Parcel Singulation Using Skewed Rollers and Vision Detection
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Solution Overview
Problem
Existing singulating systems in parcel sorting facilities face challenges in handling parcels in side-by-side arrangements and those with irregular shapes, as they struggle to effectively transition these items from bulk flow to a singulated stream.
Innovation Solution
A singulating system incorporating a visioning subsystem with cameras and a motor control system, along with skewed rollers and selectively activated belts, identifies and separates parcels in side-by-side arrangements or with irregular shapes by activating specific rollers or zones to guide them into a discharge chute, ensuring proper alignment and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional singulating systems are used, then regular parcels can be processed, but parcels in side-by-side arrangements and irregularly shaped parcels cannot be effectively singulated
Solution Approach 1:
The visioning subsystem performs preliminary identification of side-by-side and irregular parcels before they reach the singulation zone. The system detects these problematic parcels upstream and pre-positions control signals to activate specific rollers at the optimal moment, ensuring effective singulation before parcels become misaligned
Solution Approach 2:
The system employs selectively activated rollers that can dynamically change their rotation state based on real-time parcel configuration. When side-by-side or irregular parcels are detected, specific rollers are activated to provide differential friction forces, dynamically adapting the singulation mechanism to handle varying parcel arrangements
2Measurement precision
If selective roller activation is used to separate side-by-side parcels, then separation accuracy improves, but system complexity increases
Solution Approach 1:
The visioning subsystem continuously monitors parcel positions and provides real-time feedback to the control system. Based on this feedback, the system selectively activates specific rollers to correct side-by-side arrangements. This closed-loop control achieves high separation accuracy while managing complexity through intelligent, event-driven activation rather than continuous operation of all components
Solution Approach 2:
The system replaces complex mechanical singulation mechanisms with a combination of vision-based detection and selectively activated rollers. Instead of using elaborate mechanical structures to physically separate all parcels, the system uses targeted friction forces from activated rollers guided by optical detection, simplifying the overall device architecture
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively identifies and separates parcels in side-by-side arrangements and with irregular shapes, ensuring they are conveyed through the system correctly, improving the efficiency of the parcel sorting process.
Implementation Method 1
a visioning subsystem, with a camera that is positioned to acquire images of parcels
Implementation Method 2
the parcels are conveyed not only in the longitudinal direction of travel, but also toward an inner wall
Implementation Method 3
a driven belt configured to convey parcels in the longitudinal direction of travel
Data Source
AI summary
A singulating system for parcels comprises: an inner wall; a first section comprised of a series of driven rollers, which are skewed relative to a longitudinal direction of travel, so that the parcels are conveyed not only in the longitudinal direction of travel, but also toward the inner wall; a second section for receiving the parcels from the first section, and then identifying and moving parcels in a side-by-side arrangement and/or parcels with an irregular shape; and a third section for receiving the parcels from the second section. In some embodiments, the singulating system also includes a visioning subsystem, including a camera for acquiring image data of the parcels as the parcels move toward or into the second section, and a computer to receive and analyze the image data from the camera to identify parcels in a side-by-side arrangement and/or parcels with an irregular shape.