Trailer Parcel Sortation Using Perception-Guided Dual Routing
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Solution Overview
Problem
Current parcel sortation systems rely heavily on human labor, are inefficient in handling a large number of diverse objects, and require extensive physical space and resources, as they often necessitate a large number of collection bins and mechanical diverts, which increase costs and complexity.
Innovation Solution
An automated object processing system within a tractor trailer that includes an input area, a perception system for identifying objects, and a primary transport system capable of directing objects into one of two primary directions based on perception data, facilitating efficient sorting and distribution to desired destinations within a confined space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated systems with multiple collection bins and mechanical diverts are used, then sortation accuracy is improved, but device complexity and operational costs increase
Solution Approach 1:
A single robotic arm performs multiple functions: picking objects from the input area, identifying them via perception system, determining routing directions, and placing them in appropriate collection bins. This multi-functional approach replaces the need for multiple specialized mechanical diverts while maintaining sortation accuracy.
Solution Approach 2:
The patent replaces mechanical divert systems with an automated robotic system that uses perception data and control algorithms to route objects. Instead of physical mechanical diverts for each destination, a single robotic arm with intelligent control dynamically directs objects to any collection bin, reducing mechanical complexity while improving accuracy.
2Adaptability or versatility
If more collection bins are deployed to handle diverse objects, then sortation capability is improved, but space requirements and operational costs increase
Solution Approach 1:
The system dynamically assigns collection bins to different destinations based on current sortation needs rather than having fixed dedicated bins for each destination. The robotic arm can adaptively route objects to any available bin, allowing the same physical bins to serve multiple destinations at different times, thereby increasing sortation capability without proportionally increasing the number of bins or space required.
Solution Approach 2:
The patent introduces dynamic routing capability that adds a temporal and control dimension to the sortation system. Instead of requiring physical separation for each destination, the system uses intelligent control to manage object flow to multiple destinations through a shared set of bins, effectively utilizing the control space dimension to overcome physical space constraints.
3Device complexity
If manual scanning and sorting processes are used, then system simplicity is maintained, but productivity and throughput are reduced
Solution Approach 1:
The robotic system autonomously performs the complete sortation process: the perception system automatically identifies objects, the control system determines routing decisions, and the robotic arm executes placement actions without human intervention. This self-service capability dramatically increases throughput compared to manual processes while keeping the physical footprint compact.
Solution Approach 2:
The patent replaces manual human labor with an automated robotic system that integrates perception, decision-making, and physical manipulation. This substitution eliminates the speed limitations of human workers while maintaining a relatively simple overall system architecture, thereby achieving high throughput without proportionally increasing complexity.
4Measurement precision
If fixed or handheld barcode scanners are used, then identification accuracy is improved, but operational flexibility and speed are reduced
Solution Approach 1:
The patent replaces manual barcode scanning with an integrated perception system that automatically detects and identifies objects as they enter the input area. The robotic system coordinates the scanning process with object movement, eliminating the need for manual positioning and button-pressing operations, thereby maintaining identification accuracy while dramatically increasing processing speed.
Solution Approach 2:
The perception system operates continuously as objects move through the input area, automatically identifying them without interruption. This continuous identification process eliminates the discrete, sequential nature of manual scanning, allowing multiple objects to be identified in parallel or rapid succession, thereby maintaining accuracy while significantly improving throughput.
Data Source
AI summary
An object processing system within a trailer for a tracker trailer is discloses. 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.