Roller-belt Sorter with Control Grid for High-Density Package Diversion
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Solution Overview
Problem
Conveyors struggle to efficiently sort packages of various sizes and orientations at high throughput rates without occupying excessive space, especially in high-density package flows, as existing systems require significant space to unscramble packages before diversion.
Innovation Solution
A sorting conveyor system with a grid of individually controlled cells that rotate article-supporting rollers transverse to the belt direction, using sensors to compute trajectories for each package and actuate rollers to divert packages across the conveyor based on size and position, allowing for efficient sorting without extensive space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional shoe sorters, pusher bars, or diverting rails are used to sort packages, then sorting functionality is achieved, but the conveyor takes up excessive floor space and cannot handle high-density package flows efficiently
Solution Approach 1:
The conveyor belt is segmented into multiple independently controllable zones or cells along its length. Each zone can independently divert packages at different locations, allowing for multi-point sorting without requiring additional conveyor sections. This segmentation enables high-density sorting within a compact footprint by utilizing the length of a single conveyor belt more efficiently.
Solution Approach 2:
The invention introduces a vertical dimension to package handling by using adjustable diverting elements that can lift packages off the belt plane and redirect them to different discharge points. This vertical movement allows packages to be sorted to multiple destinations without requiring horizontal expansion of the conveyor system, thereby reducing floor space while maintaining high throughput capability.
2Reliability
If packages are unscrambled before sorting to prevent blocking, then sorting reliability improves, but the conveyor requires additional space and time for the unscrambling process
Solution Approach 1:
The system performs preliminary sensing and trajectory computation for each package as it enters the conveyor, determining its destination and required diverting sequence before the package reaches the sorting zones. This advance planning allows packages to be sorted directly without requiring unscrambling sections, as the control system anticipates and prepares the appropriate diverting actions in advance.
Solution Approach 2:
The system uses sensors to continuously monitor package position, size, and orientation, and the control system adjusts diverting element activation in real-time based on this feedback. This closed-loop control ensures that packages are diverted accurately to their destinations without requiring additional space for manual unscrambling or repositioning, maintaining reliability while minimizing conveyor length.
3Adaptability or versatility
If the conveyor is designed to handle various package sizes and orientations, then adaptability improves, but the complexity of controlling individual rollers increases
Solution Approach 1:
The diverting elements are designed with universal functionality to handle packages of various sizes, shapes, and orientations using the same basic mechanism. Each diverting element can adjust its angle and timing to accommodate different package characteristics, eliminating the need for multiple specialized mechanisms. The control system uses standardized commands to manage all packages, reducing overall system complexity while maintaining high adaptability.
Data Source
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AI summary
Apparatus and method for sorting a mass flow of articles without collisions between articles (p). The apparatus includes a sorting conveyor (20) having a plurality of article-supporting belt rollers (30) selectively rotatable in a direction transverse to the direction of belt (28) travel. The belt rollers (30) are selectively rotated in individual grid cells (38) formed along the conveyor's (20) carryway. A control system creates an image of the incoming mass flow, computes trajectories along the sorting conveyor for each package, and actuates or deactuates the belt rollers (30) passing through each grid cell according to the trajectories to orderly and rapidly divert articles (p) off the side of the sorting conveyor. (20)