Suspended Container Discharge System for Sortation
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Solution Overview
Problem
Conventional unit sortation systems face inefficiencies due to the long perimeter required for a large number of sort destinations, leading to increased manual labor for workers to process items across numerous chutes or sort destinations.
Innovation Solution
An object processing system is introduced, featuring a distribution system for distributing objects among multiple containers, an output conveyance system for receiving completed containers, and a container discharge system that allows containers to be suspended and moved along a conveyor while their bottom opens to discharge contents into a destination location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of sort destinations is increased to improve sorting capacity, then the perimeter of the unit sorter increases, but the manual labor required for workers to process items across numerous chutes increases
Solution Approach 1:
The patent introduces a vertical dimension by implementing multi-level stacking of containers. Instead of horizontally expanding the sorter perimeter to add more destinations, the system stacks containers vertically (e.g., two or more levels high) to increase sorting capacity. This dimensional transition reduces the horizontal footprint and perimeter while maintaining or increasing the number of sort destinations, thereby reducing manual labor requirements.
Solution Approach 2:
The patent combines multiple containers into stacked configurations where containers are positioned one above another. This merging of spatial resources allows the system to handle more items simultaneously without proportionally increasing the perimeter. The stacked containers share common structural support and discharge mechanisms, improving efficiency while reducing the operational complexity for workers.
2Productivity
If the perimeter of the unit sorter is increased to accommodate more destinations, then the sorting efficiency improves, but the time expended by human personnel in waiting and walking increases
Solution Approach 1:
By transitioning from horizontal expansion to vertical stacking, the system maintains sorting efficiency through increased destination capacity while reducing the walking distance workers must traverse. The vertical arrangement allows workers to access multiple destinations more efficiently, reducing the time spent moving between horizontally dispersed chutes.
Solution Approach 2:
The system pre-organizes items into stacked containers at their respective destinations before workers need to collect them. This preliminary sorting and stacking action reduces the time workers spend making decisions and searching for items, as everything is already organized and ready for retrieval in an optimized vertical configuration.
3Stability of the object's composition
If conventional unit sorters use fixed attachment of containers to the conveyance system, then container stability is maintained, but system flexibility and ease of container exchange are reduced
Solution Approach 1:
The patent implements a dynamic container attachment system where containers can be easily attached and detached from the conveyance system. Instead of permanent fixed attachments, the system uses removable coupling mechanisms that provide stability during transport while allowing quick exchange. This dynamic approach enables flexible reconfiguration of container assignments based on sorting requirements while maintaining stability when containers are in use.
Solution Approach 2:
The container system is segmented into independent, modular units that can be individually attached and detached. Each container operates as a discrete element on the conveyance system, allowing for easy replacement and reassignment without affecting other containers. This segmentation provides both stability during transit and flexibility for exchange, resolving the contradiction between these two requirements.
Data Source
AI summary
An object processing system is disclosed that includes a distribution system for distributing a plurality of objects among a plurality of containers, an output conveyance system for receiving a plurality of completed containers, and a container discharge system for emptying any contents of a container of the plurality of completed containers into a destination location, the container discharge system including a discharge conveyor section in which the container is suspended and moved in a conveyor direction while permitting a bottom of the container to drop open to discharge any contents of the container into the destination location.