Two-Pass Sorting System with Tray Manipulation for Mail Sequencing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automatic feeding and sorting systems for items like mail are inefficient in terms of space usage and processing time, as they require large equipment and multiple bins to handle bulk sorting and sequencing, which can lead to increased operational costs and reduced efficiency.
Innovation Solution
A system comprising a processor, scanner, intake system, diverter member, and container manipulator that sorts items into containers based on intended delivery destinations, using a sorting scheme that assigns delivery end points to stop groups, allowing for efficient sequencing and reduced equipment footprint by using a two-pass sorting process and tray manipulation to optimize container usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional bulk sorting systems are used to handle large volumes of items, then sorting capacity is sufficient, but the equipment footprint and space requirements increase significantly
Solution Approach 1:
The sorting system is divided into multiple workstations, each handling a specific portion of the sorting process. Items are sorted in passes through different workstations rather than requiring one large bulk sorting system, reducing the footprint of each individual station while maintaining overall sorting capacity.
Solution Approach 2:
The system transitions from horizontal bulk sorting to vertical stacking arrangements. Containers are stacked vertically at workstations, utilizing vertical space rather than horizontal floor space, thereby reducing the equipment footprint while maintaining sorting capacity.
2Productivity
If multiple bins are used to handle different item categories simultaneously, then sorting efficiency improves, but the number of required containers and space increases
Solution Approach 1:
The same container is reused across multiple passes and workstations. Instead of having dedicated containers for each item category, the system uses a single container that is repeatedly filled and emptied as items are sorted in sequential passes, reducing the total number of containers needed.
Solution Approach 2:
The system employs a single container that is discarded (emptied) and recovered (refilled) repeatedly during the sorting process. After items are sorted into the container at one workstation, the container is emptied and later refilled at subsequent workstations, eliminating the need for multiple permanent storage containers.
3Reliability
If items are sorted into individual sequences immediately, then delivery readiness is achieved, but the sorting process requires more time and passes
Solution Approach 1:
Items are preliminarily sorted by geographic region or delivery route in the first pass, grouping items that will eventually go to the same general area. This preliminary grouping reduces the complexity of subsequent sorting passes, allowing items to be fully sequenced more quickly in later passes without requiring all sorting to be completed in one time-consuming operation.
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 can then sort the items into output bins in delivery sequence order.