Parcel Sorter Carousel Pallet Pre-positioning
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Solution Overview
Problem
Current parcel sorting and palletizing systems are inefficient, requiring significant manual labor and resulting in low productivity due to the need for manual sorting, pallet loading, and frequent movement of pallets, leading to increased costs and errors.
Innovation Solution
A parcel sorter system with a control system that automates the sorting and palletizing process by using a combination of parcel readers, destination chutes, and carousels, allowing for pre-indexing of pallets and storage units, and utilizing robots or human operators to efficiently move parcels to their designated destinations, along with sensors and machine vision for accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sorting and pallet loading are used, then labor flexibility is maintained, but productivity is low and waiting times are significant
Solution Approach 1:
The system performs preliminary indexing of destination pallets on carousels before parcels arrive. The control system pre-positions pallets at destination chutes based on predicted sorting requirements, eliminating waiting time when parcels need to be sorted. This advance preparation of sorting destinations directly addresses the productivity-time contradiction by ensuring destinations are ready before parcels arrive.
Solution Approach 2:
The patent replaces manual mechanical sorting operations with an automated control system that uses sensors, machine vision, and automated carousel positioning. The control system automatically identifies parcel destinations, positions corresponding pallets on carousels, and directs parcel routing without manual intervention. This substitution of automated control for manual mechanical operations significantly increases productivity while reducing waiting times.
2Productivity
If frequent manual movement of pallets is performed, then sorting accuracy is maintained, but labor costs increase and efficiency decreases
Solution Approach 1:
The patent implements multi-functional carousels that serve dual purposes: storing destination pallets and automatically positioning them at sorting chutes. The same carousel structure performs both storage and active sorting functions, eliminating the need for separate manual handling operations. This multi-functionality increases palletizing efficiency while the integrated control system manages the complexity rather than increasing it.
Solution Approach 2:
The system enables pallets to be automatically positioned and delivered to the correct chutes without manual intervention. The control system monitors parcel flow and autonomously adjusts carousel positions to bring the correct pallet to each chute at the appropriate time. This self-service capability improves efficiency by eliminating manual pallet movement while the automated control manages system complexity.
3Productivity
If automated sorting systems are implemented, then productivity increases, but initial system complexity and cost increase
Solution Approach 1:
The patent divides the sorting system into modular components: multiple independent carousels, separate destination chutes, and distributed sensors. Each carousel can operate independently with its own control, allowing the system to scale incrementally. This segmentation enables high sorting throughput through parallel operations while managing complexity by breaking the system into manageable, interchangeable modules that can be added or removed based on needs.
Data Source
AI summary
A parcel sorter system and method. A process performed by a parcel sorter system includes receiving sorting information of a first parcel. The process includes identifying a first destination pallet corresponding to the sorting information. The first destination pallet is associated with a first carousel and a first destination chute. The process includes transporting the first parcel toward the first destination chute. The process includes, while transporting the parcel toward the first destination chute, operating the first carousel to move the first destination pallet proximate to the first destination chute. The process includes delivering the first parcel at the first destination chute for placement on the first destination pallet.