Multi-Level Delivery Vehicle Sorting for Compact Mail Handling
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Solution Overview
Problem
Existing automated sorting systems for mail and items are costly and inefficient, particularly for mid- to large-sized organizations, due to their size and complexity, which makes them unsuitable for handling the volume and diversity of mail pieces, and they require significant labor for storage and retrieval operations.
Innovation Solution
A compact automated sorting system with semi-autonomous delivery vehicles that travel along a track with interconnected vertical and horizontal sections, maintaining item orientation as it changes direction, and a central controller managing vehicle positions and operations to efficiently sort items into multiple storage locations or bins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional automated sorting equipment is used, then sorting efficiency is improved, but cost and system size increase significantly
Solution Approach 1:
The system is divided into modular components: multiple independent delivery vehicles, segmented track sections (vertical and horizontal), and distributed control units. Each vehicle operates semi-autonomously, and the track is composed of interchangeable modules that can be configured for different sorting needs, reducing overall system complexity while maintaining high productivity.
Solution Approach 2:
The patent introduces vertical track sections to add a third dimension to the sorting system. Instead of only horizontal movement, vehicles can travel vertically to access different levels of storage locations. This dimensional addition increases sorting capacity and efficiency without proportionally increasing the horizontal footprint of the system.
2Adaptability or versatility
If delivery vehicles travel between levels using ramps, then access to multiple storage levels is enabled, but space requirements and travel time increase
Solution Approach 1:
The system uses vertical track sections that allow vehicles to move between levels in a direct vertical path rather than through diagonal ramps. This vertical dimension enables multi-level access while minimizing the horizontal space required, as vehicles transition between levels through dedicated vertical shafts rather than extending ramp structures across the facility.
Solution Approach 2:
The track sections use curved transitions at the intersections of vertical and horizontal paths, allowing vehicles to smoothly change direction between levels. These curved transitions eliminate the need for long ramp approaches and enable compact positioning of vertical track sections, reducing the overall space footprint while maintaining vehicle accessibility to all levels.
3Device complexity
If manual sorting is used, then system cost is reduced, but labor requirements and time consumption increase
Solution Approach 1:
The delivery vehicles are equipped with semi-autonomous capabilities including onboard navigation, automatic destination identification, and self-directed travel along the track. The vehicles can independently determine their routing and execute delivery operations with minimal human intervention, providing automated sorting functionality at a lower cost than fully automated systems while significantly exceeding manual sorting productivity.
Solution Approach 2:
The system uses universal delivery vehicles that can service multiple storage locations across different levels and areas. Each vehicle is designed to handle various item types and can be dispatched to any destination on the track network, eliminating the need for specialized equipment for different sorting tasks and reducing overall system cost while maintaining high throughput capability.
4Quantity of substance
If items are stored in extensive storage areas, then storage capacity is increased, but retrieval time and labor requirements increase
Solution Approach 1:
The system organizes storage locations in a multi-level vertical configuration accessible through the track network. Items are stored in bins arranged across multiple floors, and the vertical track sections enable rapid retrieval by allowing vehicles to directly access any level without traversing horizontal distances across the entire storage area, significantly reducing retrieval time while maintaining high storage capacity.
Solution Approach 2:
The system replaces manual retrieval operations with automated delivery vehicles that travel along the track to fetch items from storage locations. The controller system substitutes human decision-making and physical retrieval actions with automated navigation and robotic delivery mechanisms, reducing both labor requirements and retrieval time while handling extensive storage capacities.
Data Source
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AI summary
A method and apparatus are provided for sorting items to a plurality of sort destinations. The items are loaded onto one of a plurality of independently controlled delivery vehicles. The delivery vehicles follow a track that guides the delivery vehicles to the sort destinations, which are positioned along the track. Once at the appropriate sort destination, the delivery vehicle ejects the item to the sort destination and returns to receive another item to be delivered.