Trailer Parcel Sortation With Vision-Guided Robotic Routing
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Solution Overview
Problem
Current parcel sortation systems rely heavily on human labor, are inefficient in space and cost, and lack flexibility in handling objects of varying sizes and weights, leading to high capital and operating costs and limited throughput.
Innovation Solution
An automated object processing system within a trailer for a tractor trailer, utilizing a perception system and primary transport system to provide a singulated stream of objects, which are then identified and routed to desired destinations using a robotic system and conveyors, with dynamic assignment of carriages or containers to optimize space and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If human workers manually sort parcels using handheld scanners, then flexibility in handling varied objects is maintained, but productivity and throughput are limited
Solution Approach 1:
The patent replaces manual mechanical scanning and sorting operations with an automated vision-based identification system. Cameras and image processing algorithms automatically identify objects and their destinations, eliminating the need for handheld scanners and manual barcode reading, thereby increasing throughput while maintaining flexibility through software-based object recognition
Solution Approach 2:
The system enables objects to be automatically identified and routed without human intervention. The vision system autonomously detects objects, determines their destinations based on visual features, and directs them to appropriate collection bins, allowing the sortation process to serve itself without continuous human operation
2Reliability
If fixed scanner systems are used at point-of-sale, then scanning reliability is improved, but ease of operation deteriorates as operators must manually position objects
Solution Approach 1:
Instead of requiring the scanner to be held or positioned manually, the patent inverts the approach by bringing the scanning capability to the object through a moving robotic arm with an integrated camera. The robotic system actively seeks out and scans objects rather than objects being brought to a fixed scanner, eliminating manual positioning requirements while maintaining reliable identification
Solution Approach 2:
The system transitions from a static fixed scanner to a dynamic robotic arm that can move and position the camera automatically. This dynamic positioning system uses sensors and control algorithms to locate objects and adjust the camera angle and position, providing both reliability through active tracking and ease of operation through automation
3Extent of automation
If recirculating conveyors with tilt trays are used, then automation extent is improved, but device complexity increases due to multiple actuators required
Solution Approach 1:
The patent extracts the actuation function from multiple individual tilt tray actuators and consolidates it into a single robotic arm with a gripper. The robotic system picks objects from the conveyor and places them directly into collection bins, eliminating the need for complex tilt tray mechanisms and their associated actuators, thereby reducing device complexity while maintaining high automation
Solution Approach 2:
The robotic arm serves multiple functions: it transports objects along the conveyor, identifies objects using its integrated camera, determines destinations, and places objects into various collection bins. This single multi-functional robotic system replaces what would otherwise require multiple specialized actuators and mechanisms, reducing overall system complexity
4Adaptability or versatility
If a large number of collection bins are deployed to handle diverse objects, then adaptability is improved, but space requirements and capital costs increase
Solution Approach 1:
The patent implements dynamic destination 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, allowing a smaller number of bins to handle a larger variety of objects, thereby reducing space requirements while maintaining high adaptability
Solution Approach 2:
The system allows collection bins to be dynamically reassigned and reused for different object types as sortation requirements change. Instead of having permanent dedicated bins for each object category, bins are recovered and repurposed for different destinations based on current workflow needs, maximizing the utilization of limited bin resources and reducing the total number of bins required
Data Source
AI summary
An object processing system within a trailer for a tractor trailer is disclosed. The object processing system includes an input area of the trailer at which objects to be processed may be presented, a perception system for providing perception data regarding objects to be processed, and a primary transport system for providing transport of each object in one of at least two primary transport directions within the trailer based on the perception data.