Sorter Element Misplacement Detection and Robotic Correction
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Solution Overview
Problem
Conventional sorting systems face issues with misplacement of goods, leading to reduced throughput, operational inefficiencies, and potential hazards due to incorrectly positioned items, which current maintenance methods fail to address effectively.
Innovation Solution
A system comprising a detection device and a robot that automatically detects and corrects misplacement of goods on a sorter element by using a sensor system and control device to guide the robot in correcting the misplacement, employing methods such as moving or ejecting the goods into the correct position or using discharge mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sorters lock segments when goods are misplaced, then safety is improved, but throughput decreases
Solution Approach 1:
The robot enables the sorter to self-correct misplacements automatically without manual intervention. The detection device identifies misplaced goods and the robot repositions them, allowing the system to maintain full operational capacity and restore throughput immediately after detecting a misplacement issue.
2Reliability
If periodic cleaning is performed to clear misplaced goods, then reliability is improved, but productivity is reduced due to labor-intensive maintenance
Solution Approach 1:
The automatic detection and correction system operates continuously during normal sorting operations, eliminating the need for periodic shutdowns for cleaning. The robot can intervene immediately when a misplacement is detected, maintaining continuous throughput without interrupting the sorting process for maintenance cycles.
Solution Approach 2:
The system performs self-maintenance by automatically detecting and correcting its own errors. The detection device monitors the sorter continuously and the robot autonomously corrects misplacements, replacing manual cleaning operations with an automated self-correcting mechanism that operates without stopping production.
3Reliability
If manual removal of misplaced goods is performed, then reliability is improved, but time is lost due to labor-intensive intervention
Solution Approach 1:
The robot enables the sorter to self-correct misplacements automatically without manual intervention. The detection device identifies misplaced goods and the robot repositions them, allowing the system to maintain full operational capacity and restore throughput immediately after detecting a misplacement issue.
4Ease of operation
If blower is used to clear lightweight misplaced mail, then ease of operation is improved, but effectiveness is reduced for heavier goods
Solution Approach 1:
The robot replaces the blower mechanism with a more versatile robotic manipulation system. Instead of using air flow that only works for lightweight items, the robot uses mechanical manipulation capabilities that can handle various types and weights of goods, providing a universal solution that works for all parcel types.
Data Source
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AI summary
System (1) for rectifying an incorrect placement (9) of piece goods (3) on a sorter element (2), comprising a robot (10) and a detection device (6); wherein the detection device (6) comprises a sensor system (14) and a control device (8) and is configured to detect a data structure (7) representing a placement of the piece goods (3) on the sorter element (2) and to identify an incorrect placement (9) of the piece goods (3) on the sorter element (2) on the basis of the data structure (7); wherein the control device (8) is configured to control the robot (10) such that the latter rectifies the incorrect placement (9) of the piece goods (3) on the sorter element (2).