Robotic Sortation With Dynamic Bin Assignment for Mixed Objects
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Solution Overview
Problem
Current automated sortation systems are inefficient and inflexible, requiring a large number of collection bins and human labor, leading to high costs and limited throughput, as they struggle to dynamically match objects with their correct destinations in a disorganized stream.
Innovation Solution
A programmable motion device and processor-driven system that acquires objects, identifies their indicia, and dynamically assigns intermediate stations to destination locations, allowing for flexible and efficient sorting without pre-assigned bins, using robotic manipulators and perception systems to handle objects in a disorganized jumble and dynamically change handling patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then the system can accommodate more object types, but the physical space, capital costs, and operating costs increase significantly
Solution Approach 1:
The system dynamically reconfigures collection bin assignments based on real-time sortation needs. Instead of having fixed, dedicated bins for each object type, the system can dynamically assign any bin to any destination, allowing the same physical bin to serve multiple different destinations at different times. This dynamic reassignment dramatically reduces the total number of bins needed while maintaining the ability to handle diverse object types.
Solution Approach 2:
The patent introduces a temporal dimension to bin assignment, where bins are not statically assigned to destinations but are dynamically allocated over time. This transforms the sortation system from a spatial solution (more bins for more destinations) to a temporal solution (same bins serving multiple destinations at different times), effectively adding a time-based dimension to the sortation process.
2Adaptability or versatility
If human workers perform sortation manually, then flexibility in handling diverse objects is maintained, but throughput is limited by worker speed
Solution Approach 1:
The sortation system is designed to be universal, where a single robotic system with dynamic bin assignment can handle multiple different object types and destinations without requiring specialized equipment for each. The same robotic arm and vision system can sort different types of parcels to different destinations by simply changing the software control logic and bin assignments, providing both high throughput and flexibility.
Solution Approach 2:
The system replaces manual human sortation with an automated robotic system that uses vision systems and programmable logic to identify and sort objects. This substitution of mechanical/human operations with automated systems dramatically increases throughput while maintaining flexibility through software-based control and dynamic bin assignment.
3Productivity
If tilt-tray or bomb-bay conveyors are used for automated sortation, then throughput increases, but the mechanical complexity and cost per divert increase significantly
Solution Approach 1:
The patent extracts the actuation mechanism from each individual divert location. Instead of having complex tilt-tray mechanisms at every bin location, the system uses a single robotic arm that can dynamically position objects to any bin. This removes the need for complex mechanical actuators at each divert point, dramatically reducing mechanical complexity while maintaining automated throughput.
Solution Approach 2:
A single robotic arm serves as a universal sortation mechanism that can direct objects to any of multiple bins, replacing the need for dedicated actuator mechanisms at each bin location. This universal robotic system provides the same throughput capability as complex conveyor systems but with significantly reduced mechanical complexity and lower cost per divert.
4Adaptability or versatility
If the number of diverts is increased to handle more destinations, then system versatility improves, but the cost per divert increases due to additional actuators
Solution Approach 1:
A single robotic arm with dynamic bin assignment serves as a universal divert mechanism that can direct objects to any of multiple destinations without requiring additional actuators at each location. This universal system allows the number of destinations to increase without proportionally increasing the number of actuators, thereby reducing the cost per divert while maintaining high system versatility.
Data Source
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.