Robotic Package Sort Cell with Modular Human Intervention Platform
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current package handling systems rely heavily on manual labor for sorting packages of varying shapes and sizes, leading to worker fatigue, injuries, and high turnover rates due to the physically demanding nature of the work.
Innovation Solution
A robotic package handling system featuring a multi-axis arm with an end-of-arm tool (EOAT) capable of picking and placing packages, integrated with a modular sort cell design and a platform for human intervention during robot downtime, along with detection systems for robot malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual workers perform package pick and place operations, then the system can handle packages of varying shapes and sizes with flexibility, but worker fatigue and injury increase leading to high turnover rates
Solution Approach 1:
The robotic system performs package pick and place operations autonomously without human intervention. The robot picks packages from the unsorted delivery location and places them at the correct route paths based on routing information, eliminating the need for manual labor and associated worker fatigue and injury.
Solution Approach 2:
The patent replaces the manual mechanical system (human workers performing pick and place) with an automated robotic system. The robot uses sensors to detect packages and routing information, processes this data, and executes pick and place operations, substituting human mechanical action with automated robotic mechanics.
2Reliability
If a robotic system is implemented to automate pick and place operations, then worker fatigue and injury are reduced, but the system complexity and initial investment increase
Solution Approach 1:
The robotic system is designed to handle multiple functions: detecting packages, reading routing information, determining correct route paths, and performing pick and place operations. This multi-functionality consolidates what would otherwise require separate systems into a single integrated robotic platform, managing complexity while providing comprehensive automation.
Solution Approach 2:
The system uses routing information (barcodes, RFID tags, or other identifiers) as an intermediary to bridge package identification and route determination. This intermediary data structure allows the robot to accurately sort packages without requiring complex direct recognition of each package's destination, simplifying the overall control logic.
3Productivity
If the robotic system operates continuously, then sorting efficiency increases, but the system becomes more vulnerable to malfunctions and downtime
Solution Approach 1:
The robotic system continuously monitors its own operation and the status of packages being sorted. Sensors detect package positions, routing information, and potential malfunctions in real-time, providing feedback to the control system. This allows for immediate detection and response to issues, maintaining high productivity while managing vulnerability through continuous monitoring.
Solution Approach 2:
The system performs preliminary detection and routing determination before the actual pick and place operation. Packages are scanned and their destination determined in advance, allowing the robot to plan its movements and anticipate potential issues before they occur, thereby maintaining continuous operation while preparing for possible malfunctions.
4Adaptability or versatility
If manual sorting is used, then the system can adapt to routing changes and package variations flexibly, but the processing speed and volume are limited
Solution Approach 1:
The patent replaces manual sorting with an automated robotic system that uses optical sensors, barcode readers, and RFID scanners to detect and process routing information. This substitution enables the system to handle high volumes of packages at speeds impossible for manual workers while maintaining flexibility through programmable routing logic that can adapt to changing sorting requirements.
Solution Approach 2:
The robotic system employs dynamic control algorithms that allow it to adapt to varying package characteristics, routing changes, and operational conditions in real-time. The robot can adjust its picking strategy, movement speed, and routing decisions based on current conditions, maintaining flexibility comparable to manual sorting while achieving much higher processing speeds and volumes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The robotic system significantly reduces manual labor requirements, decreases worker fatigue and injury, and enhances sorting efficiency by automating the pick and place process, while also allowing for seamless human intervention during robot downtime.
Implementation Method 1
The end of arm tool may include vacuum assist to hold the package on the conveyor during the pick and place package transfer process.
Data Source
AI summary
A package sort cell includes a robot with an end of arm tool for transporting packages from an in-feed conveyor to a selected one of a plurality of out-feed conveyors or bins, the robot receiving instruction from the package reader as to which of the plurality of conveyors or bins to hand-off the package. An end of arm tool may be in the configuration of a conveyor which may be aligned with the out-feed conveyor on a bottom up movement. The end of arm tool may also be in the configuration of a hanging carriage frame suspending a conveyor in a top down movement. A worker platform may be provided which may be movable between in-use and out-of-use positions whereby upon robot downtime, the platform may move into the in-use position for a worker to temporarily takeover the transfer functions of the robot. A plurality of sort cells may be arranged in side by side relation adjacent a like plurality of package delivery points (e.g., truck bays) and include diverter conveyors to allow diversion of a selected quantity of packages from one cell to an adjacent cell when the adjacent cell has no associated package delivery occurring at that time.