Package Convergence Control via Virtual Buffering

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Solution Overview

Problem

Physical distribution systems experience stagnation of packages at junctions or conveyance path intersections due to inefficiencies in routing and sorting processes, where packages may not converge effectively to a single path.

Innovation Solution

A physical distribution system with two sorters and a control device that manages conveyance paths and chutes to direct packages to their correct destinations, using sensors to read package codes and control valves to route packages efficiently, ensuring packages converge onto one conveyance path from multiple paths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If packages are routed through multiple conveyance paths to sorters, then sorting flexibility is improved, but package stagnation occurs at junctions

Engineering Contradiction:

Improvesorting flexibilityVSAvoidpackage flow continuity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

A virtual buffer is introduced as an intermediary mechanism between conveyance paths and sorters. This virtual buffer manages package flow by controlling the timing and sequence of package convergence at junctions, preventing stagnation while maintaining sorting flexibility. The control device acts as a mediator that coordinates package release from different conveyance paths based on sorter capacity and package destination.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system dynamically adjusts package routing and convergence timing based on real-time conditions. The control device monitors sorter status, conveyance path occupancy, and package flow rates, then dynamically controls valve operations and conveyor speeds to optimize package flow. This dynamic control prevents stagnation by adapting to changing system conditions while maintaining flexible sorting capabilities.

Inventive Principle:

Principle #15Dynamics

2Productivity

If packages from multiple infeeders converge to a single sorter, then resource utilization is improved, but congestion occurs at convergence points

Engineering Contradiction:

Improvesorter utilizationVSAvoidconvergence path complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The convergence process is segmented into multiple controlled stages. Instead of direct convergence of all packages to the sorter, packages are first grouped by destination using valves that direct them to specific intermediate convergence zones. This segmentation reduces congestion at the main sorter entrance by distributing package flow across multiple entry points and timing the convergence of different package groups.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Package routing decisions and valve operations are performed in advance before packages reach the convergence point. The control device pre-calculates optimal convergence timing and valve sequences based on package destinations and sorter capacity. This preliminary action prevents congestion by ensuring packages are routed efficiently before they arrive at the convergence zone, rather than making decisions at the point of convergence.

Inventive Principle:

Principle #10Preliminary action

3Speed

If package routing decisions are made at junctions, then response time is improved, but stagnation occurs due to waiting for decisions

Engineering Contradiction:

Improverouting decision speedVSAvoidpackage waiting time

Core Design Contradiction:

SpeedVSLoss of time

Solution Approach 1:

Package routing decisions are made in advance based on package destination codes read at the infeeder. The control device determines the optimal sorter and conveyance path before the package leaves the infeeder, eliminating waiting time at junctions. Valves are pre-positioned and packages are routed continuously without stopping for decision-making at convergence points.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical decision-making process at junctions (where packages would physically wait for routing decisions) is replaced with an automated control system that makes routing decisions electronically based on package codes. Sensors read package identifiers, the control device calculates optimal routing, and valves automatically direct packages without manual intervention or package waiting, substituting electronic control for mechanical decision delays.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3539681B1Physical distribution system, physical distribution method and program

Publication Date: 2022.11.02 KK TOSHIBA

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AI summary

A physical distribution system includes first and second conveyance paths, first and second sensors, and a processor. The first sensor detects a package passing along the first conveyance path. The second conveyance path merges with the first conveyance path at a junction. The second sensor detects a package passing along the second conveyance path. The processor counts a first number of packages present in a first convergence monitoring section determined in the first conveyance path upstream the junction, and counts a second number of packages present in a second convergence monitoring section determined in the second conveyance path upstream the junction, determines an order in which packages in the first and second convergence monitoring sections pass the junction, based on the first number and the second number, and control the first and second conveyance paths, such that the packages pass the junction in the determined order.