Vacuum Divert Conveyor Sorting for Multi-Destination Object Routing
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Solution Overview
Problem
Existing object distribution systems require large numbers of collection bins and incur high costs due to inefficiencies in matching incoming objects to assigned destinations, often relying on human labor and mechanical complexity, and struggle with handling objects of varying sizes and weights.
Innovation Solution
A distribution system utilizing an air intake and forced air transfer system to move objects from a conveyor to adjacent receiving units, combined with perception units and programmable motion devices to identify and route objects to appropriate destinations, minimizing the need for physical space and reducing mechanical complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large number of collection bins are used to handle dissimilar objects, then the system can accommodate more destinations, but the physical space requirement and system complexity increase significantly
Solution Approach 1:
The patent implements a dynamic recirculating conveyor system where collection bins are reused across multiple cycles. Objects that miss their destination on one pass continue circulating and are diverted on subsequent passes. This dynamic approach allows the system to handle many more destinations than the number of physical bins, resolving the contradiction between destination capacity and physical space requirements.
Solution Approach 2:
The system adds the time dimension to the sorting process by implementing multi-pass sorting. Instead of requiring all destinations to be simultaneously accessible in space, the system allows objects to be sorted across multiple time cycles. Objects circulate through the system and are diverted to different bins on different passes, effectively expanding destination capacity beyond physical constraints.
2Adaptability or versatility
If traditional mechanical sorting systems are used with multiple collection bins, then objects can be sorted to multiple destinations, but the mechanical complexity and operating costs increase
Solution Approach 1:
The recirculating conveyor system serves multiple functions: it transports objects to be sorted, provides multiple passes for sorting the same object to different destinations, and reuses collection bins across different sorting cycles. This multi-functionality reduces the need for separate mechanical sorting mechanisms for each destination, thereby reducing overall system complexity while maintaining high adaptability.
Solution Approach 2:
The system maintains continuous circulation of objects through the conveyor loop, eliminating idle time and repeated mechanical operations. Objects that are not sorted on one pass immediately continue circulating rather than being returned to the input, ensuring continuous productive action and reducing the mechanical overhead required for repeated sorting attempts.
3Adaptability or versatility
If human workers manually sort objects, then flexibility in handling various objects is maintained, but labor costs and processing time increase
Solution Approach 1:
The patent replaces manual human sorting with an automated system combining recirculating conveyors, perception units (cameras/scanners), and automated divert mechanisms. This substitution maintains flexibility through programmable control while dramatically increasing processing speed and productivity, resolving the contradiction between handling flexibility and processing efficiency.
4Productivity
If objects are sorted in a single pass through the system, then processing speed is maximized, but the number of collection bins required increases
Solution Approach 1:
The system dynamically assigns objects to different bins across multiple passes rather than requiring all objects to be sorted in a single static pass. This dynamic multi-pass approach allows the same set of bins to serve multiple destinations over time, reducing the total number of bins needed while maintaining high processing throughput.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system efficiently sorts dissimilar objects into appropriate collection bins while reducing costs and handling objects of varying sizes and weights, enhancing throughput and minimizing mechanical complexity.
Implementation Method 1
an air transfer system including a forced air system and an air intake system that together aid in moving an object on the conveyor section from the conveyor section to one of a plurality of adjacent conveyors
Data Source
AI summary
A distribution system for use in an induction system with an object processing system. The distribution system provides dissimilar objects into one of a plurality of receiving units. The distribution system includes an air intake system with an opening that is a fixed distance from a conveyor section, said air intake system aiding in moving an object on the conveyor section from the conveyor section to one of a plurality of adjacent transport units.