Bulk Flow Sortation System with Dual Singulators and Combiner
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Solution Overview
Problem
Existing systems for organizing a bulk flow of mixed articles of various sizes and shapes into separate destinations are inefficient in terms of equipment footprint and sorting rate, leading to high costs and limited capacity.
Innovation Solution
A mixed article sortation system comprising at least two bulk flow singulators, article inducts, sensors, and a combiner that arranges and sorts articles into single-file flows, using lateral displacement and dynamic accumulators to achieve high-speed sorting with minimal equipment footprint, capable of sorting up to 10,000 articles per hour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If equipment capacity is increased by multiplying equipment, then sorting capacity is improved, but capital outlay and building size requirements increase
Solution Approach 1:
The patent combines multiple single-file article flows into a consolidated bulk flow using a combiner mechanism. Multiple article streams that would traditionally require separate handling equipment are merged into a single high-rate bulk flow, allowing one sorter to handle the combined volume of what would otherwise require multiple smaller sorters, thereby reducing equipment footprint and capital outlay.
Solution Approach 2:
The invention transitions from handling articles in separate single-file streams (one-dimensional processing) to consolidating them into a high-rate bulk flow (three-dimensional bulk handling). This dimensional change allows the system to process multiple article streams simultaneously in a compact footprint, achieving high capacity without proportionally increasing building space requirements.
2Productivity
If equipment capacity is increased by multiplying equipment, then sorting capacity is improved, but overall system cost increases
Solution Approach 1:
The combiner merges multiple article flows into a single bulk stream, allowing one sorter to replace multiple sorters. This consolidation reduces the total number of expensive sorting devices required, thereby lowering capital outlay and operational costs while maintaining high sorting capacity.
Solution Approach 2:
The single sorter handling the combined bulk flow from multiple sources performs the function of what would otherwise require multiple specialized sorters. This multi-functionality allows one piece of equipment to achieve the throughput of several devices, reducing overall system cost and complexity.
3Productivity
If articles are processed in single-file flows, then sorting precision is maintained, but sorting rate is limited
Solution Approach 1:
The system performs preliminary singulation of articles into controlled single-file flows before consolidation. Article inducts and singulators prepare articles by establishing proper spacing and orientation in advance, ensuring that even when articles are later combined into a high-rate bulk flow, they maintain the positioning accuracy needed for precise sorting.
Solution Approach 2:
Photo sensors and control systems monitor article positions and flow rates in real-time, providing feedback to adjust the combiner and sorter operations. This feedback mechanism ensures that articles maintain proper spacing and positioning during the high-rate bulk flow processing, preserving sorting precision despite the increased throughput.
Data Source
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AI summary
A mixed article sortation system and method of sorting the bulk flow of mixed articles being of various sizes and shapes to separate destinations includes at least two bulk flow singulators, each configured to receive a bulk flow of mixed articles and arrange the articles to respective first and second single-file flows. A first article induct arranges the first flow of articles from one of the singulators to a first flow of gapped articles and a first article sensor senses the identity and weight of each article. A second article induct arranges the single-file flow of articles from the other singulator to a second flow of gapped articles and a second article sensor senses the identity and weight of each article in said second single-file flow. A combiner combines the first and second single-file flow of articles into a third single-file flow of articles. A sorter receives the third single-file flow of mixed articles and sorts the articles to separate destinations.