Track-Guided Delivery Vehicles With Vertical Routing for Item Sorting

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Solution Overview

Problem

Large organizations face challenges in efficiently and cost-effectively sorting and retrieving items due to the labor-intensive nature of manual processes and the high costs of traditional automated sorting systems, which are often not justified by the volume of mail or items handled.

Innovation Solution

A material handling system featuring a track with interconnected vertical and horizontal sections that guides semi-autonomous delivery vehicles to sort items into multiple bins, using a central controller to manage vehicle operations and gate mechanisms to direct vehicles along the track, ensuring efficient item delivery and retrieval while maintaining item orientation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual sorting is used, then labor costs are high and time consumption is significant, but the system remains simple and affordable

Engineering Contradiction:

Improvesorting efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides the sorting function into independent modular units: delivery vehicles, gates, bins, and control modules. Each vehicle operates independently on the track, and gates can be controlled individually to direct vehicles to different bins. This modular segmentation enables automated sorting functionality while keeping each component simple and maintainable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The delivery vehicles serve multiple functions: they transport items along the track, respond to control signals for sorting, and can be directed to different destination bins. The same vehicle infrastructure handles both transportation and sorting operations, eliminating the need for separate dedicated sorting mechanisms and reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If traditional automated sorting equipment is used, then sorting efficiency increases, but the cost becomes prohibitively high for mid-sized organizations

Engineering Contradiction:

Improvesorting efficiencyVSAvoidsystem cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The system uses relatively simple, cost-effective delivery vehicles that can be manufactured at lower cost compared to traditional automated sorting equipment. These vehicles are designed for straightforward construction with basic propulsion mechanisms and simple control interfaces, making the overall system affordable for mid-sized organizations while still providing automated sorting capability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The delivery vehicles are equipped with onboard controllers that enable them to autonomously navigate the track, receive sorting instructions, and execute sorting operations without requiring complex external control infrastructure. This self-service capability reduces the need for expensive centralized control systems and manual operation, lowering overall system cost while maintaining high sorting efficiency.

Inventive Principle:

Principle #25Self-service

3Area of stationary object

If vertical track sections are added to change travel direction, then space utilization improves, but the track complexity increases

Engineering Contradiction:

Improvefootprint areaVSAvoidtrack structure complexity

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The track system incorporates vertical sections that allow delivery vehicles to change horizontal direction by traveling vertically. This three-dimensional track configuration enables the system to compactly arrange multiple destination bins in different horizontal directions while utilizing vertical space for direction changes, effectively reducing the horizontal footprint area without requiring an overly complex track layout.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Adaptability or versatility

If vehicles change from horizontal to vertical direction, then routing flexibility improves, but item orientation stability may be compromised

Engineering Contradiction:

Improverouting flexibilityVSAvoiditem orientation

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The system design anticipates orientation disturbances during direction changes by implementing controlled transitions between horizontal and vertical track sections. The vehicle control system manages acceleration and deceleration during these transitions to minimize item movement, and the track geometry is designed to provide smooth transitions that prevent excessive tilting or shifting of items during routing changes.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS8622194B2Material handling apparatus for delivering or retrieving items

Publication Date: 2014.01.07 OPEX CORP

AI summary

A method and apparatus are provided for sorting or retrieving items to/from a plurality of destinations areas. The items are loaded onto one of a plurality of independently controlled delivery vehicles. The delivery vehicles follow a track that guides the delivery vehicles to/from the destination areas, which are positioned along the track. Once at the appropriate destination area, an item is transferred between the delivery vehicle and the destination area.