Robotic Parcel Sorting Grid for Direct Dispatch Sequencing
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Solution Overview
Problem
Existing sorting systems for shipment items are inefficient, requiring multiple passes and manual sequencing, and are not optimized for dynamic parcel volumes and limited processing points, especially in large geographical areas with high volumes and quick turnarounds.
Innovation Solution
A system comprising a storage-and-retrieval system with robotic pickers/load handlers and a processor that receives destination information to select and dispatch shipment containers based on priority, vehicle capacity, and destination addresses, using a grid-based sorter to efficiently manage and sequence containers for dispatch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyor-type sorting systems with multiple stations are used, then sorting capacity is improved, but system complexity and processing time increase due to multiple passes
Solution Approach 1:
The patent transitions from a linear conveyor-based sorting system to a three-dimensional grid-based storage and retrieval system. Packages are stored in vertical stacks within a framework, and robotic pickers retrieve them from multiple levels, enabling simultaneous access to multiple packages without requiring sequential passes through multiple conveyor stations.
Solution Approach 2:
The patent replaces traditional mechanical conveyor-based sorting mechanisms with an automated robotic picking system. Instead of using conveyors, tilt trays, or live roller beds to move and sort packages, the system uses robotic pickers that can autonomously retrieve packages from storage locations and place them onto dispatch vehicles based on destination and priority.
2Reliability
If multiple passes through conveyor stations are required, then comprehensive sorting is achieved, but processing time and throughput efficiency deteriorate
Solution Approach 1:
The system performs preliminary sorting by destination and priority before packages are fully processed. The processor determines the optimal retrieval sequence based on destination addresses and priority levels, allowing packages to be pre-grouped and prepared for dispatch without requiring multiple review passes through the system.
Solution Approach 2:
The robotic pickers operate continuously to retrieve and dispatch packages without interruption. Unlike conveyor systems that require packages to complete full cycles through multiple stations, the robotic system can directly retrieve packages from storage and place them onto dispatch vehicles in a continuous, uninterrupted flow, maximizing throughput efficiency.
3Adaptability or versatility
If manual sequencing at processing points is used, then flexibility in handling different parcel types is maintained, but productivity and automation level decrease
Solution Approach 1:
The system employs intelligent algorithms that automatically determine the optimal retrieval sequence based on package characteristics, destination, and priority. The processor analyzes package data and generates retrieval instructions without human intervention, allowing the system to adapt to different parcel types and sorting requirements while maintaining high automation and productivity.
Solution Approach 2:
The system dynamically adjusts retrieval parameters such as picker assignment, retrieval sequence, and dispatch timing based on real-time conditions including package priority, destination capacity, and system workload. This allows the automated system to maintain flexibility in handling diverse parcel types while optimizing throughput efficiency through data-driven decision-making.
4Device complexity
If limited processing points are used in large geographical areas, then system simplicity is maintained, but sorting capacity and coverage area are restricted
Solution Approach 1:
The grid-based storage system serves multiple functions: it acts as both a storage facility and a sorting mechanism. The same framework and robotic pickers that store packages also retrieve and sort them for dispatch to various geographical destinations, eliminating the need for separate processing points at different locations and enabling a single facility to handle diverse routing requirements.
Data Source
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AI summary
A system for managing shipment containers includes a storage and retrieval system and at least one processor. The storage-and-retrieval system includes a framework defining a plurality of adjacent stacks capable of receiving a plurality of stackable containers, each stackable container suitable for containing a shipment container; and a plurality of robotic pickers/load handlers configured to retrieve selected stackable containers from the framework for sortation and/or dispatch. The at least one processor is configured to: receive or access destination address information for each of the plurality of shipment containers entering the system; select a subset of the plurality of shipment containers for dispatch based on shipment container and generate signals for instructing at least one of the plurality of robotic pickers to retrieve the selected shipment containers for dispatch.