Two-Pass Sorting System for Bulk Item Sequencing
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Solution Overview
Problem
Existing sorting and sequencing systems for bulk items, such as mail, require large equipment footprints and inefficient use of resources due to the need for numerous bins and complex sorting processes, especially in high-volume processing facilities like those of the United States Postal Service.
Innovation Solution
A two-pass sorting system that uses scanners to identify destinations, processors to associate items with stop groups, and diverting members to sort items into lanes and bins based on delivery sequence order, reducing the number of bins required and optimizing machine run-time by using a combination of sorting apparatuses and conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional sorting apparatuses with numerous bins are used to sort bulk items, then sorting accuracy is improved, but equipment footprint and space requirements increase
Solution Approach 1:
The sorting process is divided into multiple passes, with each pass handling a subset of destinations. Items are sorted in stages rather than all at once, allowing the system to manage complex sorting requirements with fewer bins at any given time.
Solution Approach 2:
Items are pre-sorted into stop groups before the final sorting pass. This preliminary organization reduces the number of bins needed during subsequent passes, as items are already partially categorized and can be directed to fewer destination groups.
2Manufacturing precision
If complex sorting processes with multiple bins are implemented, then sorting completeness is improved, but device complexity increases
Solution Approach 1:
The sorting system is divided into multiple passes, each with a specific function. The first pass groups items by stop groups, while subsequent passes handle final destination sorting. This segmentation simplifies each individual sorting stage compared to a single complex pass.
Solution Approach 2:
The system dynamically adjusts the number of bins and sorting configurations based on the specific pass being executed. Bins are reassigned different destination groups in different passes, allowing the same physical bins to serve multiple purposes and reducing overall system complexity.
3Productivity
If more bins are used to handle all destinations simultaneously, then processing speed is improved, but space requirements and equipment size increase
Solution Approach 1:
The sorting process uses periodic passes through the sorting apparatus, with each pass handling a specific subset of destinations. Items may cycle through the system multiple times, being sorted into different bin configurations in different passes, which maintains processing momentum while using fewer bins.
Solution Approach 2:
The same physical bins are reused across multiple passes and different destination groups. Each bin serves multiple destinations at different times, maximizing the utilization of limited bin resources and reducing the total number of bins needed to handle all destinations.
Data Source
AI summary
Embodiments of a system and method for sorting and sequencing articles in a processing facility are disclosed. Delivery endpoints are divided and grouped into stop groups. A first sorter sorts items according to stop group and outputs the items to trays. The output trays from the first sorter are loaded to a second sorter in stop group order. The second sorter sorts items for each stop group into separate lanes. Each lane can then be sorted into output bins in delivery sequence order.