Robotic Tray Transfer Tool for Item Sorting
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Solution Overview
Problem
Current sorting systems face inefficiencies when handling smaller volumes of items, as manual labor is error-prone and costly, while large conveyor systems are cumbersome for smaller quantities, and struggle with difficult-to-handle products like round or cylindrical items.
Innovation Solution
A sorting system comprising a tray handling system and a tote handling system, utilizing a robotic arm with a tray transfer tool that includes a frame, upper and lower tray attachment assemblies, and a slidable coupling mechanism, allowing for efficient transfer of items from trays to totes, which can handle various item shapes and sizes, including round or cylindrical items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual labor is used for sorting, then flexibility in handling various item types is maintained, but throughput is limited and costs are high
Solution Approach 1:
The system uses vision systems and sensors to automatically detect and identify items, eliminating the need for manual inspection and classification. The robotic arm autonomously picks and places items based on real-time feedback from sensors, enabling the system to serve itself without human intervention for sorting decisions
Solution Approach 2:
The patent replaces manual mechanical sorting operations with an automated robotic system that uses computer vision, sensors, and controlled mechanical arms. This substitution enables higher throughput while maintaining the flexibility to handle diverse item types through programmable control rather than human judgment
2Productivity
If large conveyor systems are used, then throughput for high volumes is improved, but the system becomes cumbersome and inefficient for smaller volumes
Solution Approach 1:
The system divides the sorting function into discrete modular components: a robotic arm for picking, a vision system for identification, and a placement mechanism for depositing items into containers. This segmentation allows the system to handle small volumes efficiently without requiring the complex infrastructure of large conveyor systems, while still achieving high throughput through optimized robotic operations
Solution Approach 2:
The robotic system provides dynamic adaptability to varying throughput requirements through programmable control. The same robotic arm can operate at different speeds and handle different item volumes by adjusting its motion parameters and pick/place cycles, eliminating the need for fixed infrastructure that is inefficient at lower volumes
3Productivity
If traditional automated equipment is used, then throughput is improved, but handling of round or cylindrical items becomes difficult
Solution Approach 1:
The system changes the parameters of the picking mechanism by using a compliant gripper with adjustable grip force and positioning. The vision system captures images from multiple angles to determine the optimal pickup position on round or cylindrical items, and the robotic arm adjusts its approach vector and gripping parameters to securely handle items of various shapes and sizes
Solution Approach 2:
The robotic arm with programmable control serves as a universal picking mechanism that can handle diverse item types including round, cylindrical, rectangular, and irregularly shaped objects. The system uses vision guidance and adaptive gripping to perform the same basic pick-and-place function across different item geometries, eliminating the need for item-specific handling mechanisms
Data Source
AI summary
An item sorting system having a tray handling system and a tote handling system. The tray handling system having a tray conveying system, a tray transfer system, and optionally a tray storage region. The tote handling system may have a cubby array, the cubby array having a plurality of cubbies into which a tote may be placed. The system can transfer an item from the tray into the tote, and a method is disclosed for the same.