Multi-Channel Parcel Sorting with Inertial Separation
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Solution Overview
Problem
Existing logistics sorting machines are limited in their ability to efficiently separate parcels of various sizes and those with high friction, often operating in single channels with low separation efficiency and high vacant regions, leading to suboptimal channel utilization.
Innovation Solution
A multi-channel sorting machine is designed with a feeding mechanism, parcel separation channels, a roller centering machine, and a dragsaw belt conveyor. Each parcel separation channel includes multiple stacked-parcel separation units and parcel singulation channels, equipped with inclined conveyor belts and visual identification systems to control conveyor belt velocities and separate stacked parcels effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If single-channel sorting is used, then device complexity is reduced, but productivity and channel utilization are low
Solution Approach 1:
The sorting machine is divided into multiple independent parcel separation channels (at least two channels), each capable of processing parcels separately. This segmentation allows simultaneous operation of multiple channels, thereby increasing overall productivity and channel utilization without requiring a completely new system architecture.
Solution Approach 2:
The patent transitions from a single-channel (one-dimensional) sorting approach to a multi-channel (two-dimensional) arrangement where channels are positioned side by side. This dimensional expansion enables parallel processing of parcels across multiple channels, significantly boosting separation efficiency while maintaining manageable device complexity through modular design.
2Adaptability or versatility
If conventional separation methods (deflector rod or gravity inclined conveyor) are used, then device complexity is low, but adaptability to various parcel sizes and high friction parcels is limited
Solution Approach 1:
The patent employs a dynamic separation mechanism where the inclined conveyor belt's velocity is actively controlled and adjusted based on real-time detection of parcel stacking conditions. The conveyor belt accelerates and decelerates to generate inertial forces that effectively separate stacked parcels, adapting to different parcel sizes and friction characteristics through velocity modulation rather than fixed mechanical structures.
Solution Approach 2:
The separation capability is enhanced by changing the velocity parameter of the inclined conveyor belt dynamically. By adjusting the belt's speed according to detected parcel conditions, the system adapts to various parcel sizes and friction levels, overcoming the limitations of static conventional separation methods without requiring complex mechanical adjustments.
3Reliability
If visual identification system controls conveyor velocity dynamically, then separation effectiveness is improved, but energy consumption and conveyor belt damage increase
Solution Approach 1:
The inclined conveyor belt operates with periodic acceleration and deceleration cycles rather than continuous high-speed operation. The visual identification system triggers velocity changes only when parcel stacking is detected, creating a periodic action pattern that maintains separation effectiveness while reducing overall energy consumption compared to sustained high-velocity operation.
Solution Approach 2:
The system uses the parcels' own inertia and weight against gravity to achieve separation during the conveyor belt's deceleration phase, rather than requiring continuous high-energy input. The dynamic velocity control leverages the physical properties of the parcels themselves, reducing the energy burden on the conveyor system while maintaining reliable separation effectiveness.
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
The multi-channel sorting machine significantly improves parcel processing efficiency by reducing vacant regions and increasing channel utilization, effectively separating parcels of various sizes and those with high friction, while minimizing energy consumption and conveyor belt damage.
Implementation Method 1
the utilization environment of both of the above methods is limited, which is not conducive to the separation of the parcels of various sizes and the parcels with high friction
Implementation Method 2
the utilization environment of both of the above methods is limited, which is not conducive to the separation of the parcels of various sizes and the parcels with high friction
Implementation Method 3
the visual identification system is capable of identifying whether the parcels are overlapped, and the visual identification system of a previous stacked-parcels separation unit is capable of controlling a maximum velocity of the inclined conveyor belt
Implementation Method 4
then the parcels are centered, rectified a misalignment, and aligned by the roller centering machine
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A multi-channel sorting machine for parcel singulation, comprising a feeding mechanism, parcel separation channels, a roller centering machine, and a dragsaw belt conveyor. Each parcel separation channel comprises a multi-channel stacked parcel separation mechanism (1) and a multi-channel parcel singulation mechanism (2). In the process of conveying parcels by an inclined conveyor belt (111), the inclined conveyor belt (111) suddenly accelerates and then suddenly decelerates, so that misalignment is caused between two stacked parcels by means of acceleration on the basis of the inertia; then a visual identification system (113) of a previous stacked parcel separation unit (11) identifies the misalignment of the parcels according to the overlapping of the parcels conveyed by the current stacked parcel separation unit (11), the maximum speed of the inclined conveyor belt (111) of a next stacked parcel separation unit (11) is controlled to further separate vertically stacked parcels, and when the vertically stacked parcels are separated, no change in the speed of the inclined conveyor belt (111) is made, thereby reducing the damage to the conveyor belt from sudden acceleration.