Grid Sorter Omnidirectional Roller Routing
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Solution Overview
Problem
Current sorting systems for high-throughput next-day delivery of articles, such as parcels and packages, face challenges in efficiently directing articles from multiple sources to selected destinations due to limitations in conveyor direction changes and article routing.
Innovation Solution
A grid sorter system comprising parallel first and second conveyor lines that intersect to form a grid, with omnidirectional-roller sorters at intersections to direct articles along selected paths, and a controller to manage conveyor directions and avoid collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional conveyor systems with fixed direction changes are used, then the system structure is simple, but the routing flexibility and throughput for high-volume sorting are limited
Solution Approach 1:
The patent applies dynamics by making the conveyor system movable and adjustable rather than fixed. Each conveyor section can change direction dynamically based on real-time sorting requirements, allowing the system to adapt to different routing needs while maintaining a relatively simple physical structure.
Solution Approach 2:
The patent transitions from traditional two-dimensional conveyor routing to three-dimensional routing by utilizing vertical layers and omnidirectional movement capabilities. Articles can be routed in multiple directions (forward, backward, left, right, upward, downward) simultaneously, dramatically increasing routing flexibility without proportionally increasing system complexity.
2Productivity
If omnidirectional-roller sorters are deployed at intersections to enable flexible routing, then routing flexibility and throughput improve, but the device complexity and cost increase
Solution Approach 1:
The patent segments the sorting system into modular omnidirectional-roller sorter units positioned at grid intersections. Each unit is an independent module that can be controlled individually, allowing high throughput through parallel processing of multiple articles while keeping each individual sorter mechanism relatively simple and manageable.
Solution Approach 2:
The omnidirectional-roller sorters are designed as universal multi-functional units that can route articles in any direction (360 degrees) and perform multiple functions (sorting, merging, diverting) depending on control signals. This multi-functionality reduces the need for multiple specialized components, thereby managing complexity while maximizing productivity.
3Adaptability or versatility
If multiple bidirectional conveyors are used to enable articles to travel in both directions, then routing options increase, but the control complexity and collision avoidance requirements increase
Solution Approach 1:
The patent implements feedback mechanisms where sensors continuously monitor article positions, conveyor directions, and intersection states. This real-time feedback enables the control system to dynamically adjust conveyor directions and timing to prevent collisions while maximizing routing flexibility, managing control complexity through intelligent real-time adjustment rather than static complex programming.
Solution Approach 2:
The control system performs preliminary actions by pre-coordinating conveyor direction changes and article movements before conflicts arise. The system anticipates potential collisions and resolves them in advance by adjusting routing paths and timing, reducing the complexity of real-time collision avoidance while maintaining high adaptability.
Data Source
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AI summary
A grid sorter for discharging articles received from many inputs to selected discharge destinations. The grid sorter comprises a rectangular grid of parallel conveyor lines. Each line has a series of bidirectional conveyors fed articles by infeed conveyors at each end of the line. Omnidirectional-roller sorters, at the intersections of the conveyor lines, can pass articles received from one line in multiple directions: along that same line; in either direction to an intersecting line; or obliquely to a selected discharge between lines. Omnidirectional rollers in the omnidirectional-roller sorters are controlled by a controller to push articles in selected directions to predetermined discharge destinations.