Automated Object Sortation Using Vision-Guided Robotic Delivery
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Solution Overview
Problem
Current object sortation and distribution systems rely heavily on human labor, are inefficient in handling varying object sizes and weights, and require a large number of collection bins, leading to high operational and capital costs, as well as inflexibility in processing diverse objects.
Innovation Solution
A programmable motion device system that includes a perception unit for identifying object indicia, an acquisition system using an end effector to select objects, and a delivery system with carriers that travel in a loop, enabling automated and efficient delivery of objects to specific processing locations based on identifying information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If human workers manually sort objects to collection bins, then flexibility in handling various object types is maintained, but labor costs and operational inefficiency increase
Solution Approach 1:
The robotic arm with interchangeable end effectors serves multiple functions: grasping objects of various sizes and weights, positioning them accurately, and adapting to different object types through tool changes. This single multi-functional device replaces multiple specialized human workers, achieving automation while managing complexity through consolidation.
Solution Approach 2:
The vision system acts as an intermediary between the objects and the robotic arm, automatically identifying object types, sizes, and weights without requiring direct human intervention. This intermediary component enables the robotic system to handle diverse objects intelligently, reducing the need for complex manual sorting procedures.
2Adaptability or versatility
If a large number of collection bins are used to handle diverse objects, then sortation capability is improved, but space requirements and capital costs increase
Solution Approach 1:
The system dynamically assigns objects to collection bins based on real-time analysis of object characteristics, destination requirements, and bin availability. This dynamic assignment allows the same set of bins to handle a much wider variety of objects over time, eliminating the need for dedicated bins for each object type and significantly reducing total bin数量和空间占用.
Solution Approach 2:
Instead of organizing bins by object type (horizontal categorization), the system uses multi-dimensional sorting criteria including destination, size, weight, and priority. Objects are routed through a conveyor system that adds a temporal and spatial dimension to the sorting process, allowing diverse objects to be efficiently distributed to the same physical bins at different times.
3Measurement precision
If fixed or robot-held code scanners are used for object identification, then identification accuracy is improved, but processing speed and flexibility deteriorate
Solution Approach 1:
The vision system continuously captures images of objects as they move along the conveyor belt, processing identification data without interrupting the flow. Multiple cameras are positioned to continuously track objects from different angles, ensuring accurate code reading while maintaining high processing speed. This continuous action eliminates the need for stopping or slowing down the conveyor for manual scanning.
Solution Approach 2:
The system replaces manual handheld scanners with an automated vision system that uses optical sensors and image processing algorithms. This substitution eliminates the mechanical limitation of handheld device movement speed and accuracy, providing both high identification precision and rapid processing capability through electronic image capture and analysis.
4Ease of operation
If objects are sorted in arrival order to collection bins, then processing simplicity is maintained, but sortation efficiency and space utilization worsen
Solution Approach 1:
The system performs preliminary analysis of incoming objects using the vision system, identifying their characteristics and determining optimal destination bins before the objects reach the sortation point. This preliminary action allows the robotic arm to pre-position objects for efficient sorting, optimizing bin utilization and reducing unnecessary movements while maintaining operational simplicity through automated decision-making.
Data Source
AI summary
A processing system for processing objects using a programmable motion device is disclosed. The processing system a perception unit for perceiving identifying indicia representative of an identity of an object associated with an input conveyance system, and an acquisition system for acquiring the object from a plurality of objects at an input area using an end effector of the programmable motion device, wherein the programmable motion device is adapted for assisting in the delivery of the object to an identified processing location. The identified processing location being associated with the identifying indicia and said identified processing location being provided as one of a plurality of processing locations. The processing system also includes a delivery system for receiving the object in a carrier and for delivering the object toward the identified processing location.