Vertical sorting system for sorting parcels

Abstract

A vertical sorting system (100, 200, 300, 400) is designed for efficient parcel sorting The vertical sorting system (100) includes an induction system (102) to receive and identify parcels (104) and one or more vertical frame structures extending upwardly from a base (108). One or more movable carriage units are 5 coupled with the one or more vertical frame structures, enabling movement in both horizontal and vertical directions. The plurality of buffer carriage units (112, 402) supports the loading operations of one or more movable carriage units, while plurality of discharge locations (114) are positioned at various heights and in horizontal racks along the one or more vertical frame structures. At least one 10 processor (132) manages parcel identification, directing each movable carriage unit to transport parcels (104) to designated discharge locations.

Description

VERTICAL SORTING SYSTEM FOR SORTING PARCELS TECHNICAL FIELD

[0001] The present disclosure relates generally to the field of material sorting systems and, more specifically, to vertical sorting system for sorting parcels. BACKGROUND

[0002] In today’s manufacturing industry, ecommerce and warehousing industry, the use of material handling equipment is important for speedy movement of materials from one location to another and sorting the materials. The common material handling equipment used in the manufacturing industry, ecommerce and warehousing industry are conveyor systems, cranes, industrial trucks, and the like. The conveyor systems are used specifically when the material is to be moved frequently between specific points along a fixed path. Further, conveyor-based sorting systems are used to sort the materials received through a conveyor.

[0003] The common sortation systems currently offered in the market are complex, require high space to install, are high maintenance driven and require high capital expenditure expense. At the same time, common sortation systems are not susceptible to adapt to the changing warehouse environments. Traditional sorting systems, operating on a single horizontal plane, rely on conveyors and mechanisms that occupy significant floor space and have limited capacity to scale or handle growing demands. The current set of automation solutions available in the market such as horizontal belt sorters, cross-belt sorters, arm-based sorters, each face challenges as they often require large floor areas, have high installation costs, and offer limited flexibility. The horizontal belt sorters and cross-belt sorters are confined to single-plane configurations, restricting expansion, while traditional vertical systems provide limited control, risking parcel damage. Operationally, the existing sorting systems are rigid, with fixed sorting capacities, limited buffering, and inefficiencies in handling varying parcel sizes, creating bottlenecks and slowingprocessing. Integration with existing warehouse systems is often complex, and system adaptability to volume changes is limited.

[0004] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional sorting systems.SUMMARY

[0005] The present disclosure provides a vertical sorting system for sorting parcels. The present disclosure provides the technical problem of how to efficiently sort a large number of parcels within a confined space and minimize floor space requirements while maintaining high sorting capacity. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art and provide an improved vertical sorting system that efficiently utilizes both horizontal and vertical space to sort in a three-dimensional space while maintaining high throughput rates. The vertical sorting system achieves three-dimensional space sorting through a unique combination of a movable carriage unit operating in multiple dimensions, supported by buffer carriage units that optimize loading operations. Further, the vertical sorting system maximizes vertical space, provides modular and scalable design, optimizes buffering, and supports real-time sorting adjustments. The vertical sorting system enables highspeed, accurate sorting, accommodates diverse parcel volumes, and simplifies maintenance, marking a significant improvement in parcel sorting.

[0006] One or more objectives of the present disclosure is achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.

[0007] In one aspect, the present disclosure provides a modular sorting machine for sorting parcels. The vertical sorting system includes an induction system configured to receive and identify parcels. The vertical sorting system furtherincludes one or more vertical frame structures extending upwardly from a base and one or more movable carriage units operatively coupled with the one or more vertical frame structures. Each movable carriage unit is configured to move in both horizontal and vertical directions within the one or more vertical frame structures. Further, the vertical sorting system further includes a plurality of buffer carriage units arranged to support loading operations of the one or more movable carriage units. Furthermore, the vertical sorting system includes a plurality of discharge locations arranged at various heights along each vertical frame structure and in horizontal racks, each discharge location configured to receive parcels from the one or more movable carriage units. Furthermore, the vertical sorting system includes at least one processor configured to receive parcel identification and destination information from the induction system, direct the movement of the one or more movable carriage units in both horizontal and vertical directions to transport parcels to designated discharge locations based on the received parcel identification and destination information, and enable three-dimensional sorting of parcels by coordinating movement of each movable carriage unit across vertical heights and horizontal positions while utilizing the plurality of buffer carriage units for efficient parcel transfer.

[0008] By incorporating vertical frame structures extending upward from the base, the vertical sorting system effectively utilizes warehouse height, reducing the floor space needed. The strategic arrangement of discharge locations at various heights, along with horizontal racks, allows for an expanded number of sorting destinations without increasing the footprint of the facility space. The three-dimensional sorting capability enhances the sorting capacity per square foot, optimizing overall facility space. The flow of parcel management is achieved with precision through the induction system that identifies each parcel and works in tandem with the processor (there can be more than one) equipped with advanced routing operations. The processor ensures precise tracking and smooth parcel movement throughout the vertical sorting system. The plurality of buffer carriage units contributes to a steady, uninterrupted loading pipeline, minimizing any waiting time for the one or more movable carriage units and maintaining a constantparcel flow management that prevents bottlenecks. Dynamic operation of the vertical sorting system is further enhanced by the processor, which coordinates movement based on real-time parcel identification and destination data. At the same time, the movable carriage units offer bi-directional flexibility, navigating both horizontally and vertically to create adaptable routing paths. The plurality of buffer carriage units also serves as temporary storage, allowing the vertical sorting system to handle fluctuating input rates efficiently. Optimized movement control ensures the precision of the vertical sorting system, as destination data integration with carriage control (i.e., the one or more movable carriage units and the plurality of the buffer carriage units) allows for detailed path planning. The cooperative operation between the plurality of the buffer carriage units and the one or more movable carriage units reduces transfer times, and the three-dimensional movement capability allows each parcel to follow the shortest possible route to its destination. Integration of components, where the induction system feeds destination data directly to the processor (can be more than one), orchestrates the plurality of the buffer carriage units and the one or more movable carriage units operations seamlessly, while the vertical frame structure supports the functions without restricting movement.

[0009] Further, the plurality of discharge locations is positioned strategically to optimize accessibility, further enhancing the flow of the vertical sorting system. The vertical sorting system reduces sorting times achieved through optimized path selection, improved throughput enabled by a continuous buffer system, and enhanced accuracy from coordinated control and precise tracking. The modular discharge locations make capacity easily scalable, offering the flexibility of the vertical sorting system for future expansions. The efficiency of the vertical sorting system is further enhanced by reducing mechanical stress through controlled acceleration and deceleration, optimizing energy consumption with efficient path planning, and improving maintenance accessibility through a modular design.

[0010] In another aspect, the present disclosure provides a method of sorting parcels in a vertical sorting system. The method includes receiving and identifyingparcels through an induction system. The method further includes determining a discharge location for each identified parcel from a plurality of discharge locations arranged at various heights along one or more vertical frame structures and in horizontal racks. The method further includes receiving parcels on a plurality of buffer carriage units for temporary storage. Further, the method includes transferring parcels from the plurality of buffer carriage units to one or more movable carriage units. The method further includes controlling the movement of each movable carriage unit in both horizontal and vertical directions within the one or more vertical frame structures. Further, the method includes monitoring parcel position using a plurality of sensors positioned along the movement paths of each movable carriage unit and the plurality of buffer carriage units. The method further includes optimizing the loading operations of each movable carriage unit through coordinated control of the plurality of buffer carriage units. Furthermore, the method further includes enabling three-dimensional sorting of parcels by directing each movable carriage unit to deliver parcels to their designated discharge locations across vertical heights and horizontal positions.

[0011] The method achieves all the advantages and technical effects of the vertical sorting system of the present disclosure.

[0012] It is to be appreciated that all the aforementioned implementation forms can be combined. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

[0013] Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed descriptionof the illustrative implementations construed in conjunction with the appended claims that follow.BRIEF DESCRIPTION OF THE DRAWINGSThe summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those skilled in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

[0014] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:FIG. 1 A is a diagram illustrating a perspective view of a vertical sorting system, in accordance with an embodiment of the present disclosure;FIG. IB is a diagram illustrating a top view of the vertical sorting system, in accordance with an embodiment of the present disclosure;FIG. 1C is a diagram illustrating a side view of the vertical sorting system, in accordance with an embodiment of the present disclosure;FIG. ID is a block diagram illustrating the vertical sorting system, in accordance with an embodiment of the present disclosure;FIG. 2 is a diagram illustrating a perspective view of a vertical sorting system, in accordance with another embodiment of the present disclosure;FIG. 3 is a diagram illustrating a top view of a vertical sorting system, in accordance with another embodiment of the present disclosure;FIG. 4 is a diagram illustrating a top view of a vertical sorting system, in accordance with another embodiment of the present disclosure; and FIG. 5 is a flowchart of a method for sorting parcels using the vertical sorting system, in accordance with an embodiment of the present disclosure.

[0015] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the nonunderlined number is used to identify a general item at which the arrow is pointing. DETAILED DESCRIPTION OF EMBODIMENTS

[0016] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.

