Pivoting Wheel Mobile Carriers for Orthogonal Grid Sortation
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Solution Overview
Problem
Current object processing systems, such as sortation and automated storage and retrieval systems, face inefficiencies and inflexibilities due to the need for a large number of collection bins and high mechanical complexity, leading to increased costs and limited throughput in handling objects of varying sizes and weights.
Innovation Solution
An automated carrier system with pivotally mounted wheels allows for orthogonal movement on a track system, enabling efficient navigation and distribution of objects across a grid without requiring extensive reorientation of 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 automation extent is improved, but device complexity increases due to actuators required for each divert
Solution Approach 1:
The patent extracts the actuator mechanism from each individual divert location and replaces it with passive gravity-fed chutes. Objects are diverted by their physical trajectory and gravity rather than active mechanical tilting at each station, eliminating the need for numerous actuators while maintaining automated sortation capability
Solution Approach 2:
The patent replaces the mechanical tilt-tray actuation system with a gravity-based passive sortation system. Instead of using motorized actuators to tilt trays at each divert location, objects are routed through gravity-fed pathways and chutes that direct items to collection bins without active mechanical intervention at divert points
2Adaptability or versatility
If a large number of collection bins are deployed to handle diverse objects, then adaptability is improved, but area occupied increases significantly
Solution Approach 1:
The patent transitions from a linear horizontal arrangement of collection bins to a three-dimensional vertical stacking configuration. Multiple collection bins are stacked vertically at each divert location, allowing the system to handle a large number of different object types without proportionally increasing the horizontal footprint of the sortation system
Solution Approach 2:
The patent implements nested collection bins where smaller bins are placed inside larger bins or on top of each other in vertical stacks. This nesting arrangement maximizes the number of collection bins that can be accommodated within a compact spatial envelope, reducing the overall area required while maintaining high adaptability
3Adaptability or versatility
If discrete trays with actuators are used for each divert, then number of diverts is improved, but manufacturing cost increases due to high cost per divert
Solution Approach 1:
The patent replaces expensive, complex actuated tilt trays with simple, low-cost passive divert structures such as gravity chutes and fixed pathways. These simpler components are much cheaper to manufacture and install, reducing the cost per divert location while still enabling a large number of divert points throughout the system
Solution Approach 2:
The patent employs universal passive divert structures that can be replicated across multiple locations without requiring custom actuated mechanisms for each. The gravity-fed chutes and standardized pathways serve multiple divert functions simultaneously, reducing overall system cost while maintaining high adaptability to handle diverse object types
4Device complexity
If human workers perform manual sortation, then device complexity is reduced, but productivity is limited by worker speed
Solution Approach 1:
The patent incorporates preliminary automated identification and routing decisions before objects reach manual sortation points. Scanners and control systems pre-determine the destination of each object and prepare the appropriate divert pathways in advance, allowing human workers to focus solely on the physical placement action rather than decision-making, thereby maintaining simplicity while increasing throughput
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.