Modular man-machine collaborative express sorting system and method based on iterative algorithm

Abstract

The invention discloses a modular man-machine collaborative express sorting system and method based on an iterative algorithm. The system comprises an annular main conveying line, a plurality of standardized sorting modules arranged along the annular main conveying line and a system control center. And each sorting module comprises a cache region, a man-machine cooperation station and a rotatable turntable with a plurality of sorting grooves. The core of the method is that a system control center operates a set of iterative sorting optimization algorithm. According to the algorithm, containers to be processed are dynamically distributed to all stations through multi-round iterative calculation according to global scanning express data, the current station of the system and the number of sorting grooves, and target delivery areas are dynamically distributed or combined for the sorting grooves of all the stations. Through the iterative process of'distribution-sorting-transfer-redistribution ', the problem of complex sorting when the number of delivery areas is far greater than the number of physical sorting grooves is efficiently solved. According to the method, the scale of the sorting system is flexible and adjustable, the sorting strategy is intelligently and dynamically optimized, and excellent balance is achieved among cost, efficiency and flexibility.

Description

Technical Field

[0001] This invention relates to the field of logistics automation technology, specifically to an express delivery sorting system, and more particularly to a modular human-machine collaborative express delivery sorting system and method based on iterative algorithms for dynamic task allocation and path planning. Background Technology

[0002] With the rapid development of e-commerce logistics, the processing volume of express sorting centers has surged, placing higher demands on sorting efficiency and flexibility. Traditional express sorting mainly relies on fully automated cross-belt sorting machines or purely manual sorting. Fully automated sorting machines require huge investments, occupy a large area, and have poor flexibility, making them difficult to adapt to small and medium-sized sorting stations or scenarios with large fluctuations in business volume. Purely manual sorting, on the other hand, is inefficient, has a high error rate, and high management costs.

[0003] Existing semi-automated sorting lines attempt to combine the advantages of humans and machines, but they typically suffer from the following problems: 1) Poor system scalability, with a fixed number of workstations that cannot be flexibly increased or decreased based on workload; 2) Rigid sorting logic, unable to dynamically optimize sorting strategies based on real-time package data; 3) Uneven task allocation across workstations, easily leading to uneven workloads, with the overall efficiency bottleneck limited to the slowest workstation. Therefore, there is an urgent need for a cost-effective, flexibly scalable solution that can dynamically improve overall sorting efficiency through intelligent algorithms. Summary of the Invention

[0004] The technical problem this invention aims to solve is to overcome the shortcomings of existing technologies and provide a modular human-machine collaborative express sorting system and method based on iterative algorithms. This system can be flexibly configured according to the scale of sorting tasks and site conditions, and dynamically optimizes the allocation and execution order of sorting tasks among various workstations through iterative algorithms, thereby achieving optimal overall system efficiency.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A modular human-machine collaborative express sorting system based on an iterative algorithm, characterized in that it includes: Circular main conveyor line: Consists of a roller conveyor system, used for the cyclical transport of standard containers carrying express parcels (“Small-capacity express transport container with a detachable locking / positioning function bar scanner”, Chinese patent CN202110561911). At least one sorting module: arranged along the outside of the circular main conveyor line, each sorting module comprising: Sorting buffer area: Connected to the main conveyor line via controllable opening and closing guardrail rollers, used for temporary storage and buffering of standard containers to be processed assigned to this module; Human-machine collaborative sorting station: It is equipped with a sorting operation table, barcode scanning equipment and operation terminal for sorting staff to scan and deliver express packages; Rotatable sorting turntable: Located next to the sorting operation table, the turntable has multiple sorting slots along the circumference, each sorting slot corresponding to a destination delivery area and accommodating a standard container; the sorting turntable can automatically rotate according to the barcode information and align the target sorting slot with the sorting operation table; System control center: Communicatively connected to the global barcode scanner on the main circular conveyor line, the opening and closing guardrail rollers of each sorting module, the barcode scanning equipment, and the rotatable sorting turntable; The system control center runs an iterative sorting optimization algorithm for: a) Initialization: Obtain global barcode scanning data of a batch of standard containers to be sorted, and obtain the set of destination delivery areas for all express parcels in each container; b) Iterative allocation: Based on the number of online sorting modules, the number of sorting slots on each module's sorting turntable, and the distribution of the destination delivery area for express parcels, iterative calculations are performed with the optimization goal of "maximizing the current processing efficiency of each workstation and balancing the load of subsequent tasks." c) Dynamic programming: In each iteration, standard containers to be processed in the current batch are assigned to each sorting module, and destination delivery areas are dynamically allocated or merged in the carousel sorting slots of each module; the delivery area tasks corresponding to express parcels that have not been fully sorted in the current iteration are used as input parameters to enter the next iteration and are passed to the downstream sorting modules. d) Control execution: Based on the iterative calculation results, control the main circular conveyor line to transport standard containers to the designated sorting module buffer area, and control the mapping relationship between the dispatch area and sorting slot of each module sorting turntable.

