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 large numbers of collection bins, high mechanical complexity, and significant costs due to the need for multiple actuators and human labor, which limits throughput and scalability.
Innovation Solution
A programmable motion device and processor-driven system that dynamically assigns intermediate stations to objects based on identifying indicia, allowing for flexible routing and reduced manual intervention, using robotic manipulators and improved perception systems to handle objects in a disorganized stream and dynamically allocate collection bins.
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 increase significantly
Solution Approach 1:
The patent replaces traditional mechanical tilt-tray or bomb-bay actuators with a robotic system consisting of a mobile robot, vision system, and control processor. The robot uses perception to identify objects and programmable motion to place them in correct bins, substituting complex mechanical divert mechanisms with a more flexible robotic manipulation system that reduces mechanical complexity while maintaining automated sortation capability.
2Adaptability or versatility
If human workers perform manual sortation, then system flexibility is maintained, but throughput is limited by worker speed
Solution Approach 1:
The system enables self-service sortation by equipping the mobile robot with vision systems and identification capabilities. The robot autonomously perceives objects, identifies their destinations, and places them in appropriate bins without human intervention. This maintains the flexibility of manual sortation while dramatically increasing throughput by operating at robotic speeds continuously without fatigue or breaks.
3Adaptability or versatility
If a large number of collection bins are used to handle diverse object types, then sortation capability is improved, but physical space and capital costs increase
Solution Approach 1:
The patent implements dynamic bin assignment where the robot can adaptively assign objects to bins based on real-time conditions rather than requiring a fixed, pre-configured bin for every possible object type. The system dynamically determines destination bins using vision systems and control processors, allowing the same physical bin to serve multiple purposes at different times. This reduces the total number of bins needed while maintaining comprehensive sortation capability for diverse object types.
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.