[0017] FIG. 1A is a diagram illustrating a perspective view of a vertical sorting system, in accordance with an embodiment of the present disclosure. With reference to FIG. 1A, there is shown a vertical sorting system 100, which includes an induction system 102 configured to receive and identify parcels 104, one or more vertical frame structures extending upwardly from a base 108. For example, as illustrated in the embodiment of FIG. 1A, the vertical sorting system 100 has only one vertical frame structure, i.e., a vertical frame structure 106 extending upwardly from the base 108. In some other implementations, two vertical frame structures may be there. In yet another implementation, three vertical frame structures may be there. The vertical sorting system 100 further includes one or more movable carriage units operatively coupled with the one or more vertical frame structures, and each movable carriage unit is configured to move in both horizontal and vertical directions within the one or more vertical frame structures. For example, as illustrated in the embodiment of FIG. 1A, the vertical sorting system 100 includes only one movable carriage unit, i.e., a movable carriage unit 110 operatively coupled with the vertical frame structure 106. The movable carriage unit 110 is configured to move in both horizontal and vertical directions within the verticalframe structure 106. In some implementations, the movable carriage unit 110 comprises a specially customized belt with cleats configured to facilitate precise movement of various parcel types, including but not limited to cylindrical and irregularly shaped parcels. The configuration enables comprehensive sorting and order consolidation across multiple applications, including logistics, e-commerce, quick commerce, and fulfilment operations.

[0018] The vertical sorting system 100 further includes a plurality of buffer carriage units 112 arranged to support loading operations of the one or more movable carriage units. For example, as illustrated in the embodiment of the FIG.1A, the plurality of buffer carriage unit 112 is arranged with the movable carriage unit 110. The vertical sorting system 100 further includes a plurality of discharge locations 114 arranged at various heights along each vertical frame structure and in horizontal racks (explained in detail in FIG. IB), each discharge location configured to receive the parcels 104 from the one or more movable carriage units. As illustrated in the embodiment of FIG. 1A, the plurality of discharge locations 114 are present on the vertical frame structure 106 and in horizontal racks and receive parcels 104 from the movable carriage unit 110. The vertical frame structure 106 is enclosed on both sides by a plurality of safety mesh assemblies, i.e., a first safety mesh assembly 116A and a second mesh assembly 116B. The safety mesh assembly (for example, the first safety mesh assembly 116A) refers to a protective structure designed to ensure safety and operational efficiency within the vertical sorting system 100. The safety mesh assembly (for example, the first safety mesh assembly 116A) comprises a durable framework of interconnected metal or rigid grid panels with uniformly spaced lattice openings. Each of the safety mesh assemblies of the plurality of safety mesh assemblies allows for easy installation and includes integrated mounting points, reinforced comers for structural integrity, and access panels for maintenance. Functionally, each of the safety mesh assembly of the plurality of safety mesh assemblies provides safety by preventing unauthorized access, shielding operators from moving parts, containing falling objects, and defining a safety boundary. Each of the safety mesh assembly of the plurality ofsafety mesh assemblies (for example, the first safety mesh assembly 116A) supports visual monitoring, ventilation, light penetration, and maintenance access. The plurality of safety mesh assembly (for example, the first safety mesh assembly 116A and the second mesh assembly 116B) integrates with the vertical frame structure 106 of the vertical sorting system 100, enhancing stability, enabling modular expansion, and ensuring safety compliance.

[0019] The vertical sorting system 100 is configured to move the parcels 104 from one location to another and further sort the parcels in a plurality of discharge locations 114, based on the delivery address of the parcels 104 (i.e., a plurality of delivery locations). The parcels 104 may refer to delivery items or products that are introduced into the vertical sorting system 100 for sorting in the plurality of discharge locations 114. Examples of the parcels 104 may include but are not limited to, boxes, finished products, tools, spare parts or any other items capable of sorting. The plurality of delivery locations refers to addresses where the parcels 104 are intended to be delivered. For example, the parcels in a warehouse include three parcels, such as a first parcel, a second parcel and a third parcel. The first parcel is to be delivered to the city A, the second parcel is to be delivered to the city B, and the third parcel is to be delivered to the city C. Therefore, the cities A, B and C are the delivery locations for the three parcels. The plurality of discharge locations 114 refer to designated areas or spaces within the vertical sorting system 100 where sorting activities take place. In continuation with the previous example, there may be three containers arranged with the vertical sorting system 100, such as containers A, B and C. The input items to be delivered to the city A may be sorted and collected within the container A. Similarly, the input items to be delivered to cities B and C may be sorted within the containers B and C, respectively. In another example, the plurality of discharge locations 114 may be segregated into five delivery or sorting zones, such as north, south, east, west, and central zones, as per the destination city of the parcel at which it is to be delivered. In an implementation, each discharge location of the plurality of discharge locations 114 includes an entry sensor to detect incoming parcels 104, a discharge destination for receiving sorted parcels, andfurther the discharge destination includes a destination full sensor to verify successful parcel discharge.

[0020] The entry sensor is a detection device, for example, a photoelectric or infrared sensor array, positioned at the entrance of each discharge location of the plurality of discharge locations 114. The entry sensor monitors the approach and entry of parcels 104, interfacing directly with the vertical sorting system 100. The entry sensor detects the presence of incoming parcels 104, triggers destination verification, initiates the discharge sequence, monitors the timing of parcel entry, provides feedback to the movable carriage unit 110, and validates parcel dimensions during entry. The plurality of discharge destinations serves as the designated receptacle for sorted parcels. In an implementation, the plurality of discharge locations 114 may be chutes, a bag, a tote, or a bin with a structured support frame and mounting system. The plurality of discharge locations 114 is equipped with fill-level monitoring capability and a quick-change mechanism, the plurality of discharge locations 114 securely receives and contains parcels 104, enabling easy receptacle changes, monitoring fill levels, supporting organized parcel collection, and facilitating smooth parcel entry. The confirmation sensor acts as a secondary sensor after the discharge point, verifying successful parcel delivery by monitoring discharge completion and providing operational validation. The confirmation sensor involves confirming that the parcels 104 has fully entered the receptacle, verifying successful discharge, detecting any discharge failures, signalling completion to the processor, enabling the next operation sequence, and maintaining sorting accuracy records. The induction system 102 refers to the system designed to receive and identify the parcels in a controlled manner as they enter the vertical sorting system 100. The induction system 102 includes an induction conveyor, barcode scanner, entry and exit sensors, transfer mechanism, rejection mechanism, and a local control unit. The induction system 102 receives parcels 104 from upstream sources, reads and validates identification data, regulates parcel spacing, and transfers compliant parcels 104 to the plurality of buffer carriage units 112.

[0021] The plurality of buffers carriage units 112 refers to workstations that are configured to receive the parcels 104 to be sorted in the plurality of discharge location 114. Further, the plurality of buffers carriage units 112 is configured to receive the parcels from the induction system 102. For example, one parcel may be placed at a time over each buffer carriage unit from the induction system 102 during the operation of the vertical sorting system 100. In an implementation, each movable carriage unit includes a conveyor surface for supporting the parcel 104 and a movement mechanism enabling motion in both horizontal and vertical directions within the one or more vertical frame structures (for example, in an illustrated embodiment of FIG.1 A, the vertical frame structure 106). The conveyor surface is motorized with either a belt or roller design, offering stable support with an antislip surface to handle various parcel sizes securely. The conveyor surface is dimensioned to accommodate a wide range of parcel dimensions and integrates with transfer mechanisms for seamless handoff.

[0022] Each of the buffer carriage units of the plurality of buffer carriage units 112 further includes a frame structure supporting a conveyor surface. The frame structure is composed of durable materials such as steel or aluminium, designed to withstand the rigours of frequent movement and weight loads from parcels 104. The frame structure is engineered to balance strength with minimal weight, maximizing load capacity while reducing energy consumption during movement. The conveyor surface is mounted on the frame structure and is responsible for parcel movement across the plurality of buffer carriage units 112. The conveyor surface is typically made of a high-friction, durable material that minimizes slippage and wear. The conveyor surface may consist of a series of belts, rollers, or similar mechanisms, depending on the design requirements, and ensures that parcels can be smoothly transported to the desired discharge destination. The plurality of buffer carriage units 112 further includes a servo motor-based drive system for precise movement control. The servo motor-based drive system uses a servo motor for driving the conveyor surface, which allows for precise and controlled movement of the carriage. The servo motors are chosen for their accuracy and reliability inpositioning, making them ideal for applications where exact parcel alignment and placement are essential. By controlling the speed and position of the conveyor surface, the servo motor ensures smooth acceleration and deceleration, reducing the risk of parcel shifting or dislodging. In some implementations, the plurality of buffer carriage units 112 may include de roller. In some other implementations, the plurality of buffer carriage units 112 may include a device which helps conveyor to move.

