Vision-Based Package Sorting via Slide Sorter Pop-Up Diversion
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Solution Overview
Problem
Conventional automated sorting systems for packages of varying sizes and shapes face challenges in efficiently diverting irregularly shaped packages without stopping the conveyor, leading to orientation issues and reduced throughput, especially when handling large or heavy items.
Innovation Solution
A vision-based conveyor package management system combined with a slide sorter pop-up diverting mechanism, utilizing cameras and sensors to detect package dimensions and characteristics, controls conveyor speed and activates the pop-up conveyor to divert items without stopping the main conveyor, ensuring proper orientation and high-speed sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional pop-up transfer conveyors are used to divert packages, then packages can be transferred to different conveyors, but the on-coming conveyor must stop which reduces throughput and causes orientation problems
Solution Approach 1:
The system dynamically adjusts the speed of the on-coming conveyor based on real-time detection of package characteristics. The conveyor speed is modulated to match the timing requirements of the pop-up transfer mechanism, allowing continuous operation without complete stops. This dynamic speed adjustment enables the system to maintain high throughput while successfully diverting packages to side conveyors.
Solution Approach 2:
The system uses vision systems and sensors to detect package dimensions, orientation, and position in real-time. This feedback information is used to control the conveyor speed and timing of the pop-up transfer mechanism, ensuring that packages are diverted at the optimal moment. The feedback loop allows the system to adapt to varying package characteristics while maintaining continuous operation.
2Manufacturing precision
If the on-coming conveyor stops for pop-up transfer, then packages can be properly oriented on the receiving conveyor, but longitudinal articles are rotated sideways causing downstream orientation problems
Solution Approach 1:
The system performs preliminary detection and speed adjustment before the package reaches the pop-up transfer point. By detecting package orientation and characteristics in advance and pre-adjusting the conveyor speed, the system ensures that packages are in the correct position and orientation when transferred, preventing rotation and misorientation issues downstream.
Solution Approach 2:
The system changes the speed parameter of the on-coming conveyor based on detected package characteristics. By adjusting the conveyor speed to specific values that match the package dimensions and transfer mechanism timing, the system achieves proper package orientation during transfer without causing rotation or misorientation problems.
3Extent of automation
If robotic gripper technology is used for sorting, then automated handling of various package types is achieved, but the system becomes expensive
Solution Approach 1:
The system replaces complex robotic gripper mechanisms with a simpler pop-up transfer conveyor system. Instead of using robots to grasp and move packages, the system uses a continuously moving conveyor with periodic pop-up transfers. This mechanical substitution maintains automated handling capabilities while significantly reducing system complexity and cost.
Solution Approach 2:
The pop-up transfer conveyor system is designed to handle multiple package types, sizes, and orientations using a single unified mechanism. The system's ability to adapt to different package characteristics through speed adjustment and timing makes it universally applicable, eliminating the need for specialized robotic grippers for different package types.
4Ease of operation
If belt and roller conveyor systems are used to move packages, then packages can be transported from loading docks to outgoing transport, but sorting speed is limited
Solution Approach 1:
The system maintains continuous conveyor operation without stops, allowing packages to be transported and sorted simultaneously. The pop-up transfer mechanism operates periodically while the main conveyor continues moving, ensuring uninterrupted package flow. This continuity enables both transport and sorting functions to occur at high speed without sacrificing either capability.
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 achieves efficient sorting and increased throughput by accurately diverting irregularly shaped packages, maintaining conveyor speed, and preventing orientation issues, thereby optimizing conveyor area utilization and reducing the need for multiple sorting sub-systems.
Implementation Method 1
at least one photo eye device... detecting a full length of an item
Data Source
AI summary
A typing tunnel off-loading and sorting system includes an off-loading conveyor, cameras and photoelectric eye. The overhead cameras detect the item size and whether it is cubic in nature and type and size of its footprint. An in-line slide sorter having alternating conveyor rollers and pop-up belts pass through to, or divert articles from, a downstream conveyor. The vision based system may also be used to detect space between articles and insert articles in the unoccupied space.