Translucent Tray Sorting System Occupancy Detection
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Solution Overview
Problem
Existing mail sorting systems face errors due to multiple occupancy of shelves, where packages are not delivered to the intended output point, leading to incorrect output of mail items.
Innovation Solution
A sorting system with a transmitted light detection unit that uses an illumination unit and a detection unit to detect occupancy through a translucent floor, allowing for simple, cost-effective, and reliable recording of shelf occupancy, preventing multiple assignments by ensuring only empty trays are filled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera-based systems are used to detect tray occupancy, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex camera-based optical detection systems with a simple mechanical sensor approach. A sensor detects the presence or absence of a mail item in the tray using direct physical contact or proximity sensing, eliminating the need for cameras, image processing hardware, and complex software algorithms while maintaining sufficient detection accuracy for occupancy status.
Solution Approach 2:
The patent employs inexpensive, simple sensors instead of expensive camera systems. These basic sensors can be easily replaced if needed and provide sufficient functionality for detecting tray occupancy without the high cost and complexity of visual detection systems.
2Productivity
If multiple feeders are used to increase productivity, then productivity is improved, but the risk of multiple occupancy increases
Solution Approach 1:
The patent implements a feedback mechanism where sensors continuously monitor tray occupancy status and communicate this information to the control system. Before each feeder operates to place a mail item in a tray, the system checks the sensor feedback to ensure the tray is empty, preventing multiple occupancy errors even when multiple feeders operate simultaneously or in sequence.
Solution Approach 2:
The system performs preliminary detection of tray occupancy status before allowing any feeder to operate. The sensor checks whether a tray is empty prior to mail item insertion, and the control system uses this advance information to coordinate multiple feeders, ensuring that no feeder attempts to place an item in an already-occupied tray.
3Productivity
If trays are moved continuously at constant speed, then productivity is improved, but the difficulty of detecting and measuring occupancy increases
Solution Approach 1:
The patent introduces a physical intermediary element - a sensor positioned to detect mail items in moving trays. This sensor acts as a mediator between the continuously moving trays and the control system, providing reliable occupancy detection despite the constant motion. The sensor may be positioned such that mail items pass through or contact it during tray movement, enabling detection without interrupting the continuous flow.
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
The system effectively prevents multiple occupancy errors by accurately detecting the presence of mail items on shelves, ensuring correct output and reducing operational complexity compared to camera-based systems.
Implementation Method 1
The at least one sensor unit is designed according to the invention as a transmitted light detection unit with an illumination unit arranged on a first side of the base with respect to a tray guided past the transmitted light detection unit, and a detection unit arranged on a second side of the base opposite the first side with respect to a tray guided past the transmitted light detection unit.
Data Source
Figure 1
Figure 2~7
AI summary
The invention relates to a sorting system (1) for sorting mail items (P) comprising a sorting device (2) with trays (3) moved along a sorting path (S) for transporting the mail items (P) and at least one feed device (6) for feeding and inserting mail items (P) into one of the trays (3) as well as at least one sensor unit arranged along the sorting path (S) for detecting mail items (P) in the trays (3) and a method for detecting the occupancy of the trays (3).The invention solves the problem of providing a sorting system and a method that enables the simplest and most reliable possible detection of the occupancy of the trays (3) by designing the trays (3) with a base (4) that is at least partially translucent and by designing the sensor unit as a transmitted light detection unit (12) with a lighting unit (13) on a first side of the base (4) and a detection unit (15) on a second side of the base (4) opposite the first side.