Portal Pick-and-Place Robots for Compact High-Capacity Bulk Sorting
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Solution Overview
Problem
Existing sorter systems for handling objects in bulk occupy a large area and have limited capacity, requiring manual intervention for singulation and induction, and are inefficient in handling objects of various shapes and sizes.
Innovation Solution
A compact sorter system using a portal structure with multiple pick and place robots that can handle objects in 2D or 3D bulk, coordinating tasks to achieve high capacity and high packet density in destination bins, with a control system optimizing object placement based on size, shape, and destination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional conveyor-based sorter systems are used, then objects can be transported and sorted, but the system occupies a large area and requires manual intervention for singulation and induction
Solution Approach 1:
The patent combines multiple functions (singulation, induction, sorting, and placement) into a single integrated robotic system. The robotic manipulator performs both singulation of objects from bulk and their placement into destination bins, eliminating the need for separate manual operations and reducing overall system footprint.
Solution Approach 2:
The robotic manipulator is designed as a multi-functional device that can handle multiple tasks: it singulates objects from 3D bulk, transports them through 3D space, and places them into destination bins. This universal robot replaces multiple specialized mechanical components, reducing the area required for the sorting system.
2Productivity
If high capacity sorting is required, then more mechanical components are needed, but this increases the area occupied by the system
Solution Approach 1:
The patent transitions from 2D conveyor-based sorting to 3D robotic manipulator operations. The robotic manipulator moves objects in three-dimensional space, allowing multiple destination bins to be accessed from a compact footprint. This vertical and lateral utilization of space enables high capacity sorting without proportionally increasing the system's ground footprint.
Solution Approach 2:
The system uses a single robotic manipulator that can service multiple destination bins sequentially, effectively copying the function of multiple dedicated sorting mechanisms. The robot picks objects from a shared bulk supply and distributes them to various bins, replacing the need for multiple parallel conveyor lines and reducing overall system area.
3Productivity
If manual induction is used, then objects can be placed on the sorter, but this reduces productivity and increases operational complexity
Solution Approach 1:
The robotic manipulator performs self-service by automatically singulating objects from the bulk supply and inducing them onto the conveyor or directly into destination bins. The system uses sensors and control algorithms to autonomously identify, grasp, and position objects without human intervention, eliminating the need for complex manual induction mechanisms and improving productivity.
4Quantity of substance
If traditional tilt tray or tote sorter is used, then objects can be sorted to fixed positions, but this reduces packet density in destination bins and increases system area
Solution Approach 1:
The patent changes the operational parameters from fixed-position sorting to flexible 3D placement. The robotic manipulator can adapt its motion paths, grasp positions, and placement locations based on real-time conditions and bin fill levels. This dynamic parameter adjustment enables optimized packet density in destination bins while maintaining a compact system footprint.
Data Source
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AI summary
A sorter system for handling a stream of objects of various shapes and sizes in bulk, e.g. 3D bulk. A first feeder section transports the objects in a first transport direction to a portal structure carrying a plurality of gantry robots, e.g. 3-10 robots, which can move along the portal structure. The robots pick objects from the first feeder section and places the objects in destination bins, e.g. roller cages, arranged in two lines within reach of the robots. Preferably, the first feeder section, the portal structure and the destination bin lines are parallel. A scanner reads information on each object regarding a destination bin for each object. The robots are controlled to either place the objects directly in their destination bins or to park objects on an intermediate parking space, e.g. one or more feeder sections, e.g. comprising an additional feeder section transporting objects in opposite direction of the first transport direction. Such intermediate parking allows coordination between the robots to optimize a total handling capacity. Objects not picked from the first feeder section may be returned to a position upstream of the first feeder section. The robots preferably place the objects in the destination bins at the lowest point available for the object to provide a careful handling and a high packing density in the destination bins. Such system provides a high sorting capacity at a small area.