[0023] Each of the buffer carriage units of the plurality of buffer carriage units 112 further includes a carriage controller for local movement control. The carriage controller is an embedded control unit responsible for local movement and operational control of each buffer carriage unit of the plurality of buffer carriage units 112. The carriage controller manages the servo motor, interprets input from various sensors, and ensures that each buffer carriage unit of the plurality of buffer carriage units 112 operates in sync with the vertical sorting system 100. The controller enables real-time adjustments based on incoming data, such as parcel weight, size, and position. The vertical sorting system 100 further includes a rejection destination 113 and a plurality of rejection locations 118.

[0024] The vertical sorting system 100 offers precise positioning at pickup and discharge points, with operation controls that include independent control of the conveyor surface, synchronized motion, position monitoring, speed regulation, and safety interlocks.

[0025] FIG. IB is a diagram illustrating atop view of the vertical sorting system, in accordance with an embodiment of the present disclosure. FIG. IB is described in conjunction with elements of FIG. 1A. With reference to FIG. IB, there is shown the vertical sorting system 100, which further includes horizontal racks 120 arranged laterally along the vertical frame structure 106 that serve as organized discharge locations for sorted parcels 104 and the plurality of guide railings 122 for allowing motion of the movable carriage unit 110.

[0026] FIG. 1C is a diagram illustrating a side view of the vertical sorting system, in accordance with an embodiment of the present disclosure. FIG. 1C is described in conjunction with elements of FIGs. 1A and IB. With reference to FIG. 1C, there is shown the vertical sorting system 100, which includes the induction system 102 having a plurality of switches 124 present on the front side (i.e., from where the parcels 104 are being inducted) for starting, stopping & acknowledging changes. The induction system 102 further includes a digital display board 126. The digital display board 126 is a human machine interface (HMI) mounted on the front side of the induction system 102, designed to provide operators with real-time visual feedback and essential operational information. Structurally, the digital display board 126 includes a human machine interface integrated with system controls. Further, the incorporation of the HMI in the digital display board 126 enables users to select operation modes, navigate and read data for troubleshooting, monitor the performance of the vertical sorting system 100, and log in to the server. The functionalities can be accessed using a touchpad and an on-screen keyboard, providing an intuitive and user-friendly interface.

[0027] The digital display board 126 displays system status information, including the current operational mode, readiness of the induction system 102, error conditions, and emergency notifications. The digital display board 126 provides parcel processing details, such as barcode read confirmation, scanning status, dimension and weight measurements, and destination allocations. Additionally, the digital display board shows operational metrics like processing speed, throughput rate, buffer status, and queue information. Alert notifications for faults, maintenance needs, safety warnings, and mode changes are also communicated to operators through the display. Serving as a critical interface, the digital display board 126 enables efficient system operation and monitoring by offering operators a comprehensive overview of system performance and parcel processing in realtime.

[0028] FIG. ID is a block diagram illustrating the vertical sorting system, in accordance with an embodiment of the present disclosure. FIG. ID is described inconjunction with elements of FIGs. 1A, IB and 1C. With reference to FIG. ID, there is shown the vertical sorting system 100 (as explained in FIGs. 1A, IB and 1C), which further includes a server 128 connected with a database 140, the plurality of buffer carriage units 112 and a user interface 146 through a communication network 138. Further, the server 128 includes at least one processor 132, a memory 130 and a network interface 136. Further, the memory 130 includes a plurality of delivery locations 134 and the plurality of discharge locations 114 of the parcels 104.

[0029] The server 128 is configured to identify the plurality of discharge locations 114 based on the plurality of delivery locations 134, operate the vertical sorting system 100 to sort the parcels 104 in corresponding discharge locations and update the sorting completion status in the database 140. In an implementation, the server 128 may be a master server or a master machine that is a part of a data center that controls an array of other cloud servers communicatively coupled to it for load balancing, running customized applications, and efficient data management. Examples of the server 128 may include, but are not limited to, a cloud server, an application server, a data server, or an electronic data processing device.

[0030] The memory 130 is configured to store the plurality of delivery locations 134 acquired by the plurality of buffer carriage units 112 and the plurality of discharge locations 114 identified by the at least one processor 132. Examples of implementation of the memory 130 may include but are not limited to, an Electrically Erasable Programmable Read-Only Memory (EEPROM), Dynamic Random-Access Memory (DRAM), Random Access Memory (RAM), Read-Only Memory (ROM), Hard Disk Drive (HDD), Flash memory, a Secure Digital (SD) card, Solid-State Drive (SSD), and / or CPU cache memory.

[0031] The at least one processor 132 is a computational element that is configured to receive parcel identification and destination information from the induction system 102, operate the plurality of buffer carriage units 112, and the one or more movable carriage units (for example, the movable carriage unit 110) to sortthe parcels 104. Examples of the at least one processor 132 may include but are not limited to, a hardware processor, a digital signal processor (DSP), a microprocessor, a microcontroller, a complex instruction set computing (CISC) processor, an application-specific integrated circuit (ASIC) processor, a reduced instruction set (RISC) processor, a very long instruction word (VLIW) processor, a state machine, a data processing unit, a graphics processing unit (GPU), and other processors or control circuitry.

[0032] In some implementations, there may be one master processor and several slave processors. The vertical sorting system 100 is controlled by the at least one processor 132, which manages and coordinates various operations of the vertical sorting system 100. The processor architecture may be implemented in multiple configurations based on operational requirements and the complexity of the vertical sorting system 100. For example, in a single processor configuration, a single master processor may handle all operations of the vertical sorting system 100, including the induction control, movement coordination, and sorting operations. The processor receives parcel identification and destination information from the induction system 102, processes the data, and controls the movement of carriage units while managing buffer operations. Further, in distributed processor configuration, the vertical sorting system 100 can employ a distributed processor architecture comprising one master processor and multiple slave processors. The master processor serves as the central control unit, managing the overall coordination of the vertical sorting system 100, while slave processors handle specific subsystem operations:

[0033] The master processor coordinates overall operation, manages communication between subsystems, handles high-level decision-making, and maintains synchronization. For example, an induction system processor controls parcel reception, identification, and transfer operations at the induction point, communicating results to the master processor, a movable carriage processor manages the movement and positioning of the movable carriage unit 110, executing motion commands from the master processor. A buffer management processorcontrols the plurality of buffer carriage units 112, optimizing loading operations and transfer timing. A discharge location processor monitors discharge operations, sensors, and bin status, ensuring proper parcel delivery.

[0034] Each slave processor operates under the supervision of the master processor, executing specific tasks while maintaining system-wide coordination. The distributed architecture enables parallel processing of different operations, enhancing responsiveness and throughput of the vertical sorting system 100. The at least one processor 132 communicate through a dedicated network, ensuring realtime data exchange and synchronized operation. In some implementations, critical operations may incorporate redundant processors to ensure the reliability of the vertical sorting system 100. In case of processor failure, the vertical sorting system 100 can switch to backup processors, maintaining essential operations. The redundancy is particularly important for continuous operation in high-throughput environments.

[0035] The database 140 is a storage device or storage server, which is configured to store the details of the correlation between the plurality of delivery locations 134 and the plurality of discharge locations 114. In an implementation, the database 140 includes a sorting completion status 144, that is details regarding whether a particular input item is sorted or not. In an implementation, the database 140 is a remote cloud-based server.

[0036] In an implementation, the vertical sorting system 100 further includes the user interface 146 displaying real-time system status, visual indicators showing the operational state of each carriage unit (i.e., each of the movable carriage unit of the one or more movable carriage units and each of the buffer carriage units of the plurality of buffer carriage units 112), and monitoring displays for sorting performance metrics.

[0037] In an implementation, the at least one processor 132 is configured to retrieve the details regarding the plurality of discharge locations 114 of the parcels 104 from the database 140 based on the plurality of delivery locations 134. Inaddition, the at least one processor 132 is configured to cause each parcel to reach the movable carriage unit 110 from the plurality of buffer carriage units 112 corresponding to the identified sorting location of each parcel.

[0038] In an implementation, the vertical sorting system 100 includes a plurality of sensors positioned along a path of each movable carriage unit and each of the plurality of buffer carriage units 112. During the operation of the vertical sorting system 100, the at least one processor 132 monitors the position of parcels 104 throughout the sorting process using a plurality of sensors. The at least one processor 132 determines the sorting location for a definite parcel based on the delivery location of the corresponding parcel. Further, based on the discharge location of the parcels 104, the at least one processor 132 determines the movable carriage unit 110, which is needed to be moved in either left or right direction perpendicular to the base 108 in order to deposit the parcels 104 into the identified discharge location. Further, in case the parcels 104 reaches to the movable carriage unit 110, the sensor mounted over the target movable carriage unit detects the presence of the parcels 104 and transmits signals to the processors.

[0039] The vertical sorting system 100 includes multiple carriage units, such as the plurality of buffer carriage units 112 and the one or more movable carriage units, which are separate modules and are detachably attached to each other. The modular design of the vertical sorting system 100 makes it easy to scale up or down as needed. For example, if the volume of parcels increases, more plurality of buffer carriage units and movable carriage units can be added to the vertical sorting system 100. The use of the plurality buffer carriage units 112 within the movable carriage units introduces a modular approach to the design. Each movable carriage unit can function as an independent unit that contributes to the overall operation of the vertical sorting system 100. The technical advancement allows the vertical sorting system 100 to reposition and rearrange items with high accuracy, leading to efficient sorting operations and reducing the chances of errors. In another example, the ability of the movable carriage units to move laterally provides the machine with greater flexibility in its sorting strategies. It can adapt to varying sortingrequirements and accommodate changes in the sorting process as needed. The technical advancement enhances the versatility and adaptability of the vertical sorting system 100.

