Vertical Ring Sorter Layout for Continuous Cross-Belt Conveyance
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Solution Overview
Problem
Existing cross-belt sorters, particularly linear cross-belt sorters, suffer from low utilization rates due to the need to unload packages at the tail end and the inability to carry packages through the entire sorter, leading to inefficiencies and wasted space.
Innovation Solution
A vertical ring-shaped sorter with parallel ring-shaped tracks and a drive assembly using sprockets and chains to maintain a fixed posture of the sorting cart, allowing continuous package conveyance without unloading at the end, utilizing upper space efficiently and reducing the footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a linear cross-belt sorter is used, then packages can be transported from front end to tail end, but the sorter cannot be used at the tail end after the sorting cart runs to the end, resulting in low utilization rate
Solution Approach 1:
The patent inverts the traditional linear structure by using a vertical ring-shaped configuration. The sorting cart travels upward along the ring track and can continuously carry packages without needing to be unloaded at the end, as the ring structure allows it to return to the starting position and continue operation, thus eliminating the idle time at the tail end.
Solution Approach 2:
The ring-shaped track enables the sorting cart to operate continuously in a loop. Packages are loaded at the bottom, transported upward, and the cart returns to the loading position without needing to be unloaded or reset, maintaining continuous useful action and maximizing the utilization rate of the sorter.
2Productivity
If a ring-type cross-belt sorter is used, then space utilization is improved, but the sorter covers a large area on the ground
Solution Approach 1:
The patent transitions from a horizontal ring structure to a vertical ring structure. By utilizing the vertical dimension instead of horizontal space, the sorter achieves compact footprint while maintaining the continuous loop operation. The vertical ring track allows the sorting cart to travel upward and return, maximizing space utilization without occupying large ground area.
3Ease of manufacture
If the sorting cart is turned over at the tail end, then the cart can be recycled, but the cart cannot carry packages during this section, resulting in wasted space
Solution Approach 1:
The vertical ring structure eliminates the need to turn over the sorting cart at the end of the line. The cart maintains its upright position throughout the entire loop, continuously carrying packages from the loading position upward and returning to the start, thus eliminating the non-productive section where the cart cannot carry packages.
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 sorter maintains a fixed posture of the sorting cart, enabling continuous package conveyance and improving overall utilization rate by eliminating the need for unloading at the tail end, thus enhancing sorting efficiency and space utilization.
Implementation Method 1
a drive assembly, which includes: at least one sprocket set comprising a driving sprocket and a plurality of driven sprockets installed on the rack; at least one chain hooping on the driving sprocket and the plurality of driven sprockets
Implementation Method 2
an electric machine configured to drive the driving sprocket to rotate
Implementation Method 3
each of the support arms may include: a guide-wheel group; two guide-wheel groups respectively travel along the two ring-shaped tracks
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
A sorter, comprising: a frame; a rail assembly comprising two ring-shaped rails both installed on the frame, the two ring-shaped rails being respectively arranged in two parallel vertical planes and aligned with each other; a drive assembly comprising sprocket sets that comprise a driving sprocket and a plurality of driven sprockets installed on the frame; chains hooping on the driving sprocket and the plurality of driven sprockets and having the same shape as the ring-shaped tracks; a motor configured to drive the driving sprocket to rotate; a sorting cart comprising a carriage that is arranged between and slidably connected to the two ring-shaped rails and is hinged with the chains; a conveying assembly that is disposed above the carriage and can carry and convey items, wherein the conveying direction of the conveying assembly is different from the moving direction of the sorting cart. The sorter occupies small floor space and is efficient.