Parcel One Pass Labeling and Sorting System
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Solution Overview
Problem
Current parcel sorting and labeling processes are labor-intensive and time-consuming, requiring multiple passes through large machines with many sort bins to qualify for discount postage, which is inefficient and space-consuming.
Innovation Solution
A system that applies shipping labels and sorts parcels in a single pass using a conveyor-based system with label applicators and a sorting scheme, dynamically allocating parcels to sort bins based on pre-sort processing rules, enabling efficient labeling and sorting of unaddressed parcels to qualify for discount postage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple sorting passes are used through a large SPBS machine, then parcels can be sorted to the finest extent of sort to qualify for discount postage, but the processing time increases and space requirements increase
Solution Approach 1:
The sorting process is divided into two independent stages: presort qualification (achieved in one pass with label application) and finest extent of sort (achieved in subsequent passes or at destination). This segmentation allows the first pass to focus solely on applying correct shipping labels with presort indicia, while finer sorting occurs later, reducing the time penalty of multiple passes.
Solution Approach 2:
The system performs preliminary labeling with presort indicia during the first pass through the sorter. By pre-applying labels that contain presort qualification information, the system enables parcels to be sorted more efficiently in subsequent passes without requiring the same sorter to perform both labeling and fine sorting in multiple time-consuming passes.
2Manufacturing precision
If multiple sorting passes are used through a large SPBS machine, then parcels can be sorted to the finest extent of sort, but the space requirements increase due to large machine size
Solution Approach 1:
The system separates the labeling function from the sorting function. A compact labeling system applies presort labels during one pass, while a smaller sorter handles subsequent sorting passes. This segmentation allows use of a smaller sorter instead of requiring a large SPBS machine to perform all functions, reducing space requirements while maintaining sorting precision.
Solution Approach 2:
The system combines labeling and presort qualification functions into a single integrated process during the first pass. By merging these functions and using external label application, the physical sorter machine can be smaller since it doesn't need to accommodate multiple large sorting mechanisms, reducing the overall space requirement while achieving the same sorting precision.
3Ease of manufacture
If a separate labeling machine or manual labeling is used, then shipping labels can be applied to parcels, but the process does not qualify for discount postage and full postage rates are charged
Solution Approach 1:
The system makes the conveyor-based labeling system multi-functional by integrating it with the sorting system. The same conveyor that transports parcels for labeling also feeds them into the sorter, and the labeling system is configured to apply presort-qualified labels. This universality allows a single integrated system to achieve both easy labeling and postage discount qualification, eliminating the need for separate specialized equipment.
Solution Approach 2:
The system enables automatic application of presort-qualified labels through an integrated conveyor and labeling system, eliminating manual labeling. The automated system applies labels with correct presort indicia that qualify for discount postage, making the process both easier (automated) and more cost-effective (discount rates) simultaneously.
4Productivity
If the conveyor moves at high speed, then processing efficiency increases, but the label applicator must apply labels quickly and accurately
Solution Approach 1:
The label applicator system is designed to be dynamic, adjusting its operation based on conveyor speed and parcel positioning. The system uses sensors to detect parcel arrival and timing, dynamically controlling the label application process to ensure precise placement even at high speeds. This dynamic adaptation maintains labeling precision while enabling high-speed processing.
Data Source
AI summary
Systems and methods for parcel one pass labeling and sorting for presort qualification. The system includes a conveyor on which parcel pieces are placed by an operator, where the conveyor ensures proper gap between parcel pieces and justifies the parcels to an edge of the conveyor in order to align the parcels with labelers which print and apply shipping documents and shipping labels. The labeled parcel pieces are then sorted according to the destination indicated and deposited into a sort bin. The system is configured to allow dynamic reassignment of the sort bins based on capacity and sort destinations processed. A single bin is used for depositing parcel pieces which do not need to be sorted by destination.