Real-Time Object Processing Analytics for Conveyor Coordination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional object processing systems face inefficiencies in time and resource utilization due to the separation of automated transport and manual processing tasks, limiting the speed and efficiency of handling a large number of objects.
Innovation Solution
An analytics system that integrates real-time data collection, aggregation, and display for object processing systems, utilizing programmable motion devices and conveyor control to optimize the processing of objects independently, with video data tagging and integration with warehouse management systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional object processing systems separate automated transport and manual processing tasks, then the system can be simpler to operate and maintain, but the processing speed and efficiency are limited
Solution Approach 1:
The patent merges automated transport systems with automated processing systems into an integrated AS/RS where both functions are automated. The system combines tote transport by automated conveyors with automated item picking and packing operations, eliminating the need for manual processing while maintaining high processing speeds through coordination between transport and processing modules.
2Ease of operation
If conventional systems use totes brought to people for processing, then the person can stand in one place and process items, but the time and resources required to move totes increase
Solution Approach 1:
The patent implements dynamic positioning where the automated conveyors and processing systems continuously adjust their operations based on real-time inventory levels and processing requirements. The system dynamically routes totes to processing stations and adjusts conveyor speeds to optimize the balance between tote movement time and processing speed, reducing overall time loss.
Solution Approach 2:
The system maintains continuous operation by keeping conveyors and processing stations constantly active. The automated system ensures that totes are continuously moved through the pipeline without idle time, and processing operations continue without interruption as long as inventory is available, maximizing useful action and minimizing time loss.
3Productivity
If automated transport systems move totes independently, then the transport function is optimized, but the overall system coordination becomes more complex
Solution Approach 1:
The patent implements feedback mechanisms where sensors monitor tote position, inventory levels, and processing status in real-time. This feedback is fed to the central control system which automatically adjusts conveyor speeds, routing decisions, and processing priorities to maintain optimal coordination between independent transport and processing modules, reducing coordination complexity through automated response.
Solution Approach 2:
The system employs universal control modules and standardized communication protocols that can manage multiple independent functions (transport, processing, inventory monitoring) through a common control framework. This multi-functionality reduces the need for separate complex coordination systems by using unified control logic across all modules.
Data Source
AI summary
An analytics system is disclosed for providing real time analytical data regarding operational characteristics of a plurality of object processing systems that process objects. The analytics system includes a communication system for accessing the warehouse management system and for obtaining object specific data, a data collection system for receiving real time data regarding processing at each of the plurality of object processing systems, each of the plurality of object processing systems including a programmable motion device that is programmed to process objects independent of other of the plurality of processing systems, an integration system for integrating the real time data with the object assignment data, and a graphic display system for displaying the real time data as associated with the assignment data.