
2Adaptability or versatility
If automated diverts are added to handle more destinations, then sortation flexibility is improved, but mechanical complexity and costs increase
Solution Approach 1:
The system extracts the complexity of destination management from the mechanical divert structure. Instead of adding mechanical complexity to handle more destinations, the patent uses a controller that software-manages bin assignments, separating the complexity into the control system rather than the mechanical system.
Solution Approach 2:
The patent replaces complex mechanical divert structures with a simplified system using controllers and software-based bin assignment. The mechanical system remains relatively simple while the controller dynamically manages which bins receive objects for which destinations, substituting mechanical complexity with computational logic.
3Device complexity
If fixed sequence operations are used for sortation, then process control is simplified, but productivity and efficiency decrease
Solution Approach 1:
The system transitions from fixed sequence operations to dynamic, adaptive sequencing. The controller can adjust the sortation sequence based on real-time conditions, object types being processed, and bin availability, optimizing throughput without sacrificing control. The process control remains manageable through software while achieving higher productivity.
4Extent of automation
If recirculating conveyors with tilt trays are used, then automated sortation is improved, but difficulty in locating and retrieving specific objects increases
Solution Approach 1:
The system implements feedback mechanisms where the controller tracks which objects have been sorted to which bins. This feedback allows the system to monitor object locations and provide real-time information about bin contents and sortation status, making it easier to locate and retrieve specific objects while maintaining automated sortation.
Data Source
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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.