Continuous Loop Conveyor Sorting System with Multiple Feeders
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Solution Overview
Problem
Existing sorting systems often require multiple passes to achieve desired sorting fidelity, leading to reduced throughput and increased errors due to the need for high base processing speeds, which can result in inefficiencies and potential damage to objects.
Innovation Solution
A continuous loop conveyor system with multiple feeders and output sections is configured such that objects are sorted into distinct groups and processed using a specific feeder and output section, preventing objects from reaching the point where other feeders load, thereby allowing for simultaneous processing and increased throughput without reducing conveyor speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple passes are used to achieve desired sorting fidelity, then sorting precision is improved, but throughput decreases
Solution Approach 1:
The sorting system is divided into multiple independent feeders (first feeder, second feeder, etc.) that can simultaneously process different groups of objects. Each feeder handles a specific subset of sorting tasks, allowing the system to achieve high sorting fidelity through parallel processing rather than sequential passes, thereby maintaining high throughput.
Solution Approach 2:
The system transitions from a single-pass sequential sorting approach to a multi-dimensional parallel processing architecture. By adding the dimension of multiple simultaneous feeders operating on the same conveyor system, the patent achieves both high sorting fidelity and maintained throughput by processing multiple object groups concurrently rather than requiring multiple sequential passes.
2Productivity
If base throughput is increased to offset multiple sort passes, then productivity is improved, but error rate increases and object damage increases
Solution Approach 1:
By segmenting the throughput across multiple feeders, each feeder can operate at a lower, more controlled speed while collectively maintaining high system throughput. This reduces the error rate and object damage associated with high-speed single-feeder operation, as each feeder processes fewer objects at a time with greater precision.
Solution Approach 2:
The system maintains continuous throughput by having multiple feeders operate simultaneously and continuously on the conveyor system. Rather than increasing the speed of individual feeders (which causes errors and damage), the system achieves continuous high throughput through the coordinated, simultaneous operation of multiple feeders, each operating at optimal speeds.
3Productivity
If multiple feeders are used to increase throughput, then productivity is improved, but system complexity increases
Solution Approach 1:
Multiple feeders share common infrastructure including the conveyor system, control mechanisms, and output destinations. Each feeder is multi-functional, capable of handling different object types and routing to various outputs, which reduces overall system complexity compared to having separate dedicated sorting lines for each feeder.
Solution Approach 2:
The patent merges multiple feeding operations into a single shared conveyor system. By combining the transport function, control system, and output mechanisms into a unified infrastructure that serves multiple feeders, the system achieves high throughput without proportionally increasing complexity. The shared resources reduce the total number of components needed compared to separate sorting systems.
Data Source
AI summary
A method for sorting objects using a continuous loop conveyor sorting system having two or more feeders. In one embodiment, the method includes sorting a batch of objects to form a first group of objects and a second group of objects, using a first feeder to feed all of the objects from the first group onto the conveyor, using a second feeder to feed all of the objects from the second group onto the conveyor, removing the objects from the first group from the conveyor prior to the any of the objects reaching the point at which the second feeder feeds objects onto the conveyor, and removing the objects from the second group from the conveyor prior to the any of the objects reaching the point at which the first feeder feeds objects onto the conveyor.