[0006] A parcel sorting method based on an iterative algorithm, applied to the above system, is characterized by comprising the following steps: S1: Standard Container Online and Global Scan: The centralized container for sorting express parcels enters the circular main conveyor line, is scanned by the global barcode scanner, identifies the destination delivery area information of all express parcels in the container, and uploads the data to the system control center; S2: Iterative Task Planning: The system control center runs an iterative sorting optimization algorithm. Based on the current system status (number of workstations, turntable capacity) and global task data, it generates a container allocation plan and a sorting plan for each workstation after multiple rounds of iterative calculations. S3: Container Distribution and Buffering: Based on the distribution scheme in S2, control the opening and closing guardrail rollers of the corresponding module to open and import the standard containers into the sorting buffer area of ​​the corresponding sorting module. S4: Human-machine collaborative sorting: The sorter takes the express package out of the container in the buffer area, scans the barcode at the sorting operation table, and the system automatically controls the rotating sorting turntable to rotate the sorting slot of the corresponding delivery area to the delivery port, and the sorter puts the express package in. S5: Container Recycling and Reuse: When a sorting slot is full of standard containers or the task is completed, the container is sent back to the main circular conveyor line. An iterative algorithm can determine whether to send it to the next sorting module for further processing or to send it out of the system as a sorted container.

[0007] The beneficial effects of this invention are as follows: Highly modular and scalable: The system uses sorting modules as the basic unit and can be flexibly configured with anywhere from one to hundreds of workstations depending on the size of the site and the volume of business, achieving "on-demand deployment and elastic scaling".

[0008] The core of intelligent iterative optimization: By introducing an iterative sorting optimization algorithm, the system can dynamically handle complex sorting tasks. When faced with a situation where the number of delivery areas far exceeds the number of individual carousel sorting slots, the algorithm ensures that all express packages can be effectively sorted by iteratively merging and transferring tasks, while simultaneously optimizing global resource allocation to avoid idle or congested workstations.

[0009] Balancing efficiency and flexibility: The human-machine collaborative model leverages the flexibility of manual handling of non-standard and complex parts while improving overall efficiency through automated conveying and intelligent scheduling. The algorithm dynamically plans based on real-time data (such as the scanning results of arriving containers), achieving "data-driven decision-making" and significantly enhancing the processing efficiency of large-scale sorting centers.

[0010] Smooth upgrade path: The current human-machine collaborative workstations can be seamlessly upgraded to fully automated robotic sorting units in the future, without major changes to the system architecture, conveyor lines and control algorithms, thus protecting the investment.

[0011] Deep integration with standardized containers: The system is designed to work with standard containers such as "small-capacity express delivery container with detachable locking / positioning scanning gun" (Chinese patent CN202110561911), realizing a unitized and information-based closed loop from transportation to sorting, which facilitates full-process tracking and cross-transportation. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the overall structure of the modular human-machine collaborative express sorting system based on iterative algorithms described in this invention.

[0013] Figure 2 This is a schematic diagram of the state of the modular human-machine collaborative express sorting system based on iterative algorithm described in this invention, where the sorting station sorts a box of express, opens the opening and closing guardrail roller (to the sorting turntable outlet), and sends it back to the roller conveyor system (circular main conveyor line).

[0014] Figure 3This is a schematic diagram of the state of the sorting station preparing to sort express packages in the modular human-machine collaborative express sorting system based on iterative algorithm described in this invention, where the opening and closing guardrail roller (to the entrance of the sorting buffer area) sends the packages to the sorting rack (sorting buffer area).

