Dual-Lane Loop Sorter with Speed-Segmented Parcel Loading
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Solution Overview
Problem
Existing parcel sorting systems using loop sorting conveyors with tubular guide rails are limited by a constant conveying speed that cannot support high speeds at parcel insertion zones, leading to reduced efficiency and require costly solutions like doubling insertion zones, increasing footprint and restricting flow management.
Innovation Solution
A parcel sorting installation with a looped conveyor that splits into two secondary conveyors, using a passive switching system with tubular rails and controlled speed transitions to allow trolleys to move at different speeds, enabling efficient parcel sorting with reduced footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conveying speed is increased to improve sorting efficiency, then productivity increases, but the parcel insertion devices cannot support the higher speed
Solution Approach 1:
The conveying system is segmented into a main conveyor and multiple secondary conveyors. The main conveyor operates at high speed for efficient parcel transport, while secondary conveyors operate at lower speeds suitable for insertion devices. This segmentation allows different parts of the system to operate at optimal speeds for their specific functions, resolving the contradiction between overall productivity and insertion device capabilities.
Solution Approach 2:
The system dynamically adjusts conveying speeds across different sections. The main conveyor maintains high speed for most of the cycle, while secondary conveyors reduce speed when parcels need to be inserted. This dynamic speed adjustment allows the system to achieve high average productivity while ensuring insertion devices can handle parcels at appropriate speeds.
2Productivity
If the number of insertion zones is doubled to maintain sorting efficiency at high speeds, then productivity is maintained, but the footprint and device complexity increase
Solution Approach 1:
Instead of adding more insertion zones in the same spatial dimension (which would increase footprint), the invention uses a temporal dimension approach with a single insertion zone that operates cyclically. The switching mechanism alternates between main and secondary conveyors, effectively creating multiple insertion opportunities over time without requiring multiple simultaneous insertion zones in space.
Solution Approach 2:
The system merges the functions of multiple conveyors into a single integrated loop with switching capability. Rather than having separate parallel conveyors each with their own insertion zones, the invention combines them into one system that dynamically routes parcels, reducing overall footprint while maintaining the functional capacity of multiple zones.
3Area of stationary object
If the radius of curvature is reduced to compact the sorting conveyor, then the footprint is reduced, but the conveying speed must be limited
Solution Approach 1:
The conveyor path is segmented into straight sections and curved sections. The main conveyor includes long straight sections where high speeds can be maintained, while curved sections with reduced radius are isolated to specific areas. This segmentation allows the system to achieve compact footprint through tight curves without forcing the entire conveying path to operate at reduced speeds.
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a parcel (2) sorting facility (1) comprising a loop sorting conveyor (3) and sorting outlets (4) distributed along the sorting conveyor, said sorting conveyor comprising parcel receptacles (5) designed to convey parcels in a certain conveying direction (D1) and to sort them into the sorting outlets according to a predetermined sorting plan, the sorting conveyor comprising two parallel rails (8), which extend in the conveying direction, and carriages (6) mounted on the rails and designed to move the parcel receptacles in said certain conveying direction. The sorting conveyor comprises a main conveyor (3A) which splits into two secondary conveyors (3B) on a certain conveying portion, said sorting conveyor comprising a switching system (9) designed to switch the carriages alternately towards one or the other of the secondary conveyors.