Logical Parcel Grouping for Bag-Free Automated Sortation
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Solution Overview
Problem
Conventional automated sortation systems for smaller packages often result in miss-sorted packages due to the need for physical bags, requiring manual intervention and additional material, and are less efficient in accumulating and tracking packages.
Innovation Solution
A system and method that accumulates packages into logical groups without physical containers, using smart bins to transfer packages directly onto a collector conveyor, where they are tracked and sorted, and then logically linked to containers with unique IDs for further processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical bags are used to accumulate packages, then packages can be contained and tracked as a group, but miss-sorted packages occur and manual intervention is required
Solution Approach 1:
The patent extracts the physical bag from the sortation system and replaces it with a virtual container concept. Packages are tracked using virtual container IDs instead of physical bags, eliminating the need for manual bag handling while maintaining group tracking capability. This resolves the contradiction by removing the source of miss-sorts while preserving organizational functionality.
Solution Approach 2:
The patent replaces the mechanical bag-based accumulation system with an automated virtual tracking system. Sensors and control systems monitor package accumulation in real-time, automatically determining when virtual containers are full and directing packages accordingly. This substitution eliminates manual intervention requirements while improving sortation reliability.
2Quantity of substance
If physical bags are used for package accumulation, then packages can be grouped and tracked, but additional material consumption and system complexity increase
Solution Approach 1:
The patent creates virtual copies of physical containers in the form of digital tracking identifiers. Each virtual container ID represents a logical group of packages without requiring physical manifestation. This copying approach maintains the grouping and tracking functionality while eliminating material consumption associated with physical bags.
Solution Approach 2:
The patent changes the state of containerization from physical to virtual. By transforming the container concept from a tangible object with material properties to a digital identifier, the system maintains organizational capability while eliminating material consumption. This parameter change resolves the contradiction between grouping capability and material loss.
3Reliability
If manual monitoring and bag closing is required, then packages can be properly contained, but productivity and efficiency decrease
Solution Approach 1:
The patent implements self-service through automated sensor systems that continuously monitor package accumulation in real-time. The system automatically determines when virtual containers are full and directs subsequent packages accordingly, eliminating the need for manual monitoring and bag closing operations. This automation maintains reliable containment while significantly improving productivity.
Solution Approach 2:
The patent incorporates real-time feedback mechanisms through sensors that track package accumulation and provide continuous information to the control system. This feedback enables automated decision-making about when to close virtual containers and redirect packages, replacing manual operations with automated control loops that maintain reliability while boosting throughput.
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 specified logical zone on conveyor, transported, sorted and/or otherwise processed as unique logical group 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, including automatically closing a container filled with the packages.