Sorting System with Variable Speed Carriers for High Density Chute Filling
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Solution Overview
Problem
Existing package sorting machines face inefficiencies due to constant carrier speeds and fixed discharge mechanisms, leading to reduced throughput and increased costs, as well as the inability to sequence items effectively for downstream operations.
Innovation Solution
The system employs independently driven carriers with variable speed control and optimized discharge mechanisms based on item attributes, dimensions, and position, allowing for dynamic adjustment of carrier speed and discharge timing to maximize throughput and sequence items correctly for efficient sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If carriers move at constant speed with fixed discharge mechanisms, then the system structure is simple, but the throughput is reduced and the number of carriers needed increases
Solution Approach 1:
The patent implements variable speed control for each carrier, allowing them to dynamically adjust their speed based on item characteristics and sort destination requirements. The control system optimizes carrier speed profiles individually, enabling some carriers to move faster while others slow down for precise item discharge, thereby increasing overall throughput without requiring additional carriers.
Solution Approach 2:
The system changes the speed parameter of carriers dynamically during operation. By adjusting carrier speed as a variable parameter rather than maintaining a fixed constant speed, the system can optimize discharge timing and positioning, improving sorting efficiency and reducing the number of carriers needed to achieve the same throughput.
2Productivity
If more carriers are added to increase capacity, then the sorting capacity increases, but the cost increases
Solution Approach 1:
By enabling dynamic speed adjustment and optimization for each carrier, the system maximizes the utilization of existing carriers. Carriers can operate more efficiently with varied speed profiles, allowing the same number of carriers to handle increased sorting capacity without requiring additional carrier units, thus reducing capital costs.
Solution Approach 2:
The system uses parameter optimization (speed, discharge timing, positioning) to extract maximum performance from each carrier. This allows the existing fleet of carriers to achieve higher throughput, effectively increasing sorting capacity without the need to add more carriers to the system.
3Manufacturing precision
If carriers slow down or stop to sort items, then items can be discharged accurately, but other carriers cannot overtake and overall throughput is reduced
Solution Approach 1:
The control system segments the carrier fleet into independent controllable units, each capable of individual speed adjustment. This segmentation allows specific carriers to slow down for accurate item discharge while others maintain higher speeds, preventing bottlenecks and maintaining overall throughput despite individual carrier deceleration.
Solution Approach 2:
The system implements dynamic speed control where carriers can independently adjust their speed profiles during operation. This dynamic capability allows carriers to slow down only when and where needed for item discharge, while maintaining optimal speeds elsewhere in the system, thereby preserving both discharge accuracy and overall throughput.
4Adaptability or versatility
If the discharge mechanism is fixed, then the system structure is simple, but items cannot be sequenced effectively for downstream operations
Solution Approach 1:
The discharge mechanism is made dynamic through variable speed control and timing adjustment. The system can sequence items by controlling when and how carriers discharge items at different locations along the sort destination, enabling flexible item sequencing for downstream operations without requiring complex mechanical discharge mechanisms.
Solution Approach 2:
The system uses parameter changes in carrier speed and discharge timing to achieve item sequencing. By varying these parameters, the system can control the order in which items are discharged and delivered to downstream processes, providing sequencing capability without adding complex mechanical discharge equipment.
Data Source
AI summary
A system and method for sorting items. the system and method including a control arrangement configured to receive information about at least one item to be sorted. a track arrangement including at least one sort location, and at least one sorter carrier. wherein the or each sorter carrier is configured to move along the track arrangement and carry an item to be sorted, and the or each sorter carrier further includes a discharge arrangement configured to discharge the item to be sorted. Additionally, a sorter carrier is provided. Sorting systems and methods configured to use independently controlled sorting carriers which travel through a framework to sorting destinations on one or more levels. wherein the sorter carriers are configured to vary the point at which they discharge an item, the system further including a system controller which is configured to use the item dimensions and position on the sorting carriers to calculate the discharge position in the framework for the sorting carrier to discharge the item allowing a high density of filling of the chute.