Dual-Loop Sorting System with Pre-Sorted Input Routing
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Solution Overview
Problem
Existing sorting systems do not achieve high sorting efficiency due to inefficient use of sorter units along loop-shaped paths, leading to uneven article distribution at outputs.
Innovation Solution
The sorting system employs a configuration where both lower and upper sorter units are loaded twice per loop, with pre-sorted articles being fed into empty units at specific inputs, allowing for efficient operation and balanced article distribution across outputs by utilizing overlapping paths and inclined discharge guides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If articles are supplied to sorter units at a single input along a loop-shaped path, then the sorting system can operate with a simple configuration, but the sorter units cannot be efficiently utilized and article distribution at outputs becomes uneven
Solution Approach 1:
The sorting system is divided into multiple independent sorter units arranged in parallel along the loop-shaped path. Each sorter unit can independently receive articles from different inputs and discharge at different outputs, allowing simultaneous operation and efficient utilization of all sorter units while maintaining a relatively simple overall configuration.
2Productivity
If sorter units are loaded once per loop, then the operation is simple, but the occupation rate of sorter units is low and sorting efficiency is reduced
Solution Approach 1:
Articles are pre-sorted and assigned to specific sorter units before entering the sorting system. This preliminary assignment ensures that each sorter unit receives articles destined for specific outputs, enabling the sorter units to be loaded multiple times per loop with different article series, thereby maximizing occupation rate while maintaining operational simplicity through predetermined routing.
Solution Approach 2:
The loop-shaped path enables continuous circulation of sorter units, allowing articles to be supplied to the same sorter units at multiple passes. This continuous operation ensures that sorter units remain occupied throughout their circulation, maximizing utilization without requiring complex stop-start operations.
3Quantity of substance
If multiple article series are supplied to the same input, then article flow is high, but article distribution at outputs becomes uneven and some outputs are overloaded
Solution Approach 1:
Different inputs along the loop-shaped path are assigned to handle different article series with different destination distributions. Each input location has specialized routing characteristics, allowing high overall article flow while maintaining balanced distribution at individual outputs by matching article destinations with appropriate input-output routing paths.
Data Source
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AI summary
A sorting system (1) for sorting articles comprises a lower sorter (2) including a plurality of lower sorter units (4) for supporting articles, which lower sorter units (4) are drivable along a loop-shaped lower path, an upper sorter (3) including a plurality of upper sorter units (5) for supporting articles, which upper sorter units (5) are drivable along a loop-shaped upper path. The upper path extends above the lower path. The lower sorter (2) is provided with a first lower input (6) and a second lower input (7) where articles are supplied to the lower sorter units (4). The first and second lower inputs (6, 7) are located at a distance from each other along the lower path. The sorting system also comprises a first lower output (8) and a second lower output (9) where articles are selectively removable from the lower sorter units (4), the first lower output (8) being located downstream of the first lower input (6) and upstream of the second lower input (7), the second lower output (9) being located downstream of the second lower input (7) and upstream of the first lower input (6). The upper sorter (3) is provided with a first upper input (11) and a second upper input (12) where articles are supplied to the upper sorter units (5). The first and second upper inputs (11, 12) are located at a distance from each other along the upper path. The sorting system also comprises a first upper output (13) and a second upper output (14) where articles are selectively removable from the upper sorter units (5), the first upper output (13) being located downstream of the first upper input (11) and upstream of the second upper input (12), the second upper output (14) being located downstream of the second upper input (12) and upstream of the first upper input (11). The sorting system also comprises a pre-sorter being configured to supply articles to the lower and upper sorter units (4, 5) at the second lower and upper inputs (7, 12), which pre-sorted articles are destined for the second lower and upper outputs (9, 14), respectively, substantially only. The second lower output (9) is located at the first upper output (13) and the first lower output (8) is located at the second upper output (14).