Multi-Object Put Wall Carriers for High-Density Sortation
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Solution Overview
Problem
Current object processing systems are inefficient in handling a variety of objects of different sizes and weights, requiring significant human labor and resulting in limited throughput and increased operational costs.
Innovation Solution
An object processing system with an induction station and a carrier system that includes independently actuatable transfer systems capable of moving multiple objects simultaneously in horizontal and vertical directions to designated destinations, optimizing throughput and reducing operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human personnel manually sort objects one at a time into bins, then flexibility in handling various objects is maintained, but throughput is limited and operational costs increase
Solution Approach 1:
The system divides objects into batches and processes them in groups rather than individually. The carrier system segments the sorting process by holding multiple objects simultaneously and delivering them to different destination locations in a coordinated sequence, thereby increasing throughput while maintaining flexibility.
Solution Approach 2:
The system transitions from one-dimensional sequential sorting (one object at a time) to multi-dimensional parallel processing by arranging destination locations in a three-dimensional array and using carriers that can deliver to multiple locations simultaneously across different spatial dimensions.
2Productivity
If a large number of collection bins are arranged within reach of workers, then all object types can be sorted simultaneously, but the physical space required and device complexity increase
Solution Approach 1:
The system arranges destination locations in a three-dimensional array (multiple levels vertically and horizontally) rather than spreading bins out in a single plane. This vertical stacking allows many more destination locations to be accessed within a compact footprint, increasing the number of diverts without proportionally increasing physical space or complexity.
Solution Approach 2:
The carrier system serves multiple functions: it transports objects horizontally, vertically, and diagonally to various destination locations; it can hold and deliver multiple objects simultaneously; and it can be reconfigured to handle different sorting patterns, thereby achieving high productivity with a single multi-functional device rather than multiple specialized bins.
3Productivity
If objects are processed in a fixed sequential manner through induction and sorting stations, then system control is simplified, but system downtime increases and efficiency decreases
Solution Approach 1:
The carrier system maintains continuous operation by eliminating idle waiting time. While carriers are delivering objects to distant destination locations, the induction station continuously feeds new objects onto carriers, and other carriers are already en route to or returning from their destinations. This overlapping of operations ensures that no component of the system is idle, maintaining continuous useful action and reducing system downtime.
Solution Approach 2:
The system performs preliminary actions by pre-positioning carriers and pre-coordinating their routes before objects need to be delivered. Carriers are prepared and dispatched in advance, and destination locations are pre-assigned to carriers based on the sorting algorithm, allowing smooth continuous operation without pauses for decision-making or reconfiguration during the sorting process.
Data Source
AI summary
An object processing system is disclosed that includes an object induction station at which objects are provided for processing, said object induction station including an in-feed conveyor system and at least one perception unit for providing perception data regarding an object, a plurality of destination locations that are arranged in a vertically and horizontally extending array of destination locations, and a carrier system for receiving at least two objects from the in-feed conveyor system of the object induction station and for moving the at least two objects together toward two different destination locations of the plurality of destination locations, the carrier system being adapted for movement in horizontal and vertical directions and including a set of at least two independently actuatable transfer systems such that the at least two objects may be deposited into each of the two different destination locations.