Recirculating Parcel Sortation With Dynamic Bin Assignment
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Solution Overview
Problem
Current parcel distribution systems are inefficient and inflexible, requiring large numbers of collection bins, significant physical space, and human labor for sorting and processing, which limits throughput and scalability.
Innovation Solution
A programmable motion device system that uses end effectors to identify and move objects to specific processing containers based on indicia, optimizing the use of input and output conveyance systems and reducing the need for multiple bin designs by using a central control system to manage object distribution and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of collection bins are used to sort all objects to all destinations at once, then the sorting capacity and throughput are improved, but the physical space requirements, investment costs, and operating costs increase significantly
Solution Approach 1:
The system dynamically reconfigures bin assignments and sorting destinations in real-time based on current workload, object types, and system state. Bins are not permanently dedicated to specific destinations but are dynamically assigned through the central control system, allowing the same physical bin to serve multiple destinations at different times, thereby reducing the total number of bins needed.
Solution Approach 2:
The patent introduces a time dimension to the sorting process by implementing multi-pass sorting where objects can be sorted in stages across different time periods. The recirculating conveyor system allows objects to pass through the sorting area multiple times, with different subsets of bins activated in different passes, effectively trading time for space.
2Measurement precision
If human workers continuously count items in bins to monitor volume, then inventory accuracy is maintained, but labor costs and operational complexity increase
Solution Approach 1:
The system implements self-monitoring capabilities where bins automatically track their own fill levels and inventory status through sensors and integrated control systems. Each bin can communicate its state to the central control system without requiring manual intervention, enabling automatic reassignment when bins reach capacity thresholds.
Solution Approach 2:
The central control system receives continuous feedback from bins regarding their fill status, object types, and readiness for collection. This feedback loop enables the system to automatically adjust sorting assignments, redistribute objects, and optimize bin utilization without human intervention, maintaining inventory accuracy through automated monitoring.
3Productivity
If parallel manual sortation cells are used to distribute objects, then sorting throughput is improved, but the system requires all cells to have the same collection bin designations, reducing flexibility
Solution Approach 1:
Each sorting cell in the parallel architecture is designed to be universal and multi-functional, capable of sorting to any destination bin in the system rather than being dedicated to a fixed set of destinations. The programmable control system allows any cell to be dynamically assigned to sort to any bin, enabling flexible workload distribution and optimizing throughput based on real-time conditions.
Data Source
AI summary
A method of processing objects using a programmable motion device is disclosed. The method includes the steps of providing an input conveyance system by which input bins of objects may be provided to a processing station that includes the programmable motion device that includes an end effector, perceiving at the processing station identifying indicia representative of an identity of a plurality of objects at an input area of the input conveyance system, grasping the an acquired object using the end effector, moving the acquired object toward an identified processing container using the programmable motion device, the identified processing container being associated with the identifying indicia and said identified processing container being provided as one of a plurality of processing containers at the processing station, and providing an output conveyance system in communication with the processing station, by which processing containers that contain processed objects may be provided.