Perception Transfer Sortation for Accurate Robotic Object Routing

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Solution Overview

Problem

Current object processing systems face inefficiencies in handling objects of varying sizes and weights, relying heavily on human labor and struggling with incorrect manifest data, leading to challenges in routing objects to appropriate destinations.

Innovation Solution

A dynamic movement analytics system utilizing a programmable motion device with an end-effector and perception transfer system, equipped with optical perception units and weight detection sensors, to provide real-time data on object weight, shape, and identity, enabling precise routing to destination containers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If human labor is used for sortation, then flexibility in handling objects of varying sizes and weights is improved, but productivity and processing speed deteriorate

Engineering Contradiction:

Improvehandling flexibilityVSAvoidprocessing speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces human mechanical sortation operations with an automated robotic system that uses perception systems (cameras, sensors) to identify objects and robotic end-effectors to manipulate them. This substitution maintains flexibility through programmable control while dramatically increasing processing speed and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables objects to be automatically identified and routed based on their own characteristics (barcodes, RFID tags, visual features) without human intervention. The robotic system autonomously performs the complete sortation process from perception to placement, eliminating the need for human operators to manually handle each object.

Inventive Principle:

Principle #25Self-service

2Productivity

If automated processing systems are implemented, then productivity is improved, but reliability deteriorates due to incorrect manifest data and unknown objects

Engineering Contradiction:

Improveprocessing efficiencyVSAvoidrouting accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements a feedback mechanism where perception systems continuously scan and verify object characteristics during processing. When discrepancies are detected between manifest data and actual object properties, the system can flag exceptions, request manual verification, or dynamically adjust routing decisions, thereby maintaining high reliability even with imperfect input data.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary perception and verification of object characteristics before final routing decisions are made. By scanning and validating object data upfront, the system can identify and handle potential issues (incorrect manifests, unknown objects) before they cause routing errors, ensuring more reliable processing.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If strict data verification is applied, then routing accuracy is improved, but loss of time increases due to rejection of objects with inconsistent data

Engineering Contradiction:

Improverouting accuracyVSAvoidprocessing delay

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent applies partial verification by prioritizing verification of critical routing attributes while allowing non-critical attributes to pass through with less scrutiny. This selective approach maintains routing accuracy for essential destinations while minimizing processing delays by not requiring exhaustive verification of all object characteristics.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

By performing data verification and exception handling in advance, the system prevents bottlenecks during critical routing operations. Objects with data issues are identified and segregated early in the process, allowing the main throughput to continue uninterrupted while exceptions are handled separately.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances processing efficiency by reducing human intervention, accurately routing objects to correct destinations, and handling objects of diverse sizes and weights with improved throughput and reduced errors.

Implementation Method 1

at least one optical perception unit

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

at least one weight detection sensor

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS12539601B2Systems and methods for providing detection via transfer of objects

Publication Date: 2026.02.03 BERKSHIRE GREY OPERATING CO INC

AI summary

A dynamic movement analytics system is disclosed that includes a programmable motion device including an end-effector, and a perception transfer system for receiving an object from the end-effector and for moving the object toward any of a plurality of destination containers. The perception transfer system includes at least one perception system for providing perception data regarding any of weight, shape, pose authority, position authority or identity information regarding the object as it is moved toward the any of the plurality of destination containers.