[0040] In operation, the at least one processor 132 is configured to receive parcels 104 identification and destination information from the induction system 102. The process begins with parcel reception, where the operator places the parcels 104 on the induction system 102. Here, the induction system 102 scans and identifies the parcelsl04, conducting an initial validation of the parcels 104. For example, the identification (for example, a tracking ID) and destination information are then assigned to each parcel for accurate tracking throughout the sorting process. During initial processing, the induction system 102 performs barcode scanning with a response time usually in milliseconds, measures the parcel’s dimensions, verifies weight, and logs the data into the database 140. The induction system 102 also has a rejection handling system for unreadable or problematic parcels. The rejection handling system for unreadable or problematic parcels is configured to identify one or more ineligible parcel from the parcels 104 that meet one or more ineligibility criteria. In an implementation, the rejection handling system is a hardware component that is connected with the at least one processor 132 and is configured to receive information regarding the barcode, weight and dimensions acquired by the plurality of buffer carriage units 112. Further, the rejection handling system is configured to check the barcode, weight, and dimensions with respect to the sorting criterion. Examples of the ineligibility criterion may include, but are not limited to, the following list of criteria:1) Parcel with a weight less than 50 g.2) Odd-shaped parcel (Odd-shaped items can be round, uneven, and oblong in shape).3) Parcels 104 with height greater than length and width.4) Parcels 104 having dimensions greater than 350 x 350 x 200 mm (LxBxH).5) Parcels 104 having dimensions less than 50 x 50 x 10 mm (LxBxH).6) Parcels 104 weighing more than 5 Kg.7) Parcels 104 weighing less than 50 g.8) Parcel has no label or barcode at all.9) The barcode is damaged or otherwise unreadable due to a number of reasons: the contrast is too low, there are ratio problems; or the bar code width or height does not comply with specifications.10) Barcodes that are covered with foil can also sometimes be hard to read due to reflections.11) The barcode is readable, but the structure of the data contained in the barcode is not compliant.12) The barcode is readable but does not contain sufficient data that enables further processing.13) Parcels 104 with barcode size lesser than 13 mil.14) Parcelsl04 placed with barcode outside matrix shown over carriage.15) Parcels 104 having multiple barcodes.16) Parcels 104 with dimensions 50 x 50 x 10 mm and weight 8 kg 17) Parcels 104 with dimensions 350 x 350 x 350 mm and weight 50 g 18) Parcels 104 that are enclosed in a soft-sided pack, such as a bubble mailer.19) Parcels 104 enclosed in a plastic shrink wrap or stretch wrap. 20) Parcels 104 bound using a plastic, metal, or cloth banding or items with wheels, straps, handles, and casters.

[0041] In an implementation, the rejection handling system utilizes the very first conveyor to manage ineligible parcels. If a parcel is determined to be ineligible by the rejection handling system, the conveyor directs the parcel to the rejection conveyor 113, where it is dropped into a designated trolley for rejected items. Conversely, if the parcel is accepted, the conveyor of induction system 102 moves the parcel to the plurality of buffers 112, allowing the parcel to proceed to subsequent conveyors for further processing... In order to perform the data acquisition of the parcels 104, a barcode scanner, a camera, and a weight sensor are positioned over the plurality of the buffer carriage units 112 to scan the barcode measure dimensions and weight, respectively. In an implementation, the at least one processor 132 is configured to obtain the delivery location of each item during the data acquisition of the parcels 104. The barcode printed over the includes information about the delivery location of the corresponding parcel. In an implementation, the correlation between the delivery location and the corresponding discharge location is predefined and stored in the memory 130 associated with the at least one processor 132.

[0042] Following initial processing the buffer management stage engages, which involves the plurality of buffer carriage units 112 receiving parcels 104 from the induction system 102 and providing temporary storage. The plurality of buffer carriage units 112 synchronize their movement with the one or more movable carriage units (for example, the movable carriage unit 110), managing the parcels 104 queues for a continuous flow.

[0043] When the parcel is received temporarily on the buffer carriage unit of the plurality of buffer carriage units 112 from the induction system 102, the plurality of buffer carriage units 112 acts as an intermediary platform to optimize sorting flow and avoid congestion of the vertical sorting system 100. The process involvesprecise control and coordination to ensure that parcels are efficiently transferred to their final destinations while maintaining system integrity.

[0044] For example, a parcel received from the induction system 102 after barcode scanning, weight, and dimensions measurement, and the determined of the discharge location (e.g., a chute “D”). However, the chute “D” is currently occupied or experiencing a delay. The induction system routes the parcel to the nearest available buffer carriage unit. The parcel “D” is securely placed on the buffer carriage unit. The at least one processor 132 keeps track of the location of the parcel location through sensors on the buffer carriage unit and maintains its sequence in the sorting order. While the parcel is on the buffer carriage unit, the at least one processor 132 continuously monitors the chute “D” to detect when the chute “D” becomes available. Once the chute “D” is ready, the at least one processor 132 sends a command to the corresponding buffer carriage unit to release the parcel.

[0045] As the parcel is temporarily held on the buffer carriage unit after being received from the induction system 102. The location of the parcel (e.g., the chute “D”) is now available, and the at least one processor 132 signals the buffer carriage unit to prepare for transfer in real time. The sensors on the buffer carriage unit of the plurality of buffer carriage units 112 verify the presence of the parcel 104 and confirm it is ready for transfer. The at least one processor 132 detects the proximity of the movable carriage unit 110 to receive the parcel 104. The movable carriage unit 110 aligns with the buffer carriage unit of the plurality of buffer carriage units 112 under the guidance of position sensors and motion controls to ensure precise placement. The buffer carriage unit activates the corresponding conveyor belt to move the parcel 104 toward the movable carriage unit 110. The process is synchronized so that the parcel 104 smoothly transitions from the buffer carriage unit to the movable carriage unit 110 without misalignment or delay. Once the parcel 104 is on the movable carriage unit 110, the entry sensors on the movable carriage unit 110 confirm the presence of the parcel 104. The at least one processor 132, updates the real-time location of the parcels 104 and ensures it is securely placed for transport to its final sorting chute. The movable carriage unit 110, nowcarrying the parcel 104, begins its journey to a corresponding discharge location (i.e., the chute “D”). The at least one processor 132 is configured to calculate the optimal path, considering other parcels in the vertical sorting system 100, and directs the movable carriage unit 110 to its discharge location.

[0046] For example, as the parcels 104 are held on the buffer carriage unit, waiting for chute ”D” to become available. The movable carriage unit 110 is directed by the at least one processor 132 to align with it. The rollers on the buffer carriage unit activate and gently push the parcels 104 onto the movable carriage unit 110. The sensors present on the movable carriage unit 110 confirm the presence of the parcels 104 on the movable carriage unit 110, and the vertical sorting system 100 updates its status.

[0047] Based on the information received from the sensors in the movable carriage unit 110, the at least one processor 132 is further configured to actuate the rotary actuator to operate the plurality of guide rails 122, which in turn causes horizontal and vertical movement of the movable carriage unit 110 in order to drop the parcel 104 into the identified discharge location (i.e., the chute “D”). In an implementation, the vertical sorting system 100 further includes a limit switch that prevents overtravel of the rotary actuator during the corresponding operation. In an implementation, each discharge location from the plurality of discharge locations 114 associated with a plurality of trolleys includes a stand for hanging one or more bags. The bags refer to a covering layer, which is to be wrapped around the parcels deposited into each discharge location. In some implementations, the plurality of trolleys comprises pigeon racks, totes, carton boxes, or any other type of container, as per client requirements, to facilitate sorting and order consolidation.

[0048] When the parcel 104 is transferred to the movable carriage unit 110, a movement mechanism enables motion in both horizontal and vertical directions within the one or more vertical frame structures (for example, the vertical frame structure 106). The movement mechanism includes a horizontal drive assembly enabling movement in a first axis (for example, X-axis), a vertical drive assemblyenabling movement in a second axis (for example, Z-axis), and position sensors to detect limits of movement in both axes. The movement mechanism of the movable carriage unit 110 encompasses a sophisticated system of drives, sensors, and control elements that enable precise three-dimensional movement within the vertical frame structure 106. The horizontal drive assembly, responsible for a first axis (i.e., X-axis movement), consists of servo motors coupled with precision belt or chain drive mechanisms mounted on linear guides. The horizontal drive assembly incorporates position encoders for accurate location tracking, speed sensors for velocity control, and limit switches to define the safe operational range. The vertical sorting system 100 enables precise control over acceleration, deceleration, and constant speed movement along the horizontal axis, ensuring smooth and efficient parcel transport. The vertical drive assembly, managing Z-axis movement, employs a counterbalanced system with the plurality of guide rails 122 and safety brakes to ensure secure and efficient vertical transportation. In an implementation, the vertical sorting system 100 utilizes dedicated height encoders for precise level positioning while incorporating multiple safety features, including emergency brakes and load monitoring sensors.

