Sorting System Transfer Buffer for Compact High-Capacity Handling
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Solution Overview
Problem
Existing sorting systems require multiple feeders and conveyors, which are expensive and occupy significant space, necessitating a more efficient and compact solution for transferring items to a main sorter.
Innovation Solution
A sorting system with an in-feed station, transfer buffer, and main sorter, utilizing independent buffer carriers on an intermediate track that can control velocity and position independently to transfer items efficiently, allowing simultaneous handling of multiple items and reducing the need for multiple feeders and conveyors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple feeders and conveyors are used to increase sorting capacity, then the capacity to transfer items increases, but the space required and cost increase
Solution Approach 1:
Multiple feeder functions are merged into a single feeder by introducing a transfer buffer with multiple independent buffer carriers. The buffer carriers collectively perform the work of multiple separate feeders, allowing items from multiple in-feed lines to be transferred to the main sorter through one feeder unit, thereby reducing space requirements while maintaining high sorting capacity
Solution Approach 2:
A transfer buffer is introduced as an intermediary between the in-feed station and the main sorter. This transfer buffer with independent buffer carriers acts as a mediator that receives items from the in-feed station and delivers them to the main sorter, enabling a single feeder to effectively handle multiple in-feed lines without requiring multiple separate feeder units
2Productivity
If multiple feeders and conveyors are used to handle many items, then the capacity increases, but the system complexity and cost increase
Solution Approach 1:
Multiple feeder units are merged into one feeder system with a transfer buffer. The transfer buffer with multiple independent buffer carriers consolidates the functionality of multiple feeders and conveyors into a single integrated system, reducing the number of separate components while maintaining the capacity to handle many items from multiple in-feed lines
Solution Approach 2:
The buffer carriers are made dynamically controllable with independent velocity and position control for each carrier. This dynamic control allows the system to efficiently manage item transfer from a single feeder to the main sorter, replacing the need for multiple static feeder units and reducing overall system complexity
3Ease of operation
If conventional induction with linear conveyor belt is used, then items can be transferred from in-feed lines to cross belt sorter, but space is occupied and capacity is limited
Solution Approach 1:
The transfer buffer introduces a temporal dimension to item transfer by using a closed-loop track with multiple buffer carriers that can be independently controlled. Instead of using a long linear conveyor belt that occupies significant space, the system uses a compact closed-loop track where items are transferred through multiple carriers in sequence, effectively utilizing the time dimension to reduce spatial requirements
Data Source
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AI summary
A sorting system and a method to sort items. The sorting system comprises an in-feed station (10), a transfer buffer (20), and a main sorter (30). The in-feed station is arranged to receive items (40) and to transfer the items from the in-feed station to the transfer buffer, the transfer buffer comprises an intermediate track (21) and one, or more, independent buffer carriers (22). The main sorter is arranged to receive items from the transfer buffer. Each independent buffer carrier on the intermediate track is arranged to move into a position to receive items from the in-feed station, move into a position to deliver the items to the main sorter, and hand over the items to the main sorter. Two, or more, independent buffer carriers may be arranged to be positioned simultaneously to receive items from the in-feed station.