3D Parcel Feeding and Robotic Separation for Sorting Lines
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Solution Overview
Problem
Current sorting systems face limitations in handling heterogeneous parcels, particularly bulky items, which reduces the capacity to handle smaller items and leads to inefficiencies due to double or overlapped items, resulting in incorrect sorting and increased manual work.
Innovation Solution
Integration of vision and robotic 'pick and place' techniques for three-dimensional scanning and manipulation of parcels on a conveyor belt, using high-resolution optical barriers and triangulation laser sensors to identify and separate items accurately, allowing for efficient loading onto sorting cells while maintaining the ability to handle bulky items.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the sorting system uses conventional conveyor belts to handle heterogeneous parcels, then bulky items can be accommodated, but the capacity to handle smaller items decreases and double or overlapped items cause sorting errors
Solution Approach 1:
The patent replaces conventional mechanical conveyor belt systems with a robotic manipulator system equipped with vision guidance. The manipulator uses optical barriers and laser sensors to detect parcel positions and dimensions, then robotically picks and places items onto sorting cells. This substitution enables precise handling of both small and bulky items without the limitations of fixed conveyor belt configurations, eliminating double or overlapped item problems while maintaining high versatility.
Solution Approach 2:
The system dynamically adjusts manipulation parameters based on real-time detection data. The vision system measures parcel dimensions, positions, and orientations, and the control system modifies manipulator movement parameters, gripper force, and placement positioning accordingly. This adaptive parameter adjustment allows the same system to efficiently handle heterogeneous parcels of varying sizes and shapes, from small items to bulky packages.
2Reliability
If manual separation processes are used to prepare parcels for sorting, then double or overlapped items can be separated, but labor costs increase and productivity decreases
Solution Approach 1:
The system implements self-service through automated vision detection and robotic manipulation. The optical barriers and laser sensors automatically detect and track parcel positions, the control system autonomously processes detection data to determine optimal placement, and the manipulator robotically separates and positions items without human intervention. This self-service capability eliminates the need for manual separation while maintaining high sorting accuracy and reliability.
Solution Approach 2:
The system incorporates continuous feedback loops where vision sensors monitor parcel positions and orientations in real-time, the control system processes this feedback data to adjust manipulator actions, and the outcome is verified by the detection system. This closed-loop feedback mechanism ensures accurate separation of double or overlapped items and maintains high sorting reliability without requiring manual verification or correction.
3Productivity
If high-speed conveyor belts are used to increase sorting capacity, then productivity increases, but the ability to accurately detect and separate overlapped items decreases
Solution Approach 1:
The patent replaces high-speed conveyor belt transport with a robotic manipulator operating in a controlled workspace. Instead of relying on conveyor speed to determine capacity, the system uses the manipulator's precise positioning capabilities and controlled movement to achieve high throughput. The vision system maintains accurate detection of overlapped items because the manipulator operates within a confined detection zone rather than on a fast-moving conveyor, eliminating the trade-off between speed and detection precision.
Solution Approach 2:
The system performs preliminary detection and tracking of all parcels using optical barriers and laser sensors before the manipulator begins manipulation. The vision system continuously monitors parcel positions, orientations, and relative arrangements in advance, allowing the control system to plan manipulation sequences that account for overlapped or double items. This preliminary action ensures accurate detection is maintained regardless of the throughput rate achieved by the manipulator system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly increases the loading line capacity, reduces sorting errors, and enhances productivity by accurately identifying and separating items, even when they are arranged side by side or overlapped, thereby optimizing the handling of both small and large parcels.
Implementation Method 1
optical barriers for the detection of the position of the items on the conveyor belt
Implementation Method 2
triangulation laser sensors for three-dimensional scanning and measurement of the items
Data Source
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AI summary
A device for feeding items to a sorting machine (1), comprising: a conveyor plane for feeding items or parcels along an advancement direction; an optical detection device (18), to allow the acquisition, while the items are in motion on the conveyor plane of the three-dimensional coordinates of a determined number of points on the surface of the items and to organize them into coordinate vectors; a manipulator (19) provided to pick the items from the conveyor plane and to place the items picked in a desired position; a control system, provided to process, for each item in motion on the conveyor plane, the coordinate vectors in order to obtain a three-dimensional representation of the item, comprising the information based on which the control system handles the manipulator for picking and placing the items. The invention also relates to a sorting machine and a method for feeding items to a sorting machine aimed at increasing production capacity and accuracy thereof.