Rotary Sorting Conveyor with Gravity-Dispensing Filling Buckets
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Solution Overview
Problem
Current sorting and distributing systems, particularly in high-demand sectors like costume jewelry, face challenges in achieving high sorting performance due to manual errors and limitations in automated systems, which result in inefficiencies and increased operator stress at high speeds.
Innovation Solution
A sorting and distributing system featuring a rotary sorting conveyor with manually filled filling buckets that use gravity to transfer articles to receiving devices, where a superordinated controlling device manages the distribution, reducing operator stress and enabling higher speeds by eliminating the need for manual tray selection and error correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual filling of trays is used, then operator flexibility is maintained, but sorting performance is limited and errors increase
Solution Approach 1:
The system segments the filling process by providing multiple filling stations along the rotary conveyor, each dedicated to specific target positions. This allows parallel processing of different article types while maintaining automated control, thereby increasing sorting performance without compromising reliability.
Solution Approach 2:
The system incorporates detection mechanisms that monitor the filling process and provide feedback to the control system. This enables real-time error detection and correction, ensuring high reliability while maintaining high sorting performance through automated control.
2Productivity
If high conveyor speeds are used, then sorting performance increases, but operator stress and errors increase
Solution Approach 1:
The system introduces an automated control system as an intermediary between the operator and the high-speed conveyor. This intermediary manages the complex coordination required at high speeds, freeing the operator from stress while maintaining high sorting performance through precise automated control.
Solution Approach 2:
The system performs preliminary actions by pre-positioning articles in filling buckets before they reach the conveyor. This preparation reduces the operational complexity during high-speed conveying, lowering operator stress while maintaining high productivity.
3Productivity
If fully automated sorting is implemented, then sorting performance reaches maximum levels, but system complexity and cost increase
Solution Approach 1:
The system implements partial automation with multiple filling stations rather than complete automation. This approach achieves high sorting performance (up to 60,000 pieces per hour) while avoiding the excessive complexity and cost of fully automated systems by maintaining manual filling at controlled stations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly increases sorting performance, reduces operator fatigue, and allows for efficient handling of small articles by automating the filling process, enabling speeds comparable to fully automated systems while minimizing errors through advanced control and detection mechanisms.
Implementation Method 1
each of which includes an opening mechanism at its lower end for allowing to dispense article units, which are order-picked into the filling buckets, to the receiving devices passing by
Data Source
AI summary
A sorting and distributing system (50) for sorting article units in accordance with customers' orders, the system having a high sorting performance and comprising: a rotary sorting conveyor (14), which may be closed, having a conveyor means, wherein the conveyor means is connected to a plurality of receiving devices (16), to which the article units are to be delivered. A plurality of target positions (54) is coupled to the sorting conveyor (14) and can supply articles units to the receiving devices (16) in accordance with a customer's order, wherein the target positions (54) are assigned to customers' orders. At least one filling station (10; 10′) manually fills the receiving devices (16) by article units, wherein the filling station (10; 10′) includes a plurality of filling buckets (12) each having an opening mechanism (18) at its lower end thereof, in order to allow supply of article units, which are order picked into the filling bucket (12), to the receiving devices (16) in an automated manner.