Sorting System Pre-Orientation for Precise Cart Loading
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Solution Overview
Problem
Existing sorting systems face inefficiencies in loading and off-loading items due to misorientation and misarrangement, leading to misplaced items and reduced capacity utilization, particularly when handling items of varying sizes.
Innovation Solution
The method involves pre-arranging and pre-orienting items upstream to maintain their configuration through a diverter and induction conveyor, ensuring precise loading and off-loading by aligning items with the support areas' longitudinal centerline, and using an induction conveyor to convey items at a predetermined angle and speed for optimal placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If items are loaded onto carts without pre-arrangement and pre-orientation, then the loading process is simpler and faster, but misplacement and misorientation of items occurs leading to lost items and inability to off-load precisely
Solution Approach 1:
The system performs pre-arrangement and pre-orientation of items on the conveyor belt before the items reach the loading zone. This preliminary action ensures that items are correctly positioned and oriented in advance, eliminating the need for complex real-time adjustments during loading and ensuring precise placement on carts.
2Reliability
If a horizontal turnable conveyor is used to re-arrange item sequence, then starboard and portside items are correctly loaded, but all transport belts must stop during turning which is time consuming
Solution Approach 1:
Instead of performing orientation changes during the loading process (which requires stopping belts), the system pre-arranges and pre-orientes items on the moving conveyor belt while it is in operation. This allows continuous operation without stopping transport belts, maintaining high productivity while ensuring correct loading orientation.
3Reliability
If complex control system is used to operate belts on carts in relation to sorter speed, then precise item orientation on carts is achieved, but system complexity increases
Solution Approach 1:
The system pre-arranges and pre-orientes items on the conveyor belt before loading, so that items are already in the correct position and orientation when they reach the carts. This eliminates the need for complex real-time control systems that coordinate belt operations with sorter speed, as the orientation work is completed in advance during conveyor operation.
4Productivity
If support areas are not fully utilized, then loading is simpler, but capacity is reduced and more carts are needed
Solution Approach 1:
The system pre-arranges items on the conveyor belt in advance to optimize their placement on support areas. By performing this arrangement while items are still on the moving conveyor, the system maximizes capacity utilization without requiring complex real-time control during the loading process itself.
Data Source
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Figure 1c~1d
Figure 1e~1f
AI summary
The present invention relates to a method of operating a sorting system for receiving items of variating sizes at one or more loading locations and off-loading items at one or more off-loading locations, where the sorting system comprises a plurality of carts, said carts having at least one support area, which may be operated to load and off-load items, respectively, or where on board or non- on board means may be used to cause loading and off-loading of one or more items, and where the loading and off-loading of items may be done both to starboard and port sides of a transport direction of the carts. More specifically, the present invention relates to a method of operating a sorting system, where items to be sorted are pre-arranged and pre-oriented upstream in a conveying path, and diverted and loaded onto the carts, while maintaining the pre-arrangement and pre-orientation.