Matrix Sorter Staging and Batch Release for Higher Throughput
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Solution Overview
Problem
Existing sorting systems in distribution centers face inefficiencies in time and space utilization due to the need for batches to be sorted sequentially, leading to long idle times and suboptimal use of resources, particularly when handling items of varying sizes.
Innovation Solution
A device with multiple sorting stages and individual breakers at each output end of sorting lines, combined with counting and identification systems, allows simultaneous sorting of multiple batches without waiting for previous batches to clear, ensuring only defined batches are released.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If objects are sorted sequentially in batches using traditional matrix sorters, then sorting reliability is maintained, but productivity decreases due to long idle times between batches
Solution Approach 1:
The sorting system is divided into multiple independent sorting stages (first sorting stage, second sorting stage, etc.), each capable of processing batches independently. This segmentation allows parallel processing of multiple batches across different stages, eliminating idle times while maintaining sorting reliability through controlled batch release mechanisms at each stage.
Solution Approach 2:
The feed conveyor continuously prepares and feeds objects for the next batch into the sorting stages before the current batch is completely removed. This preliminary action ensures no idle time occurs between batches, as the system is already prepared for continuous operation while maintaining proper batch separation through the release mechanism.
2Adaptability or versatility
If sorting lines are designed to accommodate maximum item dimensions, then adaptability improves for large items, but device complexity and space requirements increase
Solution Approach 1:
The sorting system uses dynamic control mechanisms (breakers, release mechanisms, conveyor speed control) that allow the same sorting line to adapt to different item sizes and batches. Instead of designing fixed infrastructure for maximum dimensions, the system dynamically adjusts batch release timing and conveyor operation to accommodate varying item sizes, reducing structural complexity while maintaining versatility.
Data Source
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AI summary
The present application relates to a device (10) for sorting several different objects and a corresponding method. The device (10) comprises at least a first sorting stage (12) with at least two sorting lines (14.1, 14.2, 14.3, 14.4, 14.5), each with an input end and an output end. The input ends of the sorting lines (14.1, 14.2, 14.3, 14.4, 14.5) of the first sorting stage (12) are connected to a feed conveyor (8) for feeding the objects, and the output ends of the sorting lines (14.1, 14.2, 14.3, 14.4, 14.5) of the first sorting stage (12) are connected to a first transport conveyor (18) for conveying the objects. At the output ends of the sorting lines (14.1, 14.2, 14.3, 14.4, 14.5) there is a breaker (15.1, 15.2, 15.3, 15.4, 15.5) arranged for the individual release of objects from the respective sorting line (14.1, 14.2, 14.3, 14.4, 14.5).5) is designed, and at the output ends of the sorting lines, a device (17.1, 17.2, 17.3, 17.4, 17.5) is arranged for counting and/or identifying the objects released from the respective sorting line (14.1, 14.2, 14.3, 14.4, 14.5).