Parcel Sorting Manifold with Actuated Diverters
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Solution Overview
Problem
Existing parcel sorting systems often lead to underutilization of associates during reduced parcel intake periods and require inefficient manual transportation, as they lack automation in directing parcels to specific destinations.
Innovation Solution
An apparatus with a transport surface and routing manifold system that uses actuatable components and diverters to automatically sort parcels based on destination information, allowing for efficient conveyance and distribution into various containers, reducing manual labor and increasing automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual sorting and transportation methods are used, then associates can handle parcels during reduced intake periods, but associate utilization is underoptimized and manual transportation is required
Solution Approach 1:
The sorting system is divided into modular components including a routing manifold with multiple outlets, individual diverters for each outlet, and separate conveyance paths. Each component can be independently controlled and maintained, allowing automation while managing complexity through functional segmentation.
Solution Approach 2:
A controller serves as an intermediary between the parcel intake system and the routing manifold, receiving parcel information and automatically actuating diverters. This intermediary automates the sorting decision-making process, reducing manual labor while maintaining system manageability.
2Productivity
If associates manually aggregate and transport parcels, then flexibility in handling reduced intake periods is maintained, but productivity and efficiency are reduced
Solution Approach 1:
The system performs preliminary sorting actions by automatically directing parcels to appropriate outlets before manual aggregation is needed. Diverters are pre-positioned based on parcel destination information, eliminating wait times and enabling continuous high-speed sorting operations.
Solution Approach 2:
The automated sorting system maintains continuous operation during reduced intake periods by keeping diverters and conveyance systems actively engaged. Associates remain continuously productive at aggregation stations receiving sorted parcels, eliminating idle wait time while maintaining flexibility for variable intake rates.
3Reliability
If manual parcel handling is used, then system simplicity is maintained, but parcel damage risk increases and sorting accuracy decreases
Solution Approach 1:
The system reads destination information directly from parcel labels or tags and automatically actuates the appropriate diverter without human intervention. This self-service capability ensures consistent accurate routing while minimizing manual handling that could cause damage, with the controller serving as an intelligent decision-making component.
Data Source
AI summary
An apparatus for sorting parcels is described comprising a transport surface configured to convey parcels between a first end and a second end thereof. An opening defined in the transport surface is dimensioned to receive one or more of the parcels therethrough. The transport surface comprises a plurality of surface segments having a selected geometry and surface characteristics for controlling speeds of the parcels as they are conveyed. The apparatus further comprises a routing manifold having a chute having an inlet registered with the opening, a plurality of outlets coupled to the inlet, and a first diverter system comprising one or more diverters disposed in the routing manifold and operable to selectively direct the received parcels toward any outlet of the plurality of outlets. The one or more diverters may be responsive to destination information associated with the individual parcels.