Dynamic Parcel Singulation With Addressable Rollers and Trajectory Control
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Solution Overview
Problem
Existing sortation systems lack flexibility and precision in directing parcels, leading to inefficiencies and potential collisions, especially when handling varying parcel sizes and orientations.
Innovation Solution
An automated singulation system using independently-addressable conveying elements, such as rollers, with real-time monitoring and control systems to dynamically adjust parcel trajectories and conveyance paths based on sensor data, ensuring precise and collision-free sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional sortation systems use fixed conveyance paths and non-addressable rollers, then the system structure is simpler, but the flexibility and precision in directing parcels of varying sizes and orientations deteriorates
Solution Approach 1:
The conveyor system is divided into multiple independently-addressable roller elements that can be individually controlled. Each roller can be independently activated or deactivated based on real-time parcel characteristics, enabling precise directional control without requiring a completely complex reconfigurable structure.
Solution Approach 2:
The system transitions from fixed, static conveyance paths to dynamic, programmable roller control. The rollers can change their operational state in real-time based on sensor feedback and priority queue data, allowing the same physical structure to adapt to varying parcel sizes and orientations dynamically.
2Manufacturing precision
If sortation systems lack real-time monitoring and dynamic control, then the system is simpler to operate, but collision risk and sorting precision deteriorate
Solution Approach 1:
Sensor systems continuously monitor parcel position, velocity, and trajectory in real-time, feeding this data back to the control system. This feedback loop enables dynamic adjustment of roller activation patterns to maintain precise sorting while preventing collisions between parcels of varying sizes.
Solution Approach 2:
The system replaces complex mechanical sorting mechanisms with programmable roller control based on real-time sensor data. Instead of physically complex adjustable guides and diverters, the solution uses software-controlled roller activation patterns to achieve precise parcel directing.
3Reliability
If parcels are processed without priority queuing and trajectory generation, then the processing speed is faster, but collision risk and sorting accuracy deteriorate
Solution Approach 1:
The system generates priority queues and trajectories in advance based on predicted parcel flow patterns. By pre-calculating optimal roller activation sequences and parcel routing paths before conflicts occur, the system ensures collision-free operation without requiring real-time reaction delays.
Solution Approach 2:
The priority queue system continuously processes parcel data and generates trajectories without interruption. This continuous operation maintains high throughput while ensuring that collision prevention measures are always in effect, as the system never stops to recalculate routes.
Data Source
AI summary
An automated sortation system includes infeed and outfeed conveyors, a singulator including an array of a plurality of independently-addressable rollers, a monitor system, and a control system. Based on input from one or more sensors of the monitor system and/or status information of one or more of the conveyors and rollers, real-time parcel status data is generated of parcels conveyed within the system; the plurality of parcels are prioritized within a priority queue based on the real-time parcel status data; trajectories are generated for the parcels; and the rollers are dynamically controlled to form dynamically changing conveyance vector fields. A cycle including real-time sensing and tracking, generating and updating parcel status data, generating and updating the priority queue, determining and updating the parcel trajectories, and dynamically controlling the singulator is repeated with data from various operations being fed back to inform and update other operations.