[0049] For example, the parcel 104 destined for the chute “D” is loaded onto the movable carriage unit 110 at level “2” within the vertical frame structure 106. The sensors on the movable carriage unit 110 detect the presence of the parcel 104 and send real-time data to the at least one processor 132 to confirm that the parcel 104 is securely loaded and ready for transport. The at least processor 132 calculates the optimal path to reach the horizontal position “X3”, aligning the movable carriage unit 110 with the correct vertical column for the chute “D”. The horizontal drive assembly, equipped with servo motors and linear guides, activates to move the movable carriage unit 110 along the X-axis. In some implementations, the horizontal drive assembly may be equipped with cart on rail track actuated by belt or rope. The position encoders continuously track the location of the movable carriage unit 110, ensuring precise alignment with “X3”. During the movement, thespeed sensors regulate the motion to ensure smooth acceleration and deceleration, preventing abrupt movements that may destabilize the parcel 104.

[0050] In some examples, once the movable carriage unit 110 reaches position “X3”, the vertical drive assembly engages to lift the movable carriage unit 110 from the level “2” to the level “5” (Z5). A counter-balanced system ensures that the lifting motion is stable and energy-efficient. Further, the height encoders monitor the vertical position of the movable carriage unit 110 to ensure it aligns accurately with level “5”. To enhance safety, brakes and load monitoring sensors are in place to prevent uncontrolled descent or overloading during the lifting process.

[0051] Further, position monitoring and control are achieved through the plurality of sensors strategically placed throughout the movement range of the movable carriage unit 110. For example, absolute position sensors help in exact location determination, incremental encoders track the movement, and proximity sensors ensure obstacle detection and alignment verification. For example, if the movable carriage unit 110 is misaligned, then proximity sensors send the information to the at least one processor 132, which, in effect, stops the operation. In an implementation, the vertical sorting system 100 further includes status indicators including start, stop, reset, and emergency indicators. During misalignment, the emergency indicators help in halting the process immediately. Examples of proximity sensors may include, but are not limited to, inductive sensors, capacitive sensors, ultrasonic sensors, photoelectric sensors, and the like. Examples of image sensors may include but are not limited to a camera, infrared sensor, charge-coupled device (CCD) sensor, complementary metal oxide semiconductor (CMOS) sensor and the like.

[0052] As the movable carriage unit 110 approaches level “5”, the sensors installed on the vertical frame structure 106 confirm the arrival and precise positioning of the movable carriage unit 110. The sensors communicate with the at least one processor 132, which verifies the alignment of the movable carriage with the chute “D” for unloading. Once the position is confirmed, the movable carriage unit 110 activates a motorized conveyor to release the parcel 104 from the movable carriageunit 110 onto the chute “D” During the transfer process, the sensors ensure the parcel is successfully transferred without slipping or misalignment. After releasing the parcel, the system processor updates the parcel's status to indicate successful delivery to the chute “D,” i.e., the discharge location.

[0053] The entire movement mechanism is governed by the at least one processor 132 (for example, a control processor) that coordinates both drive assemblies to execute optimized movement paths. In an implementation, the control processor calculates and implements efficient acceleration and deceleration profiles, manages speed transitions, and ensures accurate positioning at pickup and discharge points. The control processor also integrates comprehensive safety features, including collision avoidance, overload protection, and emergency stop functionality.

[0054] When the movable carriage unit 110 discharges the parcel 104 to the discharge location (i.e., the chute “D” for the parcel 104) the at least one processor 132 (for example, a discharge processor) manages entry and discharge processes meticulously. The entry process involves approach detection, position verification, speed control, and alignment checks. The discharge process follows, with entry sensor activation, parcel transfer, confirmation sensing, and success verification. When the parcel 104 approaches its designated discharge location, the entry sensor first detects the incoming parcel. For example, when the parcel 104 approaches the discharge location ( the chute “D”), the entry sensortriggers and signals the vertical sorting system 100 to prepare for discharge operations. The movable carriage unit 110 then precisely aligns with the corresponding discharge location (for example, the chute “D”), ensuring optimal positioning for a smooth transfer. As the parcel 104 enters the discharge location, the confirmation sensor verifies the successful transfer by detecting the parcel's complete passage.

[0055] Additionally, each discharge location of the plurality of discharge location 114 is equipped with a bag / tote full sensor that continuously monitors the fill level. For example, if the discharge location reaches 80% capacity, the full sensortriggers an alert sequence. The at least one processor 132 (for example, an indicationprocessor) immediately notifies operators through visual indicators (such as tower lamps) showing the specific location requiring attention. During this time, the vertical sorting system 100 automatically redirects subsequent parcels destined for this location to a temporary overflow area, preventing system disruption. The operation continues with the operator acknowledgement process. When an operator arrives to change the discharge location (for example, full chute or bag), the operator first scan the bag ’ s barcode to initiate the closure sequence . After replacing the full bag with an empty one, the operator scans the new bag's barcode and presses the acknowledge button, confirming the change is complete. The vertical sorting system 100 then verifies proper bag installation through its sensors and resumes normal sorting operations at the discharge location. The entire sequence ensures uninterrupted sorting operations while maintaining accurate tracking of all parcels. For example, if the discharge location (the chute "D)" processes an average of 100 parcels per hour, the full sensor might trigger after 85 parcels, allowing sufficient time for bag replacement without causing system delays. The integrated approach at each discharge location combines sensor technology, operator interaction, and system controls to maintain efficient and reliable sorting operations while ensuring proper parcel handling and system throughput.

[0056] FIG. 2 is a diagram illustrating a perspective view of a vertical sorting machine, in accordance with another embodiment of the present disclosure. FIG. 2 is explained in conjunction with elements of FIGs. 1A to ID. With reference to FIG.2, there is shown a vertical sorting system 200 having a direct bagging mechanism. In terms of functionality and operational function, the vertical sorting system 200 is similar to the vertical sorting system 100. However, the vertical sorting system 200 includes a vertical frame structure 202, a movable carriage unit 204, the plurality of buffer carriage units 112. The vertical sorting system 200 further includes a plurality of safety mesh assemblies (for example, as illustrated in the embodiment of FIG. 2, a first safety mesh assembly 206A and a second mesh assembly 206B) and a plurality of chutes 208.

[0057] The direct bagging mechanism in the vertical sorting system 200 represents an approach to parcel sorting where parcels are directly discharged into the bags positioned at various discharge locations along the vertical frame structure 202. The vertical sorting system 200 is specifically designed to optimize the final sorting stage by eliminating intermediate handling steps between sorting and bagging operations.

[0058] The vertical frame structure 202 provides a robust framework supporting multiple discharge levels, each equipped with dedicated bagging stations. At each discharge point, the structure incorporates mounting brackets and support frames specifically designed to securely hold bags in the optimal position for direct parcel reception. The plurality of chutes 208 are angled discharge paths that guide parcels smoothly into the bags, ensuring controlled and damage-free delivery.

[0059] The operation sequence begins at the induction system 102, where parcels are identified and assigned to specific bag locations. The movable carriage unit 204 transports parcels to their designated discharge points, working in conjunction with the plurality of buffer carriage units 112 to maintain continuous flow. When approaching the discharge location, the sensors verify both bag presence and available capacity before initiating the discharge sequence. Safety and accessibility are ensured through the implementation of the first safety mesh assembly 206A and the second mesh assembly 206B. The plurality of safety mesh assemblies protects operators from moving components, prevent unauthorized access to operational areas, and contains any potential falling objects.

[0060] Each bagging station in the vertical sorting system 200 is equipped with bag-holding mechanisms for stable attachment, fill-level sensors to monitor bag capacity, and quick-release systems for easy and fast bag changes. Status indicators display the current bag condition and fill levels, and access platforms allow operators to intervene when necessary. The direct bagging process is enhanced by control systems that optimize sorting efficiency through real-time monitoring of bag fill levels, automatic alerts for nearly full bags, and synchronized bag changeoperations. The vertical sorting system 200 also ensures load balancing across multiple discharge points and automatically redirects parcels if a bag location is unavailable. The integrated approach provides numerous operational benefits, such as reduced handling steps and labour needs, improved sorting accuracy through direct discharge, increased throughput capacity, better ergonomics for operators, simplified bag management, and a reduced risk of parcel damage. With a modular design, the vertical sorting system 200 can be flexibly configured to suit specific facility requirements, enabling the addition or modification of discharge locations as needed.

