Automated Tote Tipping System for Parcel Sorting

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Solution Overview

Problem

In sorting facilities, operators face inefficiencies when manually collecting and replacing bags of parcels, and existing tote systems require manual handling and tipping, which can be labor-intensive and time-consuming.

Innovation Solution

A tote tipping system with a frame, tote support fixture, and drive mechanism that rotates the tote from a secure position to a tipping position, allowing parcels to fall out under gravity, facilitated by rails, motors, and flexible members for controlled movement and tipping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If operators manually collect and replace bags of parcels, then the sorting process can be completed, but labor intensity and time consumption increase

Engineering Contradiction:

Improvesorting efficiencyVSAvoidtime for manual bag collection and replacement

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The tote system enables self-service by automatically transporting totes from sorting locations to tipping locations without requiring operators to manually collect and replace bags. The totes self-containedly complete the transport cycle through the facility.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations (operators collecting and replacing bags) are replaced by an automated mechanical system consisting of conveyors, lifting mechanisms, and tipping apparatus that automatically transport and empty totes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If operators manually tip totes to dump parcels, then parcels can be transferred to chutes or bags, but labor intensity increases

Engineering Contradiction:

Improveease of parcel transferVSAvoidautomation of tote tipping

Core Design Contradiction:

Ease of operationVSExtent of automation

Solution Approach 1:

Manual tipping operations are replaced by an automated mechanical tipping system that uses conveyors, lifting mechanisms, and controlled dumping apparatus to automatically transfer parcels from totes to chutes or bags without operator intervention.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The tote tipping system performs self-service by automatically positioning, tilting, and emptying totes at designated locations without requiring operators to manually tip each tote.

Inventive Principle:

Principle #25Self-service

3Quantity of substance

If rigid totes are used to hold multiple parcels, then sorting capacity improves, but manual handling becomes more difficult

Engineering Contradiction:

Improvenumber of parcels per containerVSAvoidease of tote handling

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

Manual handling of rigid totes is replaced by mechanical systems including conveyors for transport, lifting mechanisms for vertical movement, and automated tipping apparatus for emptying, eliminating the difficulty of manually handling heavy, rigid containers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces intermediary mechanical systems (conveyors, lift mechanisms, tipping apparatus) that mediate between the rigid totes and operators, allowing high-capacity totes to be handled easily through automated equipment rather than direct manual manipulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Automates the process of tipping totes, reducing manual labor and increasing efficiency by allowing parcels to be easily transferred from totes to chutes or bags, enhancing the sorting process in facilities.

Implementation Method 1

a drive mechanism configured to move the tote support fixture between the first end of the frame and the second end of the frame

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

when the tote support fixture is at the second angular orientation, parcels fall out of the tote under the force of gravity

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS20240294343A1Tote tipping system

Publication Date: 2024.09.05 FORTNA SYSTEMS INC

AI summary

A tote tipping system including a frame extending from a first (lower) end to a second (upper) end, a tote support fixture configured to selectively engage and secure a tote, and a drive mechanism configured to move the tote support fixture between the first end of the frame and the second end of the frame. When the tote support fixture is at the first end of the frame, the tote support fixture is at a first angular orientation relative to the frame, and when the tote support fixture is at the second end of the frame, the tote support fixture is at a second angular orientation relative to the frame. In the first angular orientation, a tote can be secured to the tote support fixture, and, in the second angular orientation, parcels fall out of the tote under the force of gravity