Postal Sorting Machine With Modular Elevator Trays
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Solution Overview
Problem
Existing automatic postal sorting machines are either too expensive for smaller post offices or are slower due to the need for multiple passes or large numbers of bins.
Innovation Solution
A sorting machine with multiple sorting modules, each equipped with an elevator assembly and input conveyor, allows for secure and efficient transfer of postal items using a tray system and flap member, enabling faster operation and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single pass sorting machine with multiple bins is used, then all postal items can be sorted in one pass, but the machine requires a large number of bins equal to the number of unique addresses, increasing device complexity and size
Solution Approach 1:
The sorting machine is divided into multiple sorting modules, where each module handles a subset of addresses. Instead of requiring one bin per unique address across the entire system, each module has its own set of bins for its assigned address subset. This segmentation reduces the number of bins per module while maintaining single-pass sorting capability for the entire system.
Solution Approach 2:
The patent introduces a modular architecture where sorting capacity is expanded in the dimension of multiple parallel modules rather than increasing bins in a single module. This allows the system to handle many unique addresses by distributing them across multiple modules, each with fewer bins, thereby reducing device complexity while maintaining high productivity.
2Device complexity
If a multiple pass sorting machine is used, then fewer bins are needed, but the sorting operation takes longer time as it requires multiple passes
Solution Approach 1:
By segmenting the sorting system into multiple modules that operate in parallel, each module can complete its sorting in a single pass. The overall system achieves single-pass sorting for all items by distributing them across modules based on address subsets, eliminating the need for multiple sequential passes and reducing sorting time.
Solution Approach 2:
The multiple sorting modules operate simultaneously and continuously, processing different subsets of postal items in parallel. This continuous parallel operation eliminates the idle time and repositioning required in multiple-pass systems, maintaining constant productive action throughout the sorting process.
3Adaptability or versatility
If more bins are added to handle more addresses, then sorting capacity increases, but the machine size and cost increase significantly
Solution Approach 1:
The sorting capacity is achieved through multiple compact modules, each handling a subset of addresses with a manageable number of bins. This segmentation allows the system to scale capacity by adding modules rather than expanding a single large bin system, keeping individual module sizes manageable and reducing overall machine complexity.
Solution Approach 2:
Each sorting module is designed as a universal unit that can handle any subset of addresses. The modules are functionally identical and can be configured to sort different address ranges, allowing the system to adapt to different sorting capacities by simply arranging and configuring existing modules rather than designing increasingly complex single-unit systems.
Data Source
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AI summary
A sorting machine for automatically sorting a plurality of postal items includes a plurality of sorting modules. Each sorting module includes an elevator assembly and an input conveyor. The sorting module has an elevator frame, an elevator cabin, a plurality of trays arranged inside the elevator cabin, and an elevator mechanism arranged to move the elevator cabin up and down. Each tray is adapted to have a first position and a second position, the first position being inside the elevator cabin and the second position being outside the elevator cabin. Moreover, the sorting machine transfers the postal item from the input conveyor to the tray by first moving the tray outside the elevator cabin to the second position, and subsequently simultaneously moving input conveyor and the tray in the same direction to allow a fall of postal item from the input conveyor to the tray.