[0061] FIG. 3 is a diagram illustrating a top view of a vertical sorting machine, in accordance with another embodiment of the present disclosure. FIG. 3 is explained in conjunction with elements of FIGs. 1A to 2. With reference to FIG.3, there is shown a vertical sorting system 300 having dual frame configuration. The vertical sorting system 300 includes two vertical frame structures, such as a first vertical frame structure 302A and a second vertical frame structure 302B. The vertical sorting system 300 further includes two movable carriage units, such as a first movable carriage unit 304A and a second movable carriage unit 304B, the plurality of the buffer carriage units 112. The plurality of buffer carriage units 112 have multiple staging positions, bi-directional transfer capability, independent conveyor zones and load distribution management. The vertical sorting system 300 demonstrates a symmetrical layout where the first vertical frame structure 302A and the second vertical frame structure 302B are positioned parallel to each other, connected by the induction system 102 and the plurality of buffer carriage units 112. Each vertical frame structure extends vertically and incorporates multiple levels of discharge locations, creating a three-dimensional sorting matrix that maximizes sorting capacity within the footprint of the vertical sorting system 300.The vertical sorting system 300 features a central section 306 having the induction system 102, marked by advanced scanning and dimensioning equipment which feeds parcels into the plurality of buffer carriage units 112. The central section 306 acts as the primary distribution hub, equipped with the plurality of buffer carriageunits 112 having conveyor systems that facilitate seamless parcel movement to either vertical frame structure. The buffer carriage units 112 are strategically positioned to optimize parcel flow and maintain continuous operation, with multiple staging positions enabling efficient load distribution and transfer timing. Each vertical frame structure incorporates a matrix of discharge locations. The discharge locations are arranged in a systematic grid pattern, with each level featuring multiple discharge positions. The vertical frame structures are equipped with robust guide rails and positioning systems that enable precise carriage movement in both vertical and horizontal directions.

[0062] The first movable carriage unit 304A and second movable carriage unit 304B operate independently within their respective frames yet maintain synchronized operation through a processor of the vertical sorting system 300.Access platforms and maintenance walkways are integrated into the design of the vertical sorting system 300, ensuring safe operator interaction with the system. The buffer and transfer systems demonstrate sophisticated engineering, with multiple conveyor segments that can operate independently or in concert. These systems include sensor arrays for precise parcel tracking, speed-controlled zones for optimal flow management, and transfer mechanisms that ensure gentle yet efficient parcel handling. The configuration of the vertical sorting system 300 allows for bidirectional movement, enabling flexible routing strategies and efficient load balancing between the two vertical frame structures. At the discharge locations, the vertical sorting system 300 incorporates advanced bag management features. Each discharge location is equipped with secure bag-holding mechanisms, fill-level sensors, and quick-change systems that facilitate efficient bag replacement without disrupting system operation. The discharge locations are designed to accommodate various bag sizes and types, providing flexibility in final sorting configurations. The configuration of the vertical sorting system 300 then significantly enhances system capability through redundancy and parallel processing. With two independent yet coordinated sorting paths, the vertical sorting system 300 can maintain operation even during maintenance procedures on one section. The design optimizesthroughput by enabling simultaneous sorting operations, while the sophisticated control system ensures balanced utilization of both frames. The result is a highly efficient, flexible, and reliable sorting solution that maximizes both space utilization and operational efficiency. The integration of these components creates a seamless sorting operation where parcels are inducted, buffered, transported, and discharged with precise control and monitoring throughout the entire process. This configuration represents a significant advancement in vertical sorting technology, offering enhanced capacity, improved reliability, and efficient operation while maintaining system flexibility and safety.

[0063] FIG. 4 is a diagram illustrating a top view of a vertical sorting system, in accordance with another embodiment of the present disclosure. FIG. 4 is explained in conjunction with elements of FIGs. 1A to 3. With reference to FIG. 4, there is shown a vertical sorting system 400 including four vertical frame structures, i.e., a first vertical frame structure 404A, a second vertical frame structure 404B, a third vertical frame structure 404C and a fourth vertical frame structure 402D. The vertical sorting system 400 further includes a first movable carriage unit 406A and a second movable carriage unit 406B. Also, a plurality of buffer carriage units 402 are arranged in between the four vertical frame structures. FIG. 4 illustrates a sophisticated quad-frame configuration of the vertical sorting system 400, representing an advanced arrangement that maximizes sorting capacity and operational efficiency. The vertical sorting system 400 implements a unique crossshaped layout where four vertical frame structures (the first vertical frame structure 404A, the second vertical frame structure 404B, the third vertical frame structure 404C, and the fourth vertical frame structure 404D) are strategically positioned around a central distribution hub 408, creating a highly efficient sorting matrix that optimizes both space utilization and throughput capacity. The central distribution hub 408 serves as the primary distribution hub, housing the induction system 102 and the plurality of buffer carriage units 402. The centralized arrangement enables efficient parcel distribution to all four vertical frame structures through a sophisticated network of buffer conveyors. The plurality of buffer carriage units402 is positioned in a cross-pattern, allowing for the seamless transfer of parcels to any of the four vertical frames. The arrangement creates multiple staging points and enables flexible routing strategies, significantly enhancing the ability of the vertical sorting system 400 to handle varying sorting demands and peak loads. Each vertical frame structure incorporates multiple discharge levels. The four vertical frame structures are positioned symmetrically around the central distribution hub 408, creating four distinct sorting zones that can operate independently or in coordination. The quad frame efficiently enables high-throughput operation while providing an increased number of destinations within the vertical sorting system 400. The vertical sorting system 400 employs two movable carriage units (i.e., the first movable carriage unit 406A and the second movable carriage unit 406B) that can service different vertical frame structures, enabling parallel sorting operations and providing operational redundancy. Access platforms and maintenance walkways are strategically positioned to ensure safe operator interaction with the vertical sorting system 400. The configuration includes emergency access points, safety interlocks, and dedicated maintenance zones that allow for the vertical sorting system 400 upkeep without compromising operational safety or efficiency. The quad-frame arrangement allows for sophisticated sorting strategies, such as zone-based sorting, priority handling, and load balancing across different vertical frames. The central distribution hub 408 acts as an intelligent distribution hub, optimizing parcel flow and minimizing transfer times between the induction system 102 and final sorting.

[0064] FIG. 5 is a flowchart of a method for sorting parcels in a vertical sorting system, in accordance with an embodiment of the present disclosure. FIG. 5 is explained in conjunction with elements of FIGs. 1A to 4. With reference to FIG. 5, there is shown amethod 500 for sorting parcels in a vertical sorting system (ofFIGs.1A, IB, 1C and ID). The method 500 includes steps from 502 to 516.

[0065] At step 502, the method 500 includes receiving and identifying parcels through the induction system 102. The parcels are positioned on the conveyor of the induction system 102, thus activating the entry sensors and initiating thescanning sequence. When the parcel 104 is positioned, the entry sensors detect the presence of the parcel 104, initiating the identification sequence. The diagonal sensor triggers the barcode camera, thereby capturing the parcel identification data. The induction system 102 processes the barcode data. Further, the induction system 102 validates the barcode integrity and checks the database 140 matches with the delivery location of the parcel 104 to confirm delivery validity. The identification data is then transmitted to the server 128 through dedicated communication ports awaiting acknowledgement of the induction system 102, and real-time data logging records all transaction details and updates the tracking status of the parcel 104. For cases where the barcode is unreadable or damaged, the induction system 102, takes the help of manual scanning via a handheld scanner. If identification fails after multiple attempts, the induction system 102 automatically routes the parcel 104 to a rejection handling area while maintaining the flow of the induction system 102.

[0066] At step 504, the method 500 includes determining the discharge location for each identified parcel from the plurality of discharge locations 114 arranged at various heights along one or more vertical frame structures and in the horizontal racks 120. Following successful identification, the induction system 102 processes the destination data of the parcel 104 and maps the data to specific discharge locations of the plurality of discharge locations 114 within the vertical frame structure 106. The at least one processor 132, analyses the current state, including occupied discharge locations, active sorting paths, and load distribution. Based on the analysis by the at least one processor 132, the processor assigns an optimal discharge location considering factors such as destination proximity, current buffer capacity, and system balance. The induction system 102 validates the availability of the assigned location and confirms the accessibility through the vertical frame structure 106. The determination process incorporates real-time feedback from location sensors of the discharge location and occupancy detectors to ensure accurate destination assignment.

[0067] At step 506, the method 500 includes receiving parcels on the plurality of buffer carriage units 112 for temporary storage. After the induction system 102completes parcel identification and determines discharge locations, the induction system 102 initiates the transfer to the plurality of buffer carriage units 112, which serve as strategic staging points for efficient parcel handling. Each buffer carriage unit of the plurality of buffer carriage units 112 is equipped with an array of sensors, including entry sensors to confirm parcel arrival, position verification sensors to ensure proper placement on the conveyor surface, and exit sensors to track the movement of parcels out of the buffer carriage unit. For example, when the parcel "D" enters the buffer carriage, the entry sensor records its arrival, and position sensors confirm the alignment and stability of the parcel 104. The coordination of the parcel 104 transfers to the plurality of buffer carriage units 112 is managed by the at least one processor 132 that maintains optimal spacing between the parcels. If the vertical sorting system 100 detects that a buffer carriage “Bi” is receiving parcels at a rate of one every three seconds, it dynamically adjusts the induction speed to prevent overflow while preserving throughput efficiency. The adaptive spacing control prevents congestion and ensures seamless operation even during peak sorting periods. Each buffer carriage unit is designed to actively contribute to the overall sorting strategy by functioning as a smart staging platform. The vertical sorting system 100 continuously monitors multiple parameters for each buffer carriage, including current load status (empty, partially filled, or full), parcel positioning and orientation, available capacity, transfer readiness, and connectivity with the movable carriage unit 110. In some examples, predictive algorithms optimize parcel distribution across the plurality of buffer carriage units 112 based on real-time data. For example, if the vertical sorting system 100 determines that the movable carriage unit 110 will next service discharge locations on the upper levels, it prioritizes loading parcels for those locations into the most accessible buffer positions. The strategic positioning minimizes waiting times and enhances overall efficiency. The synchronization between the buffer carriage units 112 and the movable carriage unit 110 is managed through real-time communication and continuous status monitoring. When the movable carriage unit 110 approaches its next pickup position, the vertical sorting system 100 ensures that the corresponding buffer carriage unit is ready, with the next parcel optimally positioned for seamlesstransfer. The comprehensive buffer management approach ensures efficient temporary storage while maintaining the flow of the vertical sorting system 100 and preparing parcels for optimal transfer to the movable carriage unit 110.