[0015] The diagram labels are as follows: 1-Roller conveyor system (circular main conveyor line); 2-Conveyor roller; 3-Guide roller; 4-Fixed guardrail roller; 5-Opening guardrail roller (to sorting turntable exit); 6-Opening guardrail roller (to sorting buffer area entrance); 7, 8-Global barcode scanner; 9-Workstation barcode scanner; 10-Sorting operating table; 11-Seat; 12-Operating computer / terminal; 13-Inclined express sorting turntable (rotatable sorting turntable); 14-Inclined sorting trough; 15-Sorting trough conveyor roller; 16-Transition section conveyor roller; 17-Pending sorting rack (pending sorting buffer area); 18-Buffer area conveyor roller; 19-Buffer area guide roller; 20, 21-Buffer area fixed guardrail roller; 22-Pending sorting express collection box (standard container); 23-Sorted express collection box (standard container). Detailed Implementation

[0016] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0017] like Figure 1 As shown, the core of the sorting system provided by this invention is a continuously operating circular main conveyor line (roller conveyor system 1). Several identical sorting modules can be installed along the outer side of this conveyor line as needed. Each module operates independently, but they coordinate with the main conveyor line and the central control system.

[0018] Taking one of the sorting modules as an example, let's illustrate its workflow: Task reception: A batch of parcel collection boxes 22 (i.e., standard containers) awaiting sorting are placed on the main conveyor line 1. As they pass through global barcode scanners 7 and 8, the QR codes on the boxes are scanned, and all parcel slip information inside the boxes is pre-read and uploaded to the system control center (which can be integrated into the operating computer 12 or the central server). The control center runs an iterative sorting optimization algorithm.

[0019] Algorithm Iteration and Decision-Making: Assume there are currently 50 sorting stations, each with a turntable 13 having only 5 sorting slots 14, and the parcels to be processed involve 100 different delivery areas. The algorithm will not simply divide the 100 areas equally among the 50 stations. Instead, it will perform the following iterative calculation: First iteration: The algorithm analyzes the destination distribution of all express packages and assigns the express containers to the sorting rack (sorting buffer area) 17 of the first workstation, but the first workstation only sorts the containers 22 of the 4 delivery areas (e.g., areas A, B, C, and D) corresponding to the 4 sorting slots on the turntable. Express packages from the 5th to the Nth delivery areas are assigned to the 5th sorting slot on the turntable of the first workstation and handed over to the next workstation for sorting.

[0020] Task Transfer and Second Iteration: After the first workstation finishes processing, the container containing the remaining unsorted parcels is returned to main conveyor line 1. The algorithm performs a second iteration, re-analyzing the distribution of these remaining parcels in the delivery areas for the second workstation, and dynamically allocating the next four delivery areas (potentially E, F, G, and H). Parcels from the 9th to Nth delivery areas are assigned to the 5th sorting slot on the turntable of the second workstation, and then handed over to the next workstation for sorting. This iterative cycle continues until all parcels have been allocated and sorted into their corresponding delivery area containers. For large sorting centers, the algorithm can perform a global iterative optimization of all workstations at once, achieving the highest overall efficiency.

[0021] Container diversion: Based on algorithmic decisions, the control center instructs the opening and closing guardrail rollers 6 to open, sending the designated container into the sorting buffer area 17 of this module. The buffer area is enclosed by fixed guardrail rollers 20 and 21, has a large area, and can temporarily store multiple layers of containers, serving as a buffer.

[0022] Human-machine collaborative sorting: such as Figure 2 As shown, the sorting operator sits on chair 11, retrieves a package from the container in buffer area 17, places it on sorting workbench 10, and scans it using workstation barcode scanner 9. After scanning, the operating computer 12, based on the "delivery area-sorting slot" mapping table set for that workstation by the algorithm, immediately controls the tilting express sorting turntable 13 to rotate, so that the sorting slot 14 of the corresponding delivery area, carrying the express container 22, is accurately aligned with the delivery port of the workbench (e.g., ...). Figure 3 (As shown in the diagram). The sorter then places the parcel into container 22 in the slot.

[0023] Container Recycling and Transfer: When a sorting slot 14 is full of containers 23, or when the sorting task in that delivery area is completed, the sorter issues an instruction via computer 12. The opening and closing guardrail rollers 5 open, and with the relay of the sorting slot conveyor rollers 15 and the transition section conveyor rollers 16, the container is returned to the main conveyor line 1. It may be sent to the next sorting module to continue participating in iterative sorting, or it may be transported to the exit as the final sorting result.

