Digital Twin Parcel Sorting Model for Sorting Plan Verification
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Solution Overview
Problem
The manual formulation of sorting plans in automated parcel sorting systems is limited by the lack of a verification environment, long verification periodicity, and high resource consumption, hindering optimization effectiveness.
Innovation Solution
A digital twin simulation model is constructed using system body and historical operation data to create a reliable simulation environment, fitting distributions and mechanisms of sorting system components, and simulating sorting strategies to optimize the sorting plan table.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual formulation of sorting plan is used, then sorting system can operate, but optimization effect is limited due to lack of verification environment
Solution Approach 1:
The patent creates a digital twin simulation model that copies the physical sorting system's structure, parameters, and operational logic into a virtual environment. This includes replicating the sorting machine, conveyors, scanners, and sorting bins with their respective parameters, enabling verification of sorting plans without affecting the actual system.
2Reliability
If manual verification of sorting plan is used, then sorting plan can be checked, but verification periodicity is long and consumes large manpower and material resources
Solution Approach 1:
The patent replaces manual verification processes with automated simulation computation. The digital twin model automatically executes sorting plans, tracks parcel flows, and evaluates performance metrics through computational algorithms, eliminating the need for manual observation and record-keeping.
Solution Approach 2:
The simulation model performs self-verification by automatically comparing simulated sorting results against expected outcomes, identifying optimization opportunities, and generating performance reports without requiring external human intervention for each verification cycle.
3Adaptability or versatility
If digital twin simulation model is constructed, then verification environment is provided, but system complexity increases
Solution Approach 1:
The patent divides the sorting system into discrete modular components for the digital twin model: sorting machine module, conveyor module, scanner module, and bin module. Each module is modeled independently with its own parameters and can be configured separately, reducing overall construction complexity.
Data Source
AI summary
The present application includes a feeding platform data model configured to fit a feeding rate distribution of a feeding platform, a gantry sorting machine data model configured to fit a parcel mis-sorting probability distribution of a gantry sorting machine, a six-sided scanner data model configured to fit a non-read rate distribution, a multi-barcode distribution, and an edge exceeding rate distribution of the six-sided scanner, and a sorting bin data model configured to fit a bin lock time distribution and a bin lock duration distribution of the sorting bin. In the present application, a reliable simulation environment and a reliable verification environment are provided, so that a sorting plan table may be verified thereby facilitating optimization of the sorting plan.