Re-Circulating Processing Stations for Dynamic Parcel Sorting
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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 circulating homogeneous bins or containers.
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 sorting capacity increases, but physical space requirements and investment costs increase significantly
Solution Approach 1:
The system dynamically assigns collection bins to destinations based on real-time sorting needs rather than having fixed static assignments. The controller can reconfigure which bin receives objects for which destination, allowing the same physical bin to serve multiple destinations sequentially, thereby reducing the total number of bins needed at any one time.
Solution Approach 2:
The system recovers and reuses collection bins after they have been filled. Once a bin reaches its capacity or completes its sorting cycle, it is removed from active service, emptied or reset, and made available for reassignment to a different destination, maximizing the utilization of each bin and reducing the total inventory of bins required.
2Adaptability or versatility
If more diverts are added to accommodate more destinations, then system versatility increases, but device complexity and cost increase
Solution Approach 1:
Each collection bin is designed to be universal and can be assigned to serve any destination through software configuration rather than being hardwired to a specific location. The system uses a programmable controller that can dynamically route objects to any bin based on the current sorting requirements, making the same physical infrastructure serve multiple functions and destinations without requiring dedicated hardware for each route.
Solution Approach 2:
The system replaces complex mechanical routing infrastructure with a software-based control system. Instead of requiring physical diverts and mechanical switches for each destination, the controller uses identification technology and software logic to determine which bin should receive each object, significantly reducing mechanical complexity while maintaining high destination capacity.
3Measurement precision
If human workers continuously count items in bins, then inventory accuracy is maintained, but labor requirements and operating costs increase
Solution Approach 1:
The system implements self-monitoring capabilities where collection bins are equipped with sensors or identification technology that automatically track and report their own inventory levels and contents to the controller. This allows the system to maintain accurate inventory records without human intervention, as the bins essentially count and report their own contents through integrated sensing and communication systems.
Solution Approach 2:
The controller receives continuous feedback from the collection bins regarding their status, contents, and capacity levels. This feedback mechanism enables the system to automatically make sorting decisions, know when bins are full, and optimize the sorting process in real-time without requiring manual counting or monitoring by human workers.
4Adaptability or versatility
If manual sortation is used, then flexibility in handling various object types is maintained, but throughput speed is limited by human capacity
Solution Approach 1:
The system replaces manual human sortation with an automated identification and routing system. Objects are equipped with or have their identification read from tags, barcodes, or RFID markers, and the controller automatically determines the correct destination bin based on this data, eliminating the need for human workers to visually inspect and manually place each object while dramatically increasing sorting speed.
Solution Approach 2:
The system introduces an intermediary identification layer (barcodes, RFID tags, or optical markers) that mediates between the physical objects and the sorting system. This intermediary carries information about the object's destination, allowing the automated system to quickly and accurately route objects without requiring human interpretation or decision-making, thereby maintaining flexibility while increasing throughput.
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.