[0068] At step 508, the method 500 includes transferring parcels from the plurality of buffer carriage units 112 to the one or more movable carriage units. The transfer operation begins with a comprehensive system assessment, where the at least one processor 132 evaluates multiple real-time parameters to establish optimal transfer conditions. The vertical sorting system 100 analyses the current position of the movable carriage unit 110, verifying its completion of previous tasks and readiness for new operations. Simultaneously, the vertical sorting system 100 checks the status of the buffer carriage unit, confirming proper parcel positioning and system readiness. For example, when preparing to transfer the parcel 104 from buffer carriage unit “B2”, the vertical sorting system 100 conducts a thorough verification sequence, checking sensor functionality, path clearance, and safety conditions before initiating the transfer sequence. The physical transfer process unfolds through a precise series of movements. During the alignment phase, the movable carriage unit 110 navigates to the exact transfer position, using high-precision sensors to achieve perfect alignment with the buffer carriage unit of the plurality of buffer carriage units 112. The vertical sorting system 100 employs speed controls to synchronize the movement of both carriages (the buffer carriage unit of the plurality of buffer carriage units 112 and the movable carriage unit 110), ensuring smooth and efficient parcel transition. The position sensors continuously monitor the alignment, providing real-time feedback to maintain optimal positioning throughout the transfer process . As the transfer execution begins, the buffer carriage unit initiates parcel movement while maintaining precise speed matching between conveyor surfaces. The vertical sorting system 100 continuously monitors multiple parameters, including parcel position, speed, and orientation. The at least one processor 132 adjusts transfer parameters in real-time, responding to any variations in parcel movement. For example, if sensors detect slight misalignment during transfer, the at least one processor 132 makes immediate micro-adjustments tomaintain optimal transfer conditions. Entry sensors on the movable carriage unit 110 confirm parcel arrival, while exit sensors on the buffer carriage unit of the plurality of buffer carriage units 112 verify complete departure. The position sensors provide additional verification of proper parcel placement on the receiving conveyor. The multi-point verification ensures transfer accuracy and maintains precise tracking throughout the process. The system immediately updates the database 140 with new parcel location data, maintaining accurate real-time tracking information.

[0069] At step 510, the method 500 includes controlling the movement of each movable carriage unit in both horizontal and vertical directions within the one or more vertical frame structures. The movement control begins with continuous realtime position tracking of the movable carriage unit 110. The system employs a network of high-precision sensors strategically positioned throughout the vertical frame structure 106 to maintain constant knowledge of exact location of the movable carriage unit 110. For example, when the movable carriage transitions from position (“Xi”, “Zi”) to target position (“X2”, “Z2 ”), absolute encoders provide continuous position feedback while proximity sensors verify alignment at key points along the path. The real-time tracking enables the vertical sorting system 100 to make instantaneous adjustments to maintain optimal movement trajectories.

[0070] The at least one processor 132 calculates optimal routes considering multiple factors simultaneously. When planning a movement sequence, the at least one processor 132 analyses the current positions of the plurality of buffer carriage units 112, system load distribution, and pending delivery requirements. For example, if multiple parcels are queued for delivery to different heights, the at least one processor 132 may identifies when a location reaches full capacity and dynamically redirects parcels to a secondary location assigned to the same destination, ensuring that the overall system throughput remains uncompromised. The vertical sorting system 100 implements dynamic motion profiles that optimize speed while ensuring gentle parcel handling. When initiating movement, the movable carriage unit 110 accelerates gradually according to pre-calculated profilesthat consider parcel weight, size, and fragility. Similarly, during deceleration, the vertical sorting system 100 applies carefully controlled braking profdes to ensure smooth approaches to transfer or discharge points. For example, when approaching a discharge location, the movable carriage unit 110 may begin deceleration at a precisely calculated point to achieve optimal positioning without abrupt movements.

[0071] At step 512, the method 500 includes monitoring parcel position using the plurality of sensors positioned along the movement paths of each movable carriage unit and the plurality of buffer carriage units 112. The network of strategically placed sensors tracks parcel movement throughout the entire sorting process. Each buffer carriage unit level is equipped with multiple sensor types for example, entry sensors detect initial parcel arrival, position sensors monitor parcel location on the conveyor surface, and exit sensors confirm successful transfers. For example, when the parcel 104 enters buffer carriage “B3”, the entry sensor triggers and initiates a tracking sequence. The vertical sorting system 100 maintains continuous position updates as the parcel moves through the buffer zone, with position sensors providing real-time location data at millisecond intervals. Along the path of the movable carriage unit 110, an advanced network of sensors monitors both carriage position and parcel status. Position encoders provide absolute location data in both horizontal and vertical axes, while proximity sensors verify carriage alignment at critical points. When the movable carriage executes a transfer operation, multiple sensor systems work in concert - approach sensors verify proper positioning, transfer sensors monitor the handoff process, and confirmation sensors verify successful completion. For example, during the vertical movement from “level 2” to “level 4”, height encoders provide continuous position feedback while proximity sensors at each level confirm precise alignment. Each parcel's movement is tracked through a series of checkpoints, with sensors confirming passage at each stage.

[0072] The vertical sorting system 100 maintains the database 140 of parcel locations, updating positions as parcels move through different zones. The tracking includes acceleration and deceleration zones, transfer points, and approach paths todischarge locations. For example, if a parcel is destined for discharge location “D”, the vertical sorting system 100 tracks its progress through multiple sensor zones, ensuring it follows the planned path and maintaining location awareness at all times. Sensors continuously verify that parcels maintain expected positions and movements. If a sensor detects an unexpected condition - such as misalignment, timing deviation, or position error - the vertical sorting system 100 immediately initiates appropriate responses. In example, appropriate response may include speed adjustments, path corrections, or, if necessary, error recovery procedures. The vertical sorting system 100 maintains multiple redundant sensor checks to ensure reliable operation even if individual sensors encounter issues. By analysing sensor data patterns, the vertical sorting system can identify potential efficiency improvements. For example, if sensors consistently detect timing variations at specific transfer points, the vertical sorting system 100 may adjust movement parameters to optimize flow. Real-time sensor feedback enables dynamic adjustments to carriage movements, transfer timing, and discharge operations. The vertical sorting system 100 maintains a constant flow of data between sensors, control processors, and actuators, enabling responsive and precise control of all moving components. For example, when sensors detect slight misalignment during a transfer operation, the at least one processor 132 may make immediate microadjustments to maintain optimal positioning. Sensors continuously verify safety parameters, including clearance zones, movement speeds, and load conditions. Emergency stop conditions are monitored at all times, with sensors ready to trigger immediate system responses if safety thresholds are exceeded.

[0073] At step 514, the method 500 includes optimizing loading operations of each movable carriage unit through coordinated control of the plurality of buffer carriage units 112. The optimization of loading operations represents a coordination between buffer carriage units 112 and the movable carriage unit 110, implementing advanced control strategies to maximize system efficiency. For example, multiple parcels are to be processed through the vertical sorting system 100. When a parcel “A” arrives at buffer carriage “Bi” destined for discharge location D4 (upper level)and a parcel "B” at “B2” for location “D 12” (lower level), the vertical sorting system 100 immediately begins calculating optimal loading sequences. The optimization process considers factors such as current system state, destination proximity, and predicted movable carriage return positions to determine the most efficient handling sequence. For load-balancing strategies across available buffer carriage units, the vertical sorting system 100 implements a balanced approach. For example, during peak operation periods when parcels arrive at a rate of one every 2 seconds, the vertical sorting system 100 may distribute them across buffer carriage “Bi” through buffer carriage “B4” in a pattern that optimizes both storage efficiency and retrieval timing.

[0074] The performance monitoring and adjustment represent continuous processes within the vertical sorting system 100. For example, if the vertical sorting system 100 detects that transfers from buffer carriage unit “B2” consistently take 0.2 seconds longer than from other buffer carriages, it automatically adjusts timing parameters and may initiate preventive maintenance notifications. The vertical sorting system 100 maintains a rolling performance analysis, tracking metrics such as transfer success rates, timing accuracy, and throughput efficiency. When performance metrics indicate a transfer time increase of more than 5% from any buffer carriage, the vertical sorting system 100 automatically implements compensatory adjustments to maintain optimal throughput. Through the comprehensive optimization approach, the vertical sorting system 100 maintains peak efficiency while adapting to varying operational conditions. For example, during a typical hour of operation processing 1000 parcels, the vertical sorting system 100 may achieve less than 0.1 seconds of average waiting time between transfers, with buffer utilization consistently maintained between 70% and 90% capacity.