[0024] The key innovation of this invention lies in the iterative sorting optimization algorithm. This algorithm decomposes large-scale sorting tasks into multiple executable sub-tasks and dynamically allocates resources (workstations, sorting slots) through iteration, effectively solving the contradiction between limited physical resources (sorting slots) and massive logical targets (delivery areas), and achieving a qualitative improvement in the system's sorting capacity and efficiency.

Claims

1. A modular human-machine collaborative express sorting system and method based on iterative algorithms, characterized in that, include: A circular main conveyor line (1) is used for the cyclical transport of standard containers (22, 23). At least one sorting module is arranged along the circular main conveyor line (1), and each sorting module includes: A controllable buffer area (17) connected to the main conveyor line is used to receive and buffer standard containers allocated to the module; Sorting stations (10, 9, 11, 12) are equipped with human-machine interaction interfaces. A rotatable sorting turntable (13) is located next to the sorting station, and its surface is provided with multiple sorting slots (14) for accommodating standard containers. The system control center is connected to the global barcode scanning devices (7, 8) set on the main conveyor line, the controllable buffer area (17) of each sorting module, the human-machine interface and the rotatable sorting turntable (13); The system control center is configured to run an iterative sorting optimization algorithm. Based on global barcode scanning data, the number of online sorting modules and the number of sorting slots, the algorithm dynamically allocates standard containers to each sorting module and dynamically allocates or merges destination delivery areas for the sorting slots of each module through multiple rounds of iterative calculations, thereby completing all sorting tasks in an iterative manner.

2. The system according to claim 1, characterized in that, The execution process of the iterative sorting optimization algorithm includes: Initialization steps: Obtain the set of delivery area information for all express parcels in all standard containers of the current batch; Iterative optimization steps: In each iteration, with the goal of maximizing the real-time processing efficiency of the sorting modules currently participating in the iteration, a set of delivery areas is assigned to the sorting slots of each module, and containers containing express parcels not assigned to delivery areas are marked as pending delivery. Task transfer steps: Take the container to be transferred as input to trigger the next iteration until all express packages are assigned to the corresponding delivery area sorting slot.

3. The system according to claim 1 or 2, characterized in that, The controllable buffer area (17) is connected to the annular main conveyor line (1) through an opening and closing guardrail roller (6) controlled by the system control center.

4. The system according to claim 1, characterized in that, The rotatable sorting turntable (13) is an inclined turntable, and its sorting groove (14) is equipped with a conveyor roller (15) for sending out full standard containers.

5. The system according to claim 1, characterized in that, The standard containers (22, 23) are unitized transport containers with unique identification codes and detachable locking scanners.

6. A parcel sorting method based on an iterative algorithm, applied to the system described in any one of claims 1-5, characterized in that, include: Standard containers are transported via the circular main conveyor line (1) and global scanning is performed to obtain the sorting task dataset; The system control center executes an iterative sorting optimization algorithm, performs multiple rounds of iterative calculations on the sorting task dataset based on the current system configuration, and generates container allocation instructions and sorting slot-delivery area dynamic mapping instructions. According to the container allocation instructions, standard containers are diverted to the buffer area (17) of the designated sorting module. At the sorting station, after the manual pick-up and scanning of the item, the system controls the rotatable sorting turntable (13) to rotate according to the sorting slot-delivery area dynamic mapping instruction, so that the target sorting slot is aligned with the delivery station. The express parcels are manually placed into the standard containers at the target sorting slot; Standard containers that have completed sorting tasks are recycled, and the results of the iterative algorithm determine whether they should enter the next round of iterative sorting or be output as the final result.

7. The method according to claim 6, characterized in that, The execution of the iterative sorting optimization algorithm includes: when the total number of destination delivery areas N is greater than the number of sorting slots M of a single sorting turntable, the algorithm selects at most M delivery areas for current sorting for each turntable in each iteration, and transfers the sorting tasks of the remaining delivery areas to subsequent iterations for processing via containers.

8. The method according to claim 6, characterized in that, In large sorting centers with multiple sorting modules, the iterative sorting optimization algorithm performs global optimization iterations, calculating the optimal container allocation and delivery area allocation scheme for all online modules at once to minimize the overall sorting completion time.

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