Dynamic Shuttle Sortation With Flexible Bin Allocation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current sortation systems are inefficient and inflexible, requiring large numbers of collection bins, high capital and operating costs, and relying heavily on human labor, with limited throughput and divert capabilities.
Innovation Solution
An automated shuttle sorter system with a movable carriage that can dynamically assign objects to multiple destination locations, using robotic manipulators and learning algorithms to optimize sorting and reduce the need for manual intervention.
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 diverts and object types, but the physical space, capital costs, and operating costs increase significantly
Solution Approach 1:
The system dynamically assigns objects to collection bins based on real-time conditions rather than using fixed, dedicated bins for each object type. The bin assignment is flexible and can change depending on current workload, object characteristics, and system state, allowing the same bin to serve multiple object types at different times.
Solution Approach 2:
Collection bins are designed to be multi-functional, handling multiple types of objects rather than being dedicated to a single object type. This universal approach allows fewer bins to serve more diverse object streams by dynamically routing different object types to the same bin based on current needs.
2Adaptability or versatility
If human workers perform sortation manually, then the system is flexible in handling various objects, but the throughput is limited by worker speed
Solution Approach 1:
The system replaces manual human sorting with an automated control system that uses sensors, algorithms, and automated mechanisms to identify objects and direct them to appropriate bins. This substitution maintains flexibility in handling diverse objects while dramatically increasing throughput beyond human capabilities.
Solution Approach 2:
The sortation system is self-regulating through automated decision-making algorithms that determine optimal bin assignments without human intervention. The system automatically adjusts to different object types and routing requirements, maintaining adaptability while operating at automated speeds.
3Productivity
If recirculating conveyors with tilt trays are used for automated sortation, then throughput increases, but the system complexity and capital costs increase
Solution Approach 1:
The patent extracts the complex tilt tray mechanism from the sortation system and replaces it with simpler automated divert mechanisms. The core sortation logic and object handling remain, but the mechanical complexity of tilting trays is removed, reducing system complexity while maintaining throughput capabilities.
Solution Approach 2:
The system introduces an automated control system as an intermediary between object identification and physical sortation. This software-based mediator handles the complexity of decision-making and bin assignment, allowing simpler physical sortation mechanisms to achieve the same throughput that would otherwise require complex mechanical systems.
4Ease of operation
If bins are arranged within efficient reach of human workers, then ease of operation is maintained, but the number of diverts is limited
Solution Approach 1:
The system transitions from a two-dimensional workspace arrangement (bins within arm's reach on a conveyor) to a three-dimensional automated storage and retrieval system. Bins can be positioned in locations that would be inaccessible to human workers, and automated mechanisms handle the retrieval and sortation, expanding the number of diverts beyond what is physically accessible to humans.
Data Source
AI summary
An automated shuttle sorter is disclosed that includes a carriage that is movable from a load position at which the carriage may be loaded, and at least two destination locations into which any contents of the carriage may be provided from the carriage.