Automated Package Relabeling System for Conveyor Sorting

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Solution Overview

Problem

Existing sorting systems face delays and disruptions when items with unreadable or unscannable labels are encountered, as they must be manually rerouted for label interpretation, disrupting the processing flow.

Innovation Solution

A system that includes a sorting component with a scan tunnel to identify label errors, redirecting items to a relabeling system where they are either singulated or flattened, and applying a new label, with automated or manual processing to associate delivery information with the new label, allowing seamless reintroduction into the sorting stream.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If items with label errors are manually rerouted for label interpretation, then label errors can be addressed, but sorting delays and processing disruptions occur

Engineering Contradiction:

Improvelabel error handlingVSAvoidsorting speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system enables items with label errors to automatically identify and redirect themselves to the relabeling system through scan tunnel detection, eliminating the need for manual intervention and maintaining continuous sorting flow

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

A dedicated relabeling system acts as an intermediary component between the sorting system and items with label errors, handling the relabeling process separately without disrupting the main sorting stream

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If manual intervention is used for label interpretation, then accurate label reading can be achieved, but processing time increases

Engineering Contradiction:

Improvelabel reading accuracyVSAvoidprocessing time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system replaces manual mechanical label reading with automated optical scan tunnels and imaging systems that capture and interpret label information automatically, achieving both accuracy and speed

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs preliminary label scanning and error detection at the scan tunnel stage before items reach the relabeling system, allowing for proactive identification and routing of problematic items

Inventive Principle:

Principle #10Preliminary action

3Reliability

If the sorting system waits for manual label correction, then accuracy is maintained, but sorting continuity is disrupted

Engineering Contradiction:

Improvesorting accuracyVSAvoidsorting continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system segments the sorting process into separate functional zones: scan tunnel for detection, relabeling system for correction, and return conveyor for reintegration, allowing parallel processing that maintains both accuracy and continuity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sorting system maintains continuous operation by automatically routing corrected items back into the sorting stream through a return conveyor, ensuring unbroken processing flow without manual intervention gaps

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS20250206489A1Package relabeling system

Publication Date: 2025.06.26 US POSTAL SERVICE

AI summary

A system may include at least one conveyor lane configured to transport items. A system may include a scan tunnel to identify any items containing unreadable or unscannable labels transported by the at least one conveyor lane. A system may include a sorter configured to redirect items traveling on the at least one conveyor lane. A system may include a relabeling component configured to apply a new label to any items that contain an unreadable or unscannable label.