Package Sorting Guidance via Light and OCR
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Solution Overview
Problem
Manual sorting of packages in shipping warehouses often results in errors, such as placing packages in incorrect bins, leading to delayed customer delivery and increased costs, due to the reliance on human interpretation of shipping labels in a chaotic environment.
Innovation Solution
A package management system utilizing guidance devices that communicate with an inventory tracking system to illuminate the correct bin for package placement, eliminating the need for human interpretation of labels by providing visual and audio cues, and using sensors to confirm correct placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual sorting is used to reduce device complexity, then ease of operation is improved, but manufacturing precision deteriorates due to human error in reading labels and placing packages
Solution Approach 1:
The patent replaces the manual visual interpretation and decision-making process with an automated optical system. Cameras capture images of shipping labels and bin labels, OCR technology extracts text, and a computing system automatically compares and determines correct bin assignments, eliminating human error in label reading and package placement decisions
Solution Approach 2:
The patent introduces an intermediary computational system that acts as a mediator between the physical packages/bins and the sorting action. The system processes label information, determines correct bin assignments, and provides guidance to workers through displays or automated mechanisms, serving as an intelligent intermediary that ensures accurate sorting
2Manufacturing precision
If automated sorting is used to improve manufacturing precision, then sorting accuracy is improved, but device complexity increases due to additional sensors, cameras, and control systems
Solution Approach 1:
The patent employs multi-functional components that perform multiple tasks. For example, the camera system not only captures label images but also tracks package movement and verifies bin placement. The OCR system extracts text from both shipping labels and bin labels. The computing system performs image processing, text recognition, comparison logic, and guidance display control, consolidating multiple functions into integrated components that reduce overall system complexity
Solution Approach 2:
The system incorporates self-verification capabilities where sensors and cameras automatically detect and confirm package placement in correct bins. The system self-monitors its own operation, automatically identifying mis-sorted packages and triggering correction mechanisms, reducing the need for external monitoring and manual intervention
3Manufacturing precision
If visual indicators are added to guide package placement, then manufacturing precision is improved, but use of energy increases due to illuminated displays and sensors
Solution Approach 1:
The patent uses periodic or on-demand activation of visual indicators rather than continuous operation. Lights and displays are activated only when a package is being sorted or when mis-sorting is detected, and remain inactive during idle periods. The system periodically scans for packages needing sorting and activates guidance only during these intervals, significantly reducing overall energy consumption while maintaining sorting accuracy when needed
Data Source
AI summary
Embodiments presented herein describe a package management system that uses guidance devices when transporting packages. In one embodiment, the package management system includes an event detecting device that detects a package transporting event such as when a package is sorted into a container, a container is moved from the warehouse to vehicle, a container is moved from a vehicle into a warehouse, a package is delivered, a package is moved to a staging location, or a package is picked-up from a staging location. Once a container or staging location corresponding to the event is identified, a gateway identifies the guidance device assigned to that container or staging location and instructs the guidance device to illuminate a light disposed thereon.