Carousel Parcel Sorting with Outline Detection
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Solution Overview
Problem
Current parcel sorting installations lack advanced automation for efficient outward and inward sorting of small international parcels, resulting in manual organization and insufficient throughput rates, particularly for a large number of destinations.
Innovation Solution
A carousel sorting conveyor system with a monitoring and control unit, optoelectronic sensors, and piston pushers that inject articles laterally into transport bins, ensuring accurate positioning and high reliability, enabling sorting into multiple directions with a throughput rate of over 11,000 parcels per hour.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual organization is used for parcel sorting, then flexibility is maintained, but productivity and throughput rate deteriorate
Solution Approach 1:
The patent replaces manual mechanical sorting operations with an automated optical-mechanical system. Outline detection sensors capture parcel positions, and a control unit automatically directs piston pushers to inject parcels into appropriate bins, eliminating manual organization while achieving high throughput rates of over 11,000 parcels per hour.
Solution Approach 2:
The system enables self-service sorting where parcels are automatically positioned and routed without human intervention. The outline detection system continuously monitors parcel positions, and the control unit autonomously adjusts piston pusher operations to ensure correct bin placement, allowing the system to serve itself in the sorting process.
2Productivity
If high-speed injection is implemented, then productivity improves, but positioning accuracy deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where outline detection sensors continuously monitor parcel positions during high-speed injection. The control unit receives real-time position data and adjusts piston pusher timing and positioning accordingly, ensuring accurate bin placement even at throughput rates exceeding 11,000 parcels per hour.
Solution Approach 2:
The system performs preliminary positioning actions by detecting parcel outlines before injection occurs. The control unit calculates the optimal injection timing and piston pusher positioning in advance, allowing high-speed operation while maintaining precision through pre-computed positioning strategies.
3Manufacturing precision
If outline detection system is added, then positioning accuracy improves, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by using the same outline detection sensors for multiple purposes: detecting parcel positions, verifying bin placement, and providing feedback for continuous positioning adjustments. This universal sensor system achieves high positioning accuracy without proportionally increasing system complexity.
Solution Approach 2:
The control unit serves as an intermediary that processes outline detection data and coordinates piston pusher operations. This central control mechanism integrates the sensors and actuators, managing the increased complexity through unified control logic while maintaining positioning accuracy.
4Adaptability or versatility
If lateral injection method is used, then adaptability to various parcel sizes improves, but device complexity increases
Solution Approach 1:
The patent employs dynamic positioning where piston pushers can be moved laterally to different positions along the conveyor. This dynamic adjustment capability allows the same injection device to handle parcels of varying sizes and shapes by adapting the injection location, achieving high versatility without requiring multiple fixed injection stations.
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
The system achieves high-speed, reliable sorting of parcels into numerous destinations with improved throughput and compactness, optimizing the sorting process by detecting and correcting improper article positioning, thus enhancing the efficiency of parcel distribution.
Implementation Method 1
piston pushers mounted to move on a slat conveyor to be moved both in said certain movement direction and transversely to said certain movement direction so as to inject an article laterally into a bin
Implementation Method 2
a system of sensors is also provided over the piston pushers to generate data representative of an outline of the article seen in plan
Data Source
AI summary
An installation for sorting articles comprises a carousel sorting conveyor having transport bins, an article feed magazine in which articles stored loosely are put into series and then injected one-by-one into the transport bins of the conveyor by an injection device, and a monitoring and control unit that acts on the bins so as to open each of them over a receptacle that corresponds to a delivery address of the article, the injection device comprising piston pushers and a system of sensors being provided to generate data representative of an outline of the article seen in plan so as to enable the data processing unit to detect inappropriate positioning of the article before it is injected into a bin, and, in such a situation, direct the improperly positioned article towards a reject receptacle.