Pivoting Wheel Mobile Carriers for Grid-Based Object Sorting
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Solution Overview
Problem
Current object processing systems, such as sortation and storage systems, face inefficiencies and inflexibilities due to the need for a large number of collection bins and high mechanical complexity, which increases costs and limits throughput and divert capabilities.
Innovation Solution
An automated carrier system with pivotally mounted wheels allows for orthogonal movement on a track system, enabling efficient redirection and realignment without rotating the carrier, thus reducing the need for multiple bins and complex divert mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then objects can be automatically routed to predefined locations, but mechanical complexity increases due to actuators required for each divert
Solution Approach 1:
The patent removes the complex actuator mechanisms from each divert location and extracts only the essential function of routing objects. Instead of active tilt trays with motors, the system uses passive gravity-fed chutes and simple gates that redirect objects based on their destination, eliminating the need for powered actuators at each sortation point.
Solution Approach 2:
The invention replaces the mechanical actuator-based tilt tray system with a gravity-based passive diversion system. Objects are routed using gravity flow through chutes and simple mechanical gates rather than powered tilting mechanisms, substituting complex mechanical actuation with simpler gravitational forces.
2Adaptability or versatility
If a large number of collection bins are deployed to handle diverse object types, then sortation capability increases, but physical space requirements and capital costs increase
Solution Approach 1:
The patent implements collection bins that can be dynamically assigned to different destinations through software control rather than having dedicated bins for each destination. A single physical bin can serve multiple destinations at different times, allowing the system to handle diverse object types with fewer physical bins, thereby reducing space requirements while maintaining high sortation capability.
Solution Approach 2:
The system employs dynamic destination assignment where collection bin mappings are not fixed but can be reconfigured based on current sortation needs. This dynamic flexibility allows the same physical infrastructure to adapt to varying sortation requirements, maximizing the utilization of limited bin resources and reducing the total number of bins needed.
3Ease of operation
If fixed sequence operations are used in distribution centers, then process control is simplified, but system flexibility to accommodate varying objects is reduced
Solution Approach 1:
The patent introduces a software-based routing dimension that operates independently of the physical conveyor sequence. While objects move through the facility in a fixed physical path, the system dynamically assigns virtual routing instructions that determine which collection bin each object should be directed to, adding a layer of flexibility without disrupting the underlying fixed operational sequence.
Solution Approach 2:
The system maintains fixed physical operational parameters (conveyor paths, station locations) while dynamically changing the routing parameters (destination assignments, bin mappings). This separation allows the physical infrastructure to remain simple and controlled while the software parameters adapt to handle varying object types and sortation requirements.
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.