Specimen Container Sorting with Transfer Arms and Compact Routing
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Solution Overview
Problem
Existing sorting apparatuses for specimen containers require large spaces and complex conveyor configurations due to frequent lane changes and merging processes, leading to increased processing time and complexity.
Innovation Solution
A sorting apparatus with a holder station, sort conveyance unit, transfer unit, and control unit that efficiently transfers specimen containers using transfer arms and conveyor mechanisms, allowing for simultaneous sorting and conveyance in a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional conveyor-based sorting with sequential lane changes is used, then sorting can be achieved, but the apparatus requires large space and complex configuration
Solution Approach 1:
The patent transitions from a two-dimensional planar conveyor system with sequential lane changes to a three-dimensional system using vertical transfer arms. Holders are transferred between conveyors at different heights, enabling direct routing to distant destinations without multiple lane changes, thus reducing space and complexity requirements
Solution Approach 2:
The transfer arm acts as an intermediary mechanism between the input conveyor and multiple sort conveyors. Instead of holders directly moving through multiple lanes on the same plane, the transfer arm mediates the transfer by picking up holders vertically and placing them on different conveyors, simplifying the overall system configuration
2Productivity
If sequential lane changes are performed for each specimen container, then sorting to designated conveyors is achieved, but processing time increases
Solution Approach 1:
The system determines the destination conveyor for each holder in advance using a control unit that processes sort information before the holder reaches the transfer point. This preliminary determination allows the transfer arm to be pre-positioned and ready for immediate transfer, eliminating delays associated with sequential decision-making during the sorting process
Solution Approach 2:
The patent replaces the mechanical sequential lane-change process with a control-based system. The control unit electronically determines optimal routing and coordinates transfer arm operations, replacing the purely mechanical sequential conveyor system with a smarter, coordinated system that reduces processing time
3Adaptability or versatility
If multiple lane changes and merging processes are implemented, then comprehensive sorting is achieved, but the conveyor configuration becomes very complicated
Solution Approach 1:
The sorting system is segmented into distinct functional modules: an input conveyor, multiple independent sort conveyors, and transfer arms positioned at specific intervals. Each transfer arm serves specific destination conveyors, creating modular segments that can be independently configured and controlled, reducing overall system complexity while maintaining versatility
Solution Approach 2:
The transfer arms are designed with universal functionality to transfer holders to multiple different sort conveyors. Rather than having dedicated transfer mechanisms for each conveyor pair, the transfer arms can service multiple destinations, reducing the number of components needed while maintaining comprehensive sorting capability
Data Source
AI summary
According to an aspect of the invention, a sorting apparatus comprises; a holder station in which a plurality of holders each configured to hold a specimen container in an upright state are disposed; a sort conveyance unit including a plurality of sort conveyance paths configured to convey the holders; a transfer unit including a plurality of transfer arms, each configured to hold one of the holders and transfer the holder to any one of the sort conveyance paths; and a control unit configured to control a transfer destination of the holder in the transfer unit.