Destination Container Removal in Automated Parcel Sorting
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Solution Overview
Problem
Current parcel and article sorting systems are labor-intensive, prone to processing errors, and inefficient, especially during non-peak periods, with automated equipment being costly, space-intensive, and underutilized, limiting their effectiveness.
Innovation Solution
A system comprising computer-controlled transport vehicles and a control system that interacts with information acquisition devices to determine product types and direct articles to destination containers based on orders, utilizing a platform for efficient sorting and a removal device for further processing, such as packaging or labeling, to optimize sorting efficiency and reduce labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated sorting equipment is used, then sorting precision and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The system divides the sorting process into discrete segments: articles are pulled from batched orders at specific locations, identified by product type, and directed to specific destination containers. Each transport vehicle handles one article at a time, breaking down the complex sorting task into manageable, automated steps that improve reliability without requiring an overly complex monolithic system.
Solution Approach 2:
The system uses information acquisition devices to automatically identify article product types and the control system to autonomously determine routing decisions. Transport vehicles self-navigate to deliver articles to the correct destination containers, reducing the need for complex manual intervention while maintaining high sorting accuracy.
2Productivity
If automated sorting equipment is deployed, then productivity is improved, but device complexity and space requirements increase
Solution Approach 1:
The transport vehicles serve multiple functions: they transport articles from supply locations, navigate to destination containers, and deposit articles. The same vehicle type is used throughout the system, and destination containers serve both as receiving vessels and as temporary storage, reducing the need for specialized equipment for each function and managing system complexity while maintaining productivity.
Solution Approach 2:
The system utilizes a three-dimensional workspace with an elevated platform for transport vehicles to traverse, allowing articles to be moved vertically and horizontally. Destination containers are positioned both on the platform level and below it, creating efficient use of space that accommodates high throughput without proportionally increasing the system's footprint.
3Productivity
If destination containers remain at the platform, then sorting efficiency is maintained, but space utilization and operational flexibility deteriorate
Solution Approach 1:
Destination containers are made dynamic rather than stationary. They are relocated by the removal device from the platform to processing locations based on real-time needs. This dynamic repositioning allows the system to maintain sorting efficiency during peak operations while optimizing space utilization and enabling flexible routing to different processing areas as conditions change.
Solution Approach 2:
The removal device acts as an intermediary between the platform and processing locations. It manages the transfer of destination containers, allowing the sorting operation to continue uninterrupted on the platform while containers are moved to processing areas. This mediator enables the system to decouple the sorting function from the processing function, improving overall space utilization and operational flexibility.
4Device complexity
If manual sorting is used, then device complexity is reduced, but productivity and accuracy deteriorate
Solution Approach 1:
The system replaces manual mechanical sorting operations with automated transport vehicles guided by a control system. Information acquisition devices automatically identify articles, and the control system makes routing decisions, substituting human judgment and physical handling with automated sensing and control mechanisms. This increases productivity while keeping the overall system architecture relatively simple and modular.
Data Source
AI summary
System includes an article supply location that includes a plurality of articles to be sorted, first and second transport vehicles, each having a first position in which an article is stowed about the vehicle and a second position in which the article is deposited into a proximal container, and one or more removal devices that transport the container to a location of further processing. System further includes a control system configured to receive an order for a plurality of disparate articles, determine one destination container of a plurality of destination containers to direct the transport vehicle to deposit a selected article, direct the first transport vehicle to transport a selected article to the destination container, deposit the article in the destination container, and transport the destination container to a location for further processing by manipulation of the removal device.