Autonomous Tote Replacement for Continuous Parcel Sorter Throughput
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing parcel sorting systems face inefficiencies due to lag time in transporting and replacing filled bags or totes, which affects overall system throughput and sorting efficiency.
Innovation Solution
A system utilizing self-driving vehicles (SDVs) to expedite the transport and replacement of totes filled to a predetermined capacity with parcels, including a sorter with chutes, a loading area with zones, an unloading area, and a queue area, with a control subsystem to manage SDV dispatch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operators continuously walk the perimeter to gather and replace filled bags, then bags can be manually replaced, but considerable lag time occurs in bag transport and replacement
Solution Approach 1:
The system employs self-driving vehicles that autonomously transport filled bags from the sorter to the unloading area and deliver empty bags to the loading area without requiring manual intervention. The SDVs self-navigate, self-load, and self-unload bags, eliminating the need for operators to continuously monitor and manually replace bags, thus resolving the contradiction between ease of operation and time loss.
Solution Approach 2:
The patent replaces the manual mechanical system of operators walking and physically handling bags with an automated mechanical system consisting of self-driving vehicles. These vehicles use sensors, processors, and automated mechanisms to perform bag transport and replacement tasks that were previously done manually, thereby eliminating lag time while maintaining operational capability.
2Productivity
If sorters offload parcels directly into bags positioned downstream, then parcels can be continuously sorted, but system throughput is reduced due to bag replacement lag time
Solution Approach 1:
The system maintains continuous parcel sorting by implementing a seamless bag replacement process. While one SDV transports filled bags to the unloading area, another SDV simultaneously delivers empty bags to the loading area. This continuous operation ensures that the sorter never stops offloading parcels into bags, eliminating interruptions and maintaining maximum system throughput throughout the sorting process.
Solution Approach 2:
Empty bags are delivered to the loading area in advance by SDVs before they are needed for parcel offloading. The system proactively replenishes the supply of empty bags downstream of the sorter, ensuring that bags are always available when the sorter needs to offload parcels, thereby preventing any lag time that would reduce system throughput.
3Speed
If multiple SDVs are deployed for tote transport, then tote replacement speed increases, but system complexity increases
Solution Approach 1:
The self-driving vehicles are designed as multi-functional units that can perform multiple tasks: transporting filled bags to the unloading area, delivering empty bags to the loading area, and navigating autonomously within the facility. By using versatile SDVs that can perform various functions, the system achieves rapid bag replacement without proportionally increasing the number of different types of equipment, thus managing system complexity while improving speed.
Solution Approach 2:
The control subsystem continuously monitors the status of bags at the loading and unloading areas and dynamically dispatches SDVs based on real-time needs. This feedback mechanism ensures that the right number of SDVs are deployed at the right times, optimizing tote replacement speed while avoiding unnecessary deployment that would increase system complexity. The system adapts its operation based on actual throughput requirements.
Data Source
AI summary
A system for loading and transporting parcels includes: a sorter including a plurality of chutes for offloading parcels from the sorter; a plurality of totes; a plurality of self-driving vehicles (“SDVs”) configured to transport the plurality of totes between a loading area, an unloading area, and a queue area; and a control subsystem. The loading area includes a plurality of zones, with each zone corresponding to one or more chutes of the sorter. The control subsystem includes a controller, which is operably connected to the SDVs, and which selectively communicates instructions to dispatch SDVs to transport and replace totes in the loading area as they become filled to the predetermined capacity. A method for loading and transporting parcels in a sorting facility including a loading area, an unloading area, and a queue area is also disclosed.