Overhead Pallet Sorting With ML-Based Grading and Stacking

The patent replaces manual mechanical sorting with an automated system using cameras, sensors, and machine learning algorithms to detect pallet conditions, assess damage, and determine sorting destinations. This substitution of mechanical/manual operations with optical and computational systems directly improves measurement precision while managing device complexity through integrated automation.

The patent introduces intermediate components such as cameras, sensors, and machine learning models that act as mediators between the pallets and the sorting mechanism. These intermediaries capture pallet data, process it through algorithms, and translate it into sorting decisions, thereby enhancing grading accuracy without requiring direct human intervention in the sorting process.

The patent employs a multi-functional conveyance system where overhead conveyors, lifting mechanisms, and sorting mechanisms work together to perform multiple operations (transport, elevate, sort, and direct pallets) within a single integrated system. This multi-functionality improves productivity by automating the entire sorting process while managing complexity through coordinated operation of unified components.

The patent utilizes vertical dimension by implementing overhead conveyors and lifting mechanisms that move pallets in three-dimensional space. This spatial arrangement allows multiple sorting streams and destinations to be organized vertically, increasing sorting capacity and efficiency while consolidating equipment footprint and managing system complexity through spatial optimization.

The patent performs preliminary data collection by positioning cameras and sensors to capture pallet images and sensor data as pallets move through the conveyance system before sorting decisions are finalized. This preliminary action ensures comprehensive information gathering occurs in advance, allowing machine learning models to process data and determine sorting destinations without delaying the actual sorting operation.

The patent maintains continuous data collection and processing throughout the pallet flow through the system. Cameras and sensors continuously capture pallet conditions, and machine learning models continuously process this data to determine sorting destinations. This continuous operation ensures no information is lost while maintaining high sorting speed by eliminating idle processing time between pallets.