Matrix Sorter Lane Balancing for Variable Unit Load Sorting
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Solution Overview
Problem
Matrix sorters face inefficiencies due to overloading or underutilization of sorting lanes, particularly when handling items with variable dimensions, leading to reduced capacity and increased space and cost requirements.
Innovation Solution
A method that determines sorting values based on the number of items and the sorting algorithm before the sorting process, ensuring a predetermined upper and/or lower limit of items per sorting lane, optimizing the distribution of items across all sorting stages without modifying the sorter's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sorting lane is designed based on the largest dimensions of individual items, then the capacity of individual sorting lanes is maintained, but the space requirements and costs increase significantly
Solution Approach 1:
The patent changes the parameter of item dimensions by introducing virtual items with reduced dimensions that represent multiple physical items. This allows the sorting lane to be designed for smaller virtual items, reducing space requirements while maintaining the ability to handle larger physical items through the virtual representation mechanism.
Solution Approach 2:
The patent creates virtual copies of physical items in the sorting lane. Multiple physical items are represented by a single virtual item with reduced dimensions, allowing the sorting lane to accommodate more items without increasing physical space requirements. The virtual items are processed through the sorting lane and then mapped back to physical items for output.
2Productivity
If the number of sorting stages and sorting lanes is increased, then the sorting capacity is improved, but the system complexity and costs increase
Solution Approach 1:
The patent uses virtual items to represent multiple physical items in the sorting lane. This allows a single sorting stage with a fixed number of sorting lanes to handle a larger number of physical items by processing virtual representations, thereby increasing sorting capacity without adding physical sorting stages or lanes.
Solution Approach 2:
The patent segments the sorting process into virtual and physical domains. Virtual items are processed through the sorting lane independently, and then multiple virtual items are mapped to physical items for output. This segmentation allows the physical sorting infrastructure to remain simple while achieving high sorting capacity through virtual processing.
3Adaptability or versatility
If items with variable dimensions are conveyed, then the adaptability of the system is improved, but the capacity of individual sorting lanes is reduced
Solution Approach 1:
The patent changes the parameter of item dimensions by introducing virtual items with standardized reduced dimensions that represent physical items of various sizes. This allows the sorting lane to maintain a fixed capacity designed for small virtual items while accommodating physical items of variable dimensions through the virtual representation mechanism.
Solution Approach 2:
The patent creates virtual copies of physical items with standardized dimensions regardless of the original item's size. This allows the sorting lane to maintain consistent capacity specifications while handling diverse physical items, as all items are represented by virtual items with uniform dimensional parameters for sorting purposes.
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3
AI summary
The invention relates to a method for sorting unit loads (10) in a conveyor system. The unit loads (10) are guided along conveyor tracks and each receives a sorting value (25, 26) which determines the order of the unit loads after sorting. From a common feed track (4), the unit loads are conveyed through several sorting stages (1, 2, 3), wherein the unit loads are directed at each sorting stage (1, 2, 3) onto one of several alternative sorting tracks (1a, 2a, 3a). The assignment to the sorting tracks is based on the sorting values (25, 26), which are evaluated by a sorting algorithm.The sorting values (25, 26) are determined before conveying to the sorting stages (1, 2, 3) depending on the number of items (10) to be sorted and the sorting algorithm, so that in each sorting stage (1, 2, 3) the maximum number of items (10) on each sorting lane corresponds to a predetermined upper limit and/or the minimum number of items (10) corresponds to a predetermined lower limit.