Segmented Mail Sorting Device with Overflow Redirection
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Solution Overview
Problem
Existing methods for sorting flat mail items are inefficient and prone to errors due to the need for multiple sorting passes and limited storage capacity, which can lead to overflow and misrouting of mail items.
Innovation Solution
A sorting device with two segments, each containing N storage modules, where overflow mail items are temporarily stored in other modules during the first pass and reintegrated into the sorting process in a second pass, allowing for efficient sorting by round order and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sorting passes are executed to sort mail items according to round order, then sorting accuracy is improved, but processing time increases
Solution Approach 1:
The sorting device is divided into multiple segments (first segment, second segment, etc.), each with its own storage modules. This segmentation allows different sorting passes to occur simultaneously in different segments, thereby maintaining high sorting accuracy through multiple passes while reducing overall processing time through parallel operation.
Solution Approach 2:
Overflow mail items are temporarily stored in available storage modules during the first sorting pass before being processed in subsequent passes. This preliminary storage action prevents loss of mail items and ensures they are included in later sorting passes, maintaining accuracy without requiring sequential processing of all items.
2Quantity of substance
If storage module capacity is increased to reduce overflow, then storage capacity is improved, but device complexity increases
Solution Approach 1:
Instead of using fewer large-capacity storage modules, the system uses multiple segments with multiple smaller storage modules each. This segmentation provides the necessary total storage capacity while keeping individual module complexity low and enabling modular, manageable system architecture.
Solution Approach 2:
Storage modules are dynamically assigned and reassigned based on current sorting needs. When a storage module becomes full during one sorting pass, it can be effectively 'discarded' for that purpose and its capacity made available for overflow items or reassigned in subsequent passes, maximizing the utilization of existing storage capacity without requiring excessive total capacity.
3Reliability
If overflow mail items are stored in separate modules, then overflow management is improved, but device complexity increases
Solution Approach 1:
Storage modules serve multiple functions: they store mail items for current sorting passes, accommodate overflow items from other modules, and can be reassigned in subsequent passes. This multi-functionality allows efficient overflow management using the same storage infrastructure, avoiding the need for separate dedicated overflow storage areas and thereby reducing device complexity.
Solution Approach 2:
The sorting device automatically manages overflow mail items by identifying full storage modules and redirecting overflow items to available modules through the process control device. This self-service mechanism handles overflow management without requiring manual intervention or complex separate overflow handling systems, maintaining reliability while minimizing added complexity.
Data Source
AI summary
A method is specified for sorting flat mail items, which allows sorting according to delivery order to be carried out swiftly and reliably. With the method a first sorting pass is carried out in a first segment with at least N storage modules of a sorting device and a second sorting pass is then carried out in a second segment with at least N storage modules of the sorting device. The overflow items, which are assigned to a storage module that has been closed because it is full, are deposited into one of the other storage modules in the first sorting pass and are included in the sorting process of the second sorting pass.