Induction Routing for Variable-Size Object Processing
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Solution Overview
Problem
Existing object distribution systems are inefficient and costly due to the need for large numbers of collection bins and manual intervention, and they struggle to handle objects of varying sizes and weights, leading to mechanical complexity and increased operating costs.
Innovation Solution
An induction system that evaluates object characteristics using perception units and routing means to direct objects to appropriate processing stations, filtering out incompatible items and optimizing the distribution process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional parcel sortation systems use human workers or automated systems to retrieve and sort objects into collection bins, then objects can be sorted based on heuristics, but a large number of collection bins are required when the number of different types of input objects is large, increasing physical space requirements and capital costs
Solution Approach 1:
The sortation process is divided into multiple passes, with each pass handling a specific subset of object types. Objects are sorted in stages rather than all at once, allowing the system to manage diverse object types with fewer bins per pass. This segmentation enables the system to scale adaptability without linearly increasing the number of bins required.
Solution Approach 2:
The system dynamically reconfigures which objects are sorted in each pass based on the mix of objects present. Collection bins are dynamically assigned to different object types across passes, allowing the same physical bins to serve multiple purposes. This dynamic allocation reduces the total number of bins needed while maintaining the ability to handle diverse object types.
2Extent of automation
If recirculating conveyors with tilt trays are used for automated sortation, then objects can be automatically routed to predefined locations, but the system requires objects to be presented in a specific way and may not efficiently handle objects of varying sizes and weights
Solution Approach 1:
Objects are pre-sorted by hand into groups based on their characteristics (size, weight, type) before entering the automated conveyor system. This preliminary classification ensures that objects presented to the automated sortation system are within the acceptable range for efficient automated handling, while still maintaining overall system versatility through the initial manual sorting stage.
Solution Approach 2:
Human workers serve as an intermediary between the diverse object input and the automated conveyor system. They perform initial sorting and preparation, translating the variability of incoming objects into a format suitable for automated processing. This intermediary role allows the system to combine automated efficiency with adaptability to varying object characteristics.
3Productivity
If a large number of collection bins are used to handle diverse object types, then all object types can be sorted simultaneously, but the system requires large physical space, large capital costs, and large operating costs
Solution Approach 1:
The sortation process is segmented into multiple passes, with each pass handling a subset of object types. This allows the system to achieve high throughput by processing different object categories in sequence rather than requiring all bins to be simultaneously accessible, reducing the number of bins needed at any one time while maintaining overall productivity.
Solution Approach 2:
The system maintains continuous operation through multiple passes, where objects that are not sorted in one pass remain on the conveyor for subsequent passes. This continuous processing ensures high productivity without requiring a large number of bins, as the same bins are reused across passes while objects continue to be sorted efficiently.
Data Source
AI summary
An induction system is disclosed for filtering the induction of objects to a plurality of object processing systems. The induction system includes an evaluation means for evaluating at least one characteristic of an object, and routing means for routing the object in one of a plurality of directions responsive to the evaluated characteristic, at least one of the plurality of directions leading to a selected one of the plurality of object processing systems.