Oblique Shuttle Bin Exchanger for Gravity-Assisted Mail Transfer
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Solution Overview
Problem
Existing postal sorting equipment requires manual handling and slow emptying of storage bins, limiting operator efficiency and throughput.
Innovation Solution
The introduction of an automated system featuring a storage bin conveyor, a dihedral-shaped shuttle bin conveyor, and a bin exchanger that transfers mail items from conventional top-opening storage bins to larger shuttle bins with front openings, utilizing gravity to facilitate efficient transfer and increasing storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual emptying of storage bins is used, then operator control is maintained, but operator handling time increases and throughput decreases
Solution Approach 1:
The system enables self-service through automated conveyors that transport storage bins and shuttle bins, and an automated bin exchanger that transfers mail items without operator intervention. The gravity-assisted transfer mechanism allows the system to serve itself by automatically emptying storage bins into shuttle bins and conveying them to the feed inlet.
Solution Approach 2:
The bin exchanger acts as an intermediary device between storage bins and shuttle bins, automatically transferring mail items. The conveyor systems serve as intermediaries to transport bins between different stations, eliminating the need for operators to manually handle and transfer mail items between containers.
2Productivity
If standard rectangular storage bins are used, then simple structure is maintained, but emptying rate is slow and throughput is limited
Solution Approach 1:
The system segments the bin system into two distinct types: storage bins for bulk mail accumulation and shuttle bins for rapid discharge to the feed inlet. This segmentation allows each bin type to be optimized for its specific function, with shuttle bins designed for quick emptying and storage bins for efficient storage and transport.
Solution Approach 2:
The system introduces dynamic elements through automated conveyors that continuously move bins between stations, and an automated bin exchanger that dynamically transfers mail items from storage bins to shuttle bins. The gravity-assisted transfer mechanism provides dynamic, rapid emptying compared to static manual emptying.
3Extent of automation
If mail items are transferred manually, then simple transfer process is maintained, but transfer speed is slow and automation level is low
Solution Approach 1:
The system replaces manual mechanical transfer with an automated bin exchanger mechanism that uses gravity-assisted transfer. The exchanger automatically positions and transfers mail items from storage bins to shuttle bins without manual intervention, substituting human-operated mechanical transfer with an automated mechanical system.
Solution Approach 2:
The bin exchanger changes the transfer parameters by using gravity-assisted transfer at an optimized angle and position, enabling rapid automatic transfer of mail items. The system changes the state from static manual transfer to dynamic automated transfer with controlled gravity assistance, increasing transfer speed and automation level.
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 solution reduces operator handling, increases emptying rates, and enhances the throughput of the sorting machine by automating the transfer process, allowing for higher capacity and faster processing of mail items.
Implementation Method 1
said exchanger is arranged to hold the shuttle bin during transfer at an oblique angle to the horizontal and vertical directions in order to obtain a gravity stabilization of the stack of mail items transferred into the bottom of said shuttle bin
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5J
AI summary
The invention relates to a postal sorting apparatus for sorting flat postal items (P) including a postal sorting machine (1), a conveyor (7A) for open-top storage bins (5) that are filled with flat-stacked postal items, a conveyor (7B) for open-front shuttle bins (8) that are generally dihedral and in which the postal items are arranged edgewise in a stack, and a bin exchanger (7) that is capable of automatically transferring the flat-stacked postal items in an open-top storage bin to an open-front shuttle bin, said transfer being achieved by turning the storage bin over in relation to the shuttle bin, which is held obliquely relative to the horizontal and vertical directions so as to jog by gravity the stack of postal items transferred into the bottom of said shuttle bin.