Pocket Sorter Buffering for High-Capacity Parcel Sorting
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Solution Overview
Problem
Distribution centers in the courier, express, and parcel (CEP) industry face limitations in sorting capacity and flexibility due to the high cost and limited number of load handling devices (LHDs) in existing sorting machines, leading to inefficient use of space and increased staffing requirements, especially during peak times.
Innovation Solution
A sorting arrangement combining a horizontal sorter with a pocket sorter, where the pocket sorter provides a buffer function and sequencing capabilities, allowing for flexible distribution and temporary storage of shipments, reducing the footprint and increasing sorting performance by decoupling logical and physical endpoints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple stationary sorters are used to achieve higher throughput, then distribution capacity is improved, but space requirements and infrastructure costs increase significantly
Solution Approach 1:
The patent transitions from horizontal stationary sorters to a vertical pocket sorter architecture. Pockets are arranged vertically along a sorting path, allowing multiple sorting operations to occur in the vertical dimension rather than requiring horizontal expansion. This enables higher throughput without proportionally increasing floor space requirements.
Solution Approach 2:
The patent introduces terminals as intermediary storage points between the pocket sorter and final destinations. Shipments are sorted into terminals temporarily, then consolidated and dispatched later. This decoupling allows the sorter to operate independently from terminal emptying schedules, improving overall system throughput without requiring proportional increases in terminal capacity or space.
2Productivity
If the number of load handling devices is increased to handle more shipments, then sorting capacity is improved, but device complexity and cost increase
Solution Approach 1:
The sorting system is segmented into multiple independent pockets, each capable of handling individual shipments. Pockets can be selectively activated or deactivated based on current sorting needs, allowing flexible capacity adjustment without requiring a proportional increase in overall system complexity. The modular pocket design enables incremental capacity expansion.
Solution Approach 2:
Each pocket in the pocket sorter is designed to handle multiple types of shipments with different characteristics. The universal pocket design eliminates the need for specialized load handling devices for different shipment types, reducing overall device complexity while maintaining high sorting capacity across diverse parcel categories.
3Adaptability or versatility
If terminals are used for temporary storage of shipments, then distribution flexibility is improved, but space requirements and staffing needs increase
Solution Approach 1:
The patent consolidates multiple terminal functions into a compact vertical terminal structure that integrates with the pocket sorter. Terminals are positioned vertically along the sorting path rather than requiring horizontal dispersion, reducing total space requirements while maintaining the ability to serve multiple destinations simultaneously.
Solution Approach 2:
The patent merges the functions of multiple terminals into a single integrated terminal system that can handle shipments for multiple destinations. By consolidating terminal operations and enabling batch processing of shipments with the same destination, the system achieves high distribution flexibility with reduced terminal capacity and space requirements.
4Ease of operation
If stationary sorters are used with fixed assignment of delivery directions, then operational simplicity is maintained, but temporal flexibility and optimization opportunities are reduced
Solution Approach 1:
The pocket sorter employs dynamic assignment of delivery directions to pockets, allowing the system to adapt to changing sorting requirements in real-time. Pockets can be reconfigured and reassigned based on current shipment volumes, destination patterns, and operational priorities, providing temporal flexibility while maintaining operational simplicity through automated control.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor sorting performance, terminal capacity, and shipment characteristics. This feedback enables automatic adjustment of pocket assignments and sorting parameters, allowing the system to optimize its operation dynamically while maintaining ease of use through automated decision-making rather than manual reconfiguration.
Data Source
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AI summary
The invention relates to a sorting arrangement for sorting objects, in particular postal items, of different shapes, volumes and/or weights, wherein the sorting arrangement comprises a horizontal sorter (1) with a plurality of load-handling devices (2) for objects to be sorted, which are moved along a sorting path (3) of the horizontal sorter (1) and can be individually controlled for diverting a lying object into at least one first end point (4) of the sorting arrangement, wherein the sorting arrangement comprises a pocket sorter (5) with a plurality of load-handling devices (2) designed as hanging pockets (2.1) for objects to be sorted, characterized in that the pocket sorter (5) has a pocket emptying mechanism (6) from which the pockets (2.1) are emptied into at least one second end point (4) different from the at least one first end point (4), wherein these two end points (4) are assigned the same sorting goal.A corresponding procedure is described below.