Sorting System Advance Object Display for Mail Centers
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Solution Overview
Problem
Current sorting systems in smaller mail distribution centers are inefficient due to high error rates and health risks for workers, as they require manual sorting of up to 20,000 objects per hour, with workers needing to constantly evaluate object markings and handle objects under time pressure, leading to potential injuries and delayed deliveries.
Innovation Solution
A sorting system that provides advance information to workers through a display unit about the arrival and properties of objects, including weight, dimensions, and destination, using a detection unit and control system to guide removal zones and potentially integrate automatic removal devices, reducing the need for manual evaluation and increasing conveyor speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conveyor speed is increased to improve productivity, then sorting throughput increases, but worker time pressure increases leading to higher error rates and health risks
Solution Approach 1:
The system displays advance information about upcoming objects (weight, dimensions, destination) before they reach the worker's zone. This preliminary presentation of data allows workers to mentally prepare and plan their actions in advance, reducing reaction time pressure and errors when handling objects at higher conveyor speeds.
Solution Approach 2:
An information display system acts as an intermediary between the conveyor control system and the worker. This mediator translates object data into visually accessible format, providing workers with critical information about upcoming objects without requiring them to physically examine markings or guess object properties, thereby reducing errors at higher speeds.
2Productivity
If conveyor speed is increased to improve productivity, then sorting throughput increases, but worker health deteriorates due to increased time pressure
Solution Approach 1:
Workers receive advance notice of upcoming objects with relevant handling information displayed before the objects arrive. This allows them to plan their movements and actions in advance, reducing sudden reactive movements and physical strain that occur under time pressure, thereby protecting worker health while maintaining higher conveyor speeds.
3Device complexity
If manual sorting is used to reduce system complexity, then device complexity decreases, but sorting accuracy decreases due to human error in reading markings
Solution Approach 1:
An information display system serves as an intermediary that translates object identification data into clear visual information for workers. This mediator eliminates the need for workers to directly read and interpret markings on objects, reducing misreading errors while maintaining manual sorting and avoiding complex automatic removal systems.
Solution Approach 2:
The system automatically detects object identifiers and retrieves associated information (weight, dimensions, destination) without worker intervention. This self-service data retrieval eliminates human error in reading markings while keeping the overall system simple by maintaining manual removal.
4Measurement precision
If automatic removal devices are integrated to improve sorting accuracy, then sorting precision increases, but device complexity increases
Solution Approach 1:
The system separates the information provision function (automated display) from the object removal function (manual action). This segmentation allows the system to provide accurate object information automatically while keeping the removal process manual, achieving improved accuracy without the full complexity of automated removal mechanisms.
Data Source
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Figure 2
AI summary
Sorting system for the targeted distribution of objects (O) arranged one after the other along a conveyor line (F), wherein an optical display unit (A) is provided, by means of which predefinable object properties for a selected group of objects (O) arranged one after the other on the conveyor line (F) can be displayed at individual removal zones (Z).