Pivoting Wheel Carrier for Fast Direction Changes in Sortation
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Solution Overview
Problem
Current object processing systems, particularly in distribution centers, face inefficiencies and inflexibilities due to the need for a large number of collection bins, which increases physical space, capital, and operating costs. These systems struggle to efficiently sort and redirect objects of varying sizes and weights into appropriate collection bins.
Innovation Solution
An automated carrier system with pivotally mounted wheel assemblies allows for movement in two orthogonal directions without rotating the carrier. This system includes a base structure with wheels mounted to motors, enabling the carrier to change direction efficiently and handle objects of different sizes and weights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to sort all objects to all destinations at once, then the sortation capacity and number of diverts increase, but the physical space requirements, capital costs, and operating costs increase significantly
Solution Approach 1:
The sortation process is divided into multiple passes, with each pass handling a subset of destinations. Objects are sorted in stages rather than all at once, allowing the system to achieve high sortation capacity with a limited number of physical bins at any given time.
Solution Approach 2:
The system dynamically reconfigures bin assignments between passes. Collection bins are reassigned to different destination groups in subsequent passes, allowing the same physical bins to serve multiple destinations over time, thereby reducing the total number of bins needed.
2Adaptability or versatility
If human workers manually sort objects to collection bins, then flexibility in handling various object types is maintained, but system throughput is limited by worker speed
Solution Approach 1:
The system uses automated scanning and identification to determine object destinations, with objects being automatically directed to the correct bins. This reduces reliance on human decision-making speed while maintaining flexibility through programmable sortation logic.
Solution Approach 2:
The sortation system is designed to handle multiple object types and destination configurations through software control. The same physical infrastructure can be reconfigured via software to accommodate different sortation requirements, providing both automation speed and adaptive flexibility.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput increases, but the system requires objects to have visible identifying codes and follows an inflexible sequence of operations
Solution Approach 1:
The system allows for dynamic sequencing of operations across multiple passes. Unlike fixed-sequence recirculating conveyors, this system can adapt the order in which destination groups are serviced based on object flow patterns and bin availability, providing operational flexibility while maintaining automated throughput.
4Ease of operation
If the carrier rotates to change direction, then directional control is achieved, but the sorting process becomes slower and system throughput decreases
Solution Approach 1:
The carrier's directional control is segmented into independent wheel assemblies rather than requiring rotation of the entire carrier body. Each wheel assembly can be steered independently to change direction, allowing for faster directional changes without the inertia and time penalties of rotating the entire carrier.
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
The automated carrier system enhances system throughput, reduces the number of required collection bins, and decreases operational costs by enabling efficient sorting and redirection of objects within dynamic environments.
Implementation Method 1
at least two wheels mounted to at least two motors
Implementation Method 2
the at least two wheel assemblies being pivotally supported on the base structure for pivoting movement from a first position to a second position to effect a change in direction of movement of the carrier
Data Source
AI summary
An automated carrier system is disclosed for moving objects to be processed. The automated carrier system includes a base structure of a carrier on which an object may be supported, and at least two wheels mounted to at least two motors to provide at least two wheel assemblies, the at least two wheel assemblies being pivotally supported on the base structure for pivoting movement from a first position to a second position to effect a change in direction of movement of the carrier.