Zone-Aware Sorting Robots for Switching Safety Modes

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Solution Overview

Problem

Existing sorting systems using mobile autonomous robots are inflexible, as they require separate collaborative and non-collaborative robots for zones with and without human presence, limiting their adaptability and efficiency.

Innovation Solution

A single robot system that can switch between collaborative and non-collaborative modes, equipped with safety systems that deactivate or activate based on zone identification, allowing high productivity in non-collaborative zones without human presence.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate collaborative and non-collaborative robots are used for different zones, then safety is ensured in zones with human presence, but system flexibility and adaptability deteriorate

Engineering Contradiction:

ImprovesafetyVSAvoidsystem flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent implements a universal robot platform that can operate in both collaborative zones (with human presence) and non-collaborative zones (without human presence) by dynamically switching between collaborative mode and non-collaborative mode. The robot is equipped with safety systems that can be activated or deactivated based on zone identification, allowing a single robot type to perform multiple functions across different operational contexts, thereby eliminating the need for separate robot types while maintaining safety requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The robot system dynamically adjusts its operational characteristics based on the zone it is operating in. When entering a collaborative zone, the robot activates safety systems and switches to collaborative mode with reduced speed limits and enhanced obstacle detection. When entering a non-collaborative zone, the robot deactivates these constraints and switches to non-collaborative mode for maximum performance. This dynamic adaptation allows the system to maintain safety when needed while achieving high productivity when appropriate.

Inventive Principle:

Principle #15Dynamics

2Productivity

If non-collaborative robots are used to maximise performance, then productivity is improved, but safety constraints and flexibility worsen

Engineering Contradiction:

ImproveproductivityVSAvoidsafety constraints

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

3Reliability

If collaborative robots with safety devices are used, then safety in human zones is improved, but speed and productivity deteriorate

Engineering Contradiction:

Improvesafety in human zonesVSAvoidspeed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The robot applies different operational parameters and safety constraints to different spatial zones. In collaborative zones where human presence is detected, the robot activates safety systems, reduces speed, and enhances obstacle detection. In non-collaborative zones without human presence, the robot deactivates these constraints and operates at maximum speed. This localized application of safety measures ensures protection only where necessary, maintaining productivity in areas where it is not needed.

Inventive Principle:

Principle #3Local quality

4Adaptability or versatility

If a single robot system operates in both collaborative and non-collaborative zones, then flexibility is improved, but system complexity worsens

Engineering Contradiction:

ImproveflexibilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The robot system automatically identifies the zone it is operating in using detection means (such as RFID readers, barcode scanners, or GPS) and autonomously switches between collaborative and non-collaborative modes without requiring manual intervention. The system self-manages the activation and deactivation of safety systems based on zone characteristics, reducing the need for complex external control mechanisms and simplifying the overall system architecture.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250264882A1Sorting system

Publication Date: 2025.08.21 FIVES INTRALOGISTICS SPA

AI summary

A method for managing one or more robots that includes providing a zone subject to restrictions in a structure; providing robots in the zone subject to restrictions; applying a limit to or inhibiting operating functions of the robots, detecting the presence of a predetermined number of first identification elements in the zone for each of the robots, detecting the presence of a predetermined number of second identification elements of the zone subject to restrictions, which are of a different type from that of the first identification elements for which the presence of the predetermined number of first identification elements has been detected and for which the presence of the predetermined number of second identification elements is detected, disapplying the limit or allowing functions; when, for a number of robots the limit has been disapplied or functions has been allowed, actuating the robots to perform operating tasks in the zone.Attachment: Clean Copy of Abstract on a separate sheet.