[0075] At step 516, the method 500 includes enabling three-dimensional sorting of parcels by directing each movable carriage unit to deliver parcels to their designated discharge locations across vertical heights and horizontal positions. The three-dimensional sorting integrates complex movement control, precisepositioning, and verified delivery operations to ensure accurate and efficient parcel distribution across multiple vertical heights and horizontal positions. The three-dimensional sorting process begins when the movable carriage unit 110 receives the parcel 104 from the buffer carriage unit of the plurality of buffer carriage units 112 along with its designated discharge coordinates (i.e., discharge location). For example, when the vertical sorting system 100 needs to deliver the parcel 104 to discharge location “D45” (positioned at height “level 4”, horizontal position “5”), the at least one processor 132 initiates a comprehensive movement sequence. The vertical sorting system 100 calculates the optimal path considering the current carriage position, system status, and the most efficient route to the target location. The calculation factors in both vertical and horizontal movement requirements while prioritizing gentle parcel handling and system efficiency.

[0076] During execution, the at least one processor 132 (for example, a movement control processor) implements motion profiles in both vertical and horizontal axes. Consider a scenario where the carriage must move from position (“Xi”, “Zi”) to (“X4”, “Z3”) the movement control processor coordinates simultaneous movement in both directions, maintaining optimal acceleration and deceleration profiles to ensure smooth parcel transport. For instance, the vertical drive assembly may initiate elevation changes while the horizontal drive assembly manages lateral movement, with both assemblies working in perfect synchronization to achieve the most efficient path to the destination. The position verification occurs continuously throughout the movement sequence through a network of sensors and encoders. As the movable carriage unit 110 approaches discharge location “D45”, high-precision encoders track both vertical and horizontal coordinates while proximity sensors verify final alignment. The movement control processor maintains constant position monitoring, making micro-adjustments as needed to ensure perfect alignment for parcel discharge. For example, if sensors detect a slight misalignment during the approach, the movement control processor automatically implements corrective adjustments while maintaining smooth motion profiles.

[0077] Once the movable carriage unit 110 achieves proper alignment at the designated location, the vertical sorting system 100 confirms readiness for discharge by verifying proper bag or tote presence and available capacity. The discharge sequence then executes with precise timing control, monitoring the parcel's movement through entry sensors, confirming successful transfer through exit sensors, and verifying proper placement through position sensors. For example, when delivering to discharge location “D28”, the vertical sorting system 100 tracks the entire discharge process from initial alignment through final confirmation, ensuring complete and accurate delivery. Throughout consecutive delivery operations, the vertical sorting system 100 maintains dynamic optimization of movement patterns. As a result, a highly efficient three-dimensional sorting operation that maintains precise control while achieving high throughput rates. The vertical sorting system 100 handles multiple deliveries per minute, maintaining consistent accuracy and gentle parcel handling throughout all operations. Through the sophisticated integration of movement control, position verification, and delivery confirmation, it ensures reliable and efficient parcel distribution throughout the entire vertical sorting, completing the sorting process with optimal efficiency and accuracy.

[0078] The steps 502 to 516 are only illustrative, and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein. Various embodiments and variants disclosed with the aforementioned machine (such as the vertical sorting system 100) apply mutatis mutandis to the aforementioned method 300.

[0079] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe, and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present.Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and / or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments" . It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.

Claims

CLAIMSWe claim:

1. A vertical sorting system (100, 200, 300, 400) for handling parcels, comprising:an induction system (102) configured to receive and identify parcels; one or more vertical frame structures extending upwardly from abase (108); one or more movable carriage units operatively coupled with the one or more vertical frame structures, wherein each movable carriage unit is configured to move in both horizontal and vertical directions within the one or more vertical frame structures;a plurality of buffer carriage units (112, 402) arranged to support loading operations of the one or more movable carriage units;a plurality of discharge locations (114) arranged at various heights along each vertical frame structure and in horizontal racks, each discharge location configured to receive parcels from the one or more movable carriage units; andat least one processor (132) configured to:receive parcel identification and destination information from the induction system (102);direct the movement of the one or more movable carriage units in both horizontal and vertical directions to transport parcels to designated discharge locations based on the received parcel identification and destination information; andenable three-dimensional sorting of parcels by coordinating movement of each movable carriage unit across vertical heights and horizontal positions while utilizing the plurality of buffer carriage units for efficient parcel transfer.

2. The vertical sorting system (100, 200, 300, 400) as claimed in claim 1, wherein each movable carriage unit comprising:a conveyor surface for supporting a parcel, anda movement mechanism enabling motion in both horizontal and vertical directions within the one or more vertical frame structures.

3. The vertical sorting system (100, 200, 300, 400) as claimed in claim 2, wherein the movement mechanism comprises: a horizontal drive assembly enabling movement in a first axis; a vertical drive assembly enabling movement in a second axis; and position sensors to detect limits of movement in both axes.

4. The vertical sorting system (100, 200, 300, 400) as claimed in claim 1, wherein each discharge location comprises: an entry sensor to detect incoming parcels; a discharge destination for receiving sorted parcels; and a confirmation sensor to verify successful parcel discharge.

5. The vertical sorting system (100, 200, 300, 400) as claimed in claim 1, further comprising a plurality of sensors positioned along a path of each movable carriage unit and each of the plurality of buffer carriage units, wherein the at least one processor (132) is further configured to monitor the position of parcels throughout the sorting process using the plurality of sensors.

6. The vertical sorting system (100, 200, 300, 400) as claimed in claim 5, wherein the at least one processor (132) is further configured to: track parcel sequence through the plurality of sensors; calculate optimal carriage movement paths to minimize sorting time; coordinate multiple carriage movements to prevent collisions; and manage buffer zones between sequential parcels.

7. The vertical sorting system (100, 200, 300, 400) as claimed in claim 5, wherein the at least one processor (132) is further configured to: maintain real-time location data for each parcel; verify parcel presence at each sensorcheckpoint; detect any misrouted parcels; and initiate error handling procedures for misrouted parcels.

8. The vertical sorting system (100, 200, 300, 400) as claimed in claim 1, further comprising a rejection handling system for unreadable or problematic parcels.

9. The vertical sorting system (100, 2002, 3003, 400) as claimed in claim 1, further comprising an emergency stop system with multiple emergency stop buttons.

10. The vertical sorting system (100, 200, 300, 400) as claimed in claim 1, further comprising status indicators including start, stop, reset, and emergency indicators.

11. The vertical sorting system (100, 200, 300, 400) as claimed in claim 1, wherein each of the movable carriage unit of the one or more movable carriage units and each of the buffer carriage units of the plurality of buffer carriage units (112) further comprises: a frame structure supporting a conveyor surface; a servo motor-based drive system for precise movement control; and a carriage controller for local movement control.

12. The vertical sorting system (100, 200, 300, 400) as claimed in claim 1, further comprising a user interface (146) displaying real-time system status, visual indicators showing operational state of each carriage unit, and monitoring displays for sorting performance metrics and select operation modes.

13. A method (500) of sorting parcels in a vertical sorting system (100, 200, 300, 400), the method (500) comprising:receiving and identifying parcels through an induction system (102);determining a discharge location for each identified parcel from a plurality of discharge locations (114) arranged at various heights along one or more vertical frame structures and in horizontal racks;receiving parcels on a plurality of buffer carriage units (112) for temporary storage;transferring parcels from the plurality of buffer carriage units (112) to one or more movable carriage units;controlling movement of each movable carriage unit in both horizontal and vertical directions within the one or more vertical frame structures; monitoring parcel position using a plurality of sensors positioned along movement paths of each movable carriage unit and the plurality of buffer carriage units (112);optimizing loading operations of each movable carriage unit through coordinated control of the plurality of buffer carriage units (112); and enabling three-dimensional sorting of parcels by directing each movable carriage unit to deliver parcels to their designated discharge locations across vertical heights and horizontal positions.

14. The method (500) as claimed in claim 13, further comprising: tracking real-time positions of each movable carriage unit and the plurality of buffer carriage units (112); calculating optimal movement paths for each movable carriage unit while considering the plurality of buffer carriage positions; managing acceleration and deceleration profiles of each movable carriage unit for smooth parcel handling; coordinating timing of parcel transfers between the plurality of buffer carriage units (112) and each movable carriage unit; and verifying successful delivery at discharge locations.

15. The method (500) as claimed in claim 13, further comprising: monitoring system performance metrics, including buffer efficiency andsorting throughput; managing error conditions and initiating recovery procedures; maintaining operation logs of sorting activities and buffer utilization; optimizing movement patterns of each movable carriage unit based on current sorting demand; and adjusting buffer carriage operations to minimize movable carriage waiting time.

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