Logical Parcel Grouping for Miss-Sort Reduction in Automated Sortation
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Solution Overview
Problem
Conventional automated sortation systems for smaller packages are inefficient and prone to miss-sorting, often requiring additional materials and manual intervention due to packages missing their intended bags, leading to inefficiencies and increased resource use.
Innovation Solution
A system and method that accumulates packages into logical groups without physical containers, using smart bins to transfer packages onto collector conveyors, where they are tracked and sorted as a group, and then logically linked to containers for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If packages are diverted into physical bags for accumulation, then packages can be grouped and tracked, but packages may miss the bag they are intended for resulting in miss-sorted packages
Solution Approach 1:
The patent removes physical bags from the sortation system, extracting the container element that causes miss-sorting issues. Packages are accumulated and tracked as a group without requiring physical containment, eliminating the problem of packages missing their intended bags while maintaining group tracking capability through logical association with bag IDs.
Solution Approach 2:
The patent creates a virtual copy of the bagging function through logical group tracking. Instead of physical bags, the system uses digital tracking where packages are associated with a bag ID and tracked as a logical group, replicating the grouping and tracking functionality without the physical container that causes sorting errors.
2Productivity
If physical bags are used for package accumulation, then packages can be contained and tracked as a group, but additional material is required and manual intervention is needed
Solution Approach 1:
The patent extracts the physical bag material from the accumulation process, eliminating consumption of additional materials while maintaining the ability to accumulate and track packages as groups. The system uses virtual containment through logical group association instead of physical material.
Solution Approach 2:
The system automates the accumulation and tracking process without requiring manual intervention to monitor and close bags or move them for further processing. The automated sortation system handles package grouping, tracking, and transfer to collector conveyors autonomously.
3Reliability
If manual intervention is used to monitor and close bags, then packages can be properly contained, but system efficiency decreases
Solution Approach 1:
The patent implements self-service automation where the sortation system automatically accumulates packages into logical groups, tracks them with bag IDs, and transfers them to collector conveyors without human intervention. The system monitors and manages the accumulation process autonomously, maintaining reliability while maximizing processing speed.
Solution Approach 2:
The patent replaces manual mechanical operations (monitoring, closing, and moving bags) with automated electronic tracking and conveyor-based transfer. The logical group tracking system substitutes for manual bag management, and automated conveyors replace manual bag movement, significantly increasing processing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces miss-sorting by eliminating the need for physical containers, enhancing efficiency and reducing manual intervention, while maintaining package tracking and processing accuracy.
Implementation Method 1
a gate moveable between a closed position configured to retain an item within the cavity, and an open position configured to allow an item to fall from within the cavity through the bottom
Data Source
AI summary
System and method are provided where parcels or packages are associated or grouped, into logical group or logical containerization of parcels or packages, without need for physical container, such that parcels or packages can be tracked as a group, for example with a unique group ID. Logical group may be tracked within a specified logical zone, transported, sorted and/or otherwise processed as unique logical group in container, or without need to be contained in physical container. System and method for automated sortation can accumulate set number or set volume of packages, and then process the accumulated set number or volume of packages.