Two-Stage Sorter Reduces Footprint and Complexity
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Solution Overview
Problem
Existing sorting systems for bulk items, such as mail and packages, are inefficient and costly due to their high volume processing requirements, leading to increased complexity and resource utilization, and often struggle with sorting irregularly shaped or oversized items.
Innovation Solution
A system comprising a scanner to identify item destinations, a processor to associate items with stop groups, and a sorting mechanism that directs items into bins based on these groups, along with a memory to store item locations, allowing for efficient sorting and delivery optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high volume processing is used to sort bulk items, then sorting throughput is improved, but device complexity and space requirements increase
Solution Approach 1:
The sorting system divides bulk items into smaller groups using multiple passes. The first pass creates preliminary groups, and the second pass further subdivides these groups into final destination bins. This segmentation approach enables high throughput sorting without requiring a single complex high-capacity sorter, thereby reducing overall device complexity while maintaining productivity.
2Productivity
If traditional sorting apparatuses are used for bulk mail, then sorting capability is provided, but space footprint and processing cost increase
Solution Approach 1:
The system uses a two-dimensional sorting approach with multiple passes instead of a single large horizontal sorter. Items are sorted in the first dimension during the first pass into intermediate groups, then sorted in the second dimension during the second pass into final bins. This dimensional transformation reduces the horizontal footprint of equipment while maintaining sorting capability.
3Manufacturing precision
If multiple sorting passes are implemented, then sorting precision is improved, but processing time increases
Solution Approach 1:
The first sorting pass performs preliminary grouping of items into intermediate groups based on destination. This preliminary action organizes items in advance, so the second pass only needs to perform final destination sorting rather than sorting from scratch. This reduces the complexity and time of the second pass while maintaining high sorting precision through the two-stage process.
Data Source
AI summary
Embodiments of a system and method for sorting and delivering articles in a processing facility. 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. The second sorter sorts items for each stop group into trays based on carrier route segments. A manifest is created that comprises a list of the items in a tray. A mobile computing device alerts a delivery carrier when there is an item that needs to be delivered.