Movable Divider for Dynamic Item Sorting
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Solution Overview
Problem
Current industrial sorting systems face inefficiencies in processing large volumes of items, leading to significant time losses as sorted collections occupy collection areas, hindering further sorting processes.
Innovation Solution
A system comprising a pocket with a movable divider and injector mechanism that dynamically separates stacks of items, allowing for the removal of one stack while continuing to sort and receive new items, using a progressive displacement system and controller to optimize sorting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sorted collections of items are placed in collection areas for further processing, then the sorting function is achieved, but the collection areas are occupied and cannot be used for further sorting processes
Solution Approach 1:
The collection area is segmented into multiple pockets, each capable of independently holding sorted collections. This allows different pockets to be used at different stages of the sorting process, enabling continuous operation without waiting for a single collection area to be emptied and reused.
Solution Approach 2:
Multiple pockets are prepared in advance for receiving sorted collections. While one pocket is being filled with sorted items, other pockets are already ready to receive the next batch, eliminating idle time and ensuring continuous processing flow.
2Productivity
If a single collection area is used for sorting, then the system structure is simple, but the processing efficiency decreases due to idle time when collection areas are occupied
Solution Approach 1:
Multiple pockets are combined into a single integrated collection assembly that moves together through the system. This allows multiple collection functions to be performed simultaneously while maintaining a unified structural unit, balancing increased capacity with manageable complexity.
Solution Approach 2:
Each pocket is designed as a universal collection unit that can receive any type of sorted collection. The pockets can be dynamically assigned to different sorting destinations, allowing the same physical structure to serve multiple functions and increasing overall system 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
This approach enhances the efficiency of industrial sorting processes by enabling the simultaneous sorting and removal of items, reducing processing time and increasing productivity in handling large volumes of items.
Implementation Method 1
The gear system is in mechanical communication with the linear member, wherein movement of the linear member is translated to rotational movement of the gear system. The rotational movement of the gear system due to movement of the linear member moves the divider between a retracted position and an extended position, wherein a corresponding output movement distance of the divider is greater than an input movement distance by the linear member.
Data Source
AI summary
Sorting systems and methods for large quantities of items in industrial processes are described. The systems, devices and methods are for receiving, sorting and removing items dynamically. A first group of items, such as letters or other mail pieces, are injected by a belt into a pocket to a form a first stack, and a progressive displacement divider with amplified output for a given input is extended near the first stack. The divider allows for a second group of items to either be injected to form a second stack behind the divider, or to be diverted and injected into another pocket. The first stack can be removed while the second group is being injected.