Dual-Layer Linear Sorter Vertical Stacking
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Solution Overview
Problem
Existing single-layer logistics sorters are inefficient as they can only utilize one layer for sorting at a time, leading to wasted resources and time, and are not suitable for high-capacity sorting centers with limited space.
Innovation Solution
A dual-layer linear sorter with a left-middle-right structure, where the middle structure is divided into an upper and lower layer, each docked with separate feeding mechanisms, allowing simultaneous delivery and sorting on both layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-layer conveyor belt sorter is used, then the structure is simple, but the sorting efficiency is low and resource utilization is wasted
Solution Approach 1:
The patent transitions from a single-layer conveyor system to a dual-layer conveyor system, utilizing the vertical dimension to double the sorting capacity. The upper layer and lower layer conveyors operate simultaneously in opposite directions, effectively doubling the sorting efficiency without proportionally increasing the horizontal footprint.
Solution Approach 2:
The dual-layer conveyor system nests one conveyor system within the space of another, with the upper layer and lower layer positioned vertically adjacent to each other. This nesting arrangement allows both layers to occupy the same horizontal footprint while operating independently, thereby increasing capacity without proportionally increasing space requirements.
2Productivity
If only one layer of the conveyor belt is used for sorting, then the system is simple to operate, but the other layer remains idle and unusable
Solution Approach 1:
Both the upper layer and lower layer conveyors are designed to perform the same sorting function, making the system multi-functional. Each layer can independently receive, transport, and sort goods, ensuring that both layers are fully utilized during operation rather than having one layer remain idle.
Solution Approach 2:
The system dynamically assigns goods to different layers based on real-time sorting requirements. The control system can flexibly direct goods to either the upper or lower layer, allowing dynamic utilization of available capacity and optimizing the utilization rate according to varying operational demands.
3Productivity
If a dual-layer sorter is implemented, then the sorting capacity doubles, but the occupied space increases
Solution Approach 1:
The patent utilizes the vertical dimension to accommodate the second conveyor layer, allowing the system to double its sorting capacity without proportionally increasing the horizontal footprint. By stacking layers vertically, the system achieves higher capacity while maintaining a compact horizontal footprint.
Solution Approach 2:
The dual-layer design nests the second conveyor system within the vertical space of the first conveyor system, effectively utilizing three-dimensional space. This nesting arrangement allows both layers to share the same horizontal footprint, thereby increasing sorting capacity without proportionally increasing the occupied horizontal space.
Data Source
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AI summary
Provided is a dual-layer linear sorter, comprising a delivery mechanism (10), a first uploading mechanism (20), a second uploading mechanism (30), a slewing mechanism (40), and a driving mechanism (50), wherein the delivery mechanism (10) is ring-shaped and arranged into upper and lower layers; the running direction of the upper layer is a first direction, and the running direction of the lower layer is a second direction; the first direction is from one end of the delivery mechanism (10) to the other end of the delivery mechanism (10), and the second direction is opposite the first direction; the first uploading mechanism (20) is close to the upper layer of the delively mechanism (10), and is docked with one end of the delivery mechanism (10); the second uploading mechanism (30) is close to the lower layer of the delivery mechanism (10) and is docked with the other end of the delivery mechanism (10); the driving mechanism (50) can drive the delivery mechanism (10) to run between the driving mechanism (50) and the slewing mechanism (40); some of the goods can be delivered to the upper layer of the delivery mechanism (10) via the first uploading mechanism (20), and are delivered and sorted in the first direction; and other goods can be delivered to the lower layer of the delivery mechanism (10) via the second uploading mechanism (30), and are delivered and sorted in the second direction.