Sleeved Sortation Receptacles for Accurate Overfill Detection
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Solution Overview
Problem
Existing article sorting systems face inefficiencies due to premature transfer of partially filled receptacles, leading to wasted space and additional labor and material costs, as well as false full signals from photo eyes due to obstructing items.
Innovation Solution
A system with sleeved receptacles that allow overfilling while preventing articles from falling out during transport, using a sleeve that extends the receptacle's volume and is equipped with sensors to detect optimal fill levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If photo eye sensors are used to detect full receptacles, then automated detection is achieved, but false full signals occur due to item obstruction
Solution Approach 1:
A camera acts as an intermediary device between the photo eye sensor and the receptacle. The camera captures images of the receptacle contents, and image processing algorithms analyze whether items are actually blocking the photo eye or if the receptacle is truly full. This intermediary system resolves the contradiction by providing accurate fullness detection without the false positives caused by direct photo eye obstruction detection.
2Productivity
If receptacles are transferred prematurely before complete filling, then throughput is maintained, but space is wasted and additional receptacles are needed
Solution Approach 1:
The system implements feedback through image capture and analysis to continuously monitor receptacle fullness. The camera system provides real-time visual feedback about actual space utilization, allowing the system to delay transfer decisions until receptacles are truly full. This feedback loop enables optimization of both throughput and space utilization by making informed transfer decisions based on accurate visual assessment rather than premature photo eye signals.
3Loss of substance
If additional items are added to partially filled receptacles, then space utilization improves, but labor and material costs increase
Solution Approach 1:
The system enables self-service by using automated image processing to determine when receptacles are full. Instead of requiring manual inspection and decision-making by packers, the system automatically analyzes images, compares them against fullness criteria, and makes transfer decisions. This eliminates the need for complex manual packing operations while maximizing space utilization through automated, consistent decision-making.
4Loss of substance
If more receptacles are used to accommodate fixed quantity of articles, then space utilization improves, but labor and material costs increase
Solution Approach 1:
The system applies partial action by transferring receptacles at optimal rather than complete fullness points. Image analysis allows the system to identify the precise moment when adding another item would exceed capacity, enabling transfer of receptacles that are sufficiently full to maximize space utilization but not so full that they require premature replacement. This partial action approach balances space optimization with operational efficiency.
Data Source
AI summary
System for use in directing a sorting operation includes receptacles configured for receiving articles therein, and a sleeve removably attached to each receptacle such that an upper portion of the sleeve extending upward above a top rim of the receptacle and defining an opening that permits access to the receiving space of the receptacle; and automated transport devices for transporting and depositing articles into the receptacles. The system configured to: assign a first count of articles to a receptacle such that the first count of articles overfills the receptacle and direct the transport devices to transport and deposit the first count of articles into the receptacle after the sleeve is removably attached over a top region of the receptacle.