Programmable Motion Sortation With Dynamic Intermediate Stations
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Solution Overview
Problem
Current distribution center sorting systems rely heavily on human labor, are inflexible, and require a large number of collection bins, leading to inefficiencies and high costs due to mechanical complexity and space requirements, with partially automated solutions failing to address the limitations of total system bins and throughput.
Innovation Solution
A programmable motion device-based system that acquires objects, identifies indicia, and dynamically assigns intermediate stations to destination locations using robotic manipulators and perception units, allowing for flexible sorting and reduced manual labor, thereby optimizing system throughput and reducing space and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human workers perform sortation manually, then labor flexibility is maintained, but throughput is limited and operating costs increase
Solution Approach 1:
The patent replaces manual human labor with an automated robotic system that uses vision guidance and programmable motion devices to perform sortation. The robotic system can operate continuously at high speeds without fatigue, dramatically increasing throughput while reducing dependency on human workers. The system uses automated detection of object features and programmable decision-making to replace human cognitive and physical processes in sortation.
Solution Approach 2:
The robotic system is designed to autonomously perform the entire sortation process without human intervention. The vision system automatically detects objects, the control system makes sorting decisions, and the robotic manipulator executes the sortation. This self-service capability eliminates the need for human workers to manually handle each object, thereby increasing throughput while reducing labor costs.
2Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then sortation capacity increases, but physical space and capital costs increase
Solution Approach 1:
The patent implements dynamic bin assignment where the mapping between objects and collection bins is not fixed but can change over time. The system can reassign bins to different object types based on current sortation needs, allowing the same physical bins to serve multiple purposes throughout the day. This dynamic flexibility enables the system to handle diverse object types with fewer physical bins, reducing space requirements while maintaining high sortation capacity.
Solution Approach 2:
The collection bins are designed to be multi-functional, serving different object types at different times rather than being dedicated to specific object categories. The robotic system can direct different types of objects to the same bin depending on the current sortation task, effectively multiplying the utility of each physical bin. This universality allows the system to achieve high adaptability with a reduced number of bins, thereby reducing physical space requirements.
3Extent of automation
If tilt-tray or bomb-bay conveyors with actuators are used for each divert, then automated sortation is achieved, but mechanical complexity and cost per divert increase
Solution Approach 1:
The patent extracts the actuation mechanism from each individual divert location and consolidates it into a centralized robotic manipulator. Instead of having multiple independent actuators distributed throughout the sortation system, a single robotic arm with programmable motion control performs all divert operations. This extraction of the actuation function reduces mechanical complexity at each divert point while maintaining full automation capability through the centralized robotic system.
Solution Approach 2:
The robotic manipulator serves as a universal actuator that can perform sortation to multiple different collection bins using the same physical mechanism. Rather than requiring dedicated actuators for each bin, the single robotic arm can dynamically position and deposit objects into any target bin within its workspace. This multi-functionality dramatically reduces the total number of actuators needed, thereby reducing mechanical complexity and cost per divert.
4Device complexity
If manual sortation cells are used to increase number of diverts, then system installation cost decreases, but operating costs increase due to multiple worker teams
Solution Approach 1:
The patent replaces multiple manual sortation cells with a single automated robotic system that can perform the work of multiple workers. The robotic manipulator with vision guidance can autonomously sort objects to numerous collection bins without requiring human intervention at each station. This substitution eliminates the need to staff multiple parallel sortation cells, thereby reducing operating costs while maintaining or increasing the number of effective diverts through automation.
Data Source
AI summary
A method of processing objects is disclosed using a programmable motion device. The method includes the steps of acquiring an object from a plurality of mixed objects at an input area, perceiving identifying indicia in connection with the object, assigning an intermediate station to a destination location for the object responsive to the identifying indicia in connection with the object, and moving the acquired object toward the intermediate station.