Dynamic Object Sortation with Robotic Bin Assignment
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Solution Overview
Problem
Current automated sortation systems are inefficient and inflexible, requiring large numbers of collection bins, high mechanical complexity, and significant operational costs due to reliance on human labor and limited conveyor flexibility, which restricts throughput and scalability.
Innovation Solution
A dynamic object sortation system utilizing programmable robotic manipulators and perception systems to dynamically assign objects to collection bins based on real-time data and heuristics, reducing the need for pre-assigned bins and minimizing manual labor, while allowing for flexible conveyor patterns and efficient object handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If tilt-tray or bomb-bay style recirculating conveyors with actuators are used for each divert, then automated sortation capability is achieved, but mechanical complexity and cost per divert become very high
Solution Approach 1:
The patent extracts the actuator mechanism from each individual divert location and replaces it with passive gravity-fed chutes. Objects are diverted at a single active location using one actuator, while other divert locations simply receive objects passively through gravity, eliminating the need for actuators at each divert point.
Solution Approach 2:
The patent introduces recirculating conveyors as intermediary transport elements that carry objects multiple times through the sortation system. This allows a single actuator to control multiple divert locations by timing object release at different circulation cycles, reducing the total number of actuators needed.
2Adaptability or versatility
If a large number of collection bins are used to handle diverse object types, then sortation capability is improved, but physical space requirements and capital costs increase significantly
Solution Approach 1:
The patent implements dynamic bin assignment where collection bins are not permanently dedicated to specific object types but are temporarily assigned based on real-time sortation needs. The system can reconfigure which bin receives which object type in different time periods, allowing the same physical bin to serve multiple purposes and reducing the total number of bins needed.
Solution Approach 2:
The patent adds the time dimension to bin utilization by allowing bins to be reused across different circulation cycles. Instead of requiring one bin per object type simultaneously, the system reuses bins across time, effectively multiplying the capacity of each physical bin and reducing space requirements.
3Adaptability or versatility
If human workers perform manual sortation, then flexibility in handling diverse objects is maintained, but throughput and sorting speed are limited
Solution Approach 1:
The patent implements self-service sortation where objects are automatically identified through scanning, their destination is determined by software algorithms, and they are mechanically diverted to the correct bin without human intervention. This automation maintains flexibility through programmable logic while dramatically increasing throughput beyond human capabilities.
4Productivity
If multiple parallel sortation cells are used to increase throughput, then processing capacity is multiplied, but system complexity and coordination requirements increase
Solution Approach 1:
The patent designs sortation cells with universal bin assignments that can handle any object type at any time. Each cell is equipped with the same capabilities and can be dynamically configured to handle different object mixes, allowing cells to work in parallel without requiring complex specialized configurations for each cell.
Data Source
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AI summary
A method of processing objects is disclosed using a programmable motion device. The method includes the steps of acquiring an object from a plurality of mixed objects at an input area, perceiving identifying indicia in connection with the object, assigning an intermediate station to a destination location for the object responsive to the identifying indicia in connection with the object, and moving the acquired object toward the intermediate station.