Description:TECHNICAL FIELD
The present disclosure relates generally to the field of material handling equipment, and optimization and more specifically, to a modular sorting machine for high throughput sorting of a plurality of items.
BACKGROUND
In today’s manufacturing industry, the use of material handling equipment is crucial for speedy movement of materials or items from one location to another. The common material handling equipment used in the manufacturing industry are conveyor systems, cranes, industrial trucks, and the like. The conveyor systems are used when the material is to be moved frequently between specific points along a fixed path. Further, conveyor-based sorting machines are used to sort the materials received through a conveyor.
However, the conventional conveyor-based sorting machines are often large and complex pieces of machinery, which require significant amount of space, and can make them difficult to install and maintain. The conventional conveyor-based sorting machines are very susceptible to hardware failures, such as sensor malfunctions, motor failures, and conveyor belt breakdowns. Such failures can cause the entire sorting machine to stop operating, which can lead to significant delays in the sorting process and entire plant operations may come to a halt. In conventional sorting machines, conveyor belts are a critical part of sorting machines. If the conveyor belts become jammed, they can prevent the sorting machine from operating properly. Thus, there is a technical problem of frequent hardware failures, jammed conveyor belts, high maintenance, and requirement of huge installation space due to their bulky size and complexity. Further, the challenge of adapting to changes in the product mix requiring re-setup.
Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the conventional sorting machines.
SUMMARY
The present disclosure provides a modular sorting machine. The present disclosure provides a solution to the technical problem of frequent hardware failures, jammed conveyor belts, high maintenance, and requirement of huge installation space due to bulky size and complexity of conventional sorting machines. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art and provide an improved modular sorting machine that due to its modular nature significantly reduces the area of floor space required for installation while achieving similar throughput in sorting of items. Further, the disclosed modular sorting machine increases ease of sorting operations lowering maintenance costs while increasing accuracy in the sorting operation compared to conventional conveyor-based sorting machines.
One or more objectives of the present disclosure is achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
In one aspect, the present disclosure provides a modular sorting machine. The modular sorting machine comprises one or more in-feed carriages configured to perform data acquisition of a plurality of input items and a stationary carriage fixedly connected to the one or more in-feed carriages and configured to receive the plurality of input items from the one or more in-feed carriages. Moreover, the modular sorting machine comprises a movable carriage movably connected to the stationary carriage and configured to receive the plurality of input items from the stationary carriage and transport the plurality of input items from one location to another along a reference axis. The movable carriage comprises a plurality of movable sub-carriages. In a rest state, each movable sub-carriage of the plurality of movable sub-carriages is configured to rest at a predefined location along the reference axis to form a unitary carriage arrangement. Moreover, in a working state, each movable sub-carriage of the plurality of movable sub-carriages is configured to move laterally in either left or right direction normal to the reference axis. The reference axis is defined normal to a direction of movement of the plurality of movable sub-carriages.
The modular sorting machine includes multiple carriages, such as in-feed carriage, stationary carriage, and movable carriage, which are separate modules and are detachably attached with each other. The modular design of the machine makes it easy to scale up or down as needed. For example, if the volume of input items increases, more in-feed carriages and movable carriages can be added to the machine. The use of the plurality of movable sub-carriages within the movable carriage introduces a modular approach to the design. Each sub-carriage can function as an independent unit that contributes to the overall operation of the sorting machine. The lateral movement of each movable sub-carriage in either left or right direction perpendicular to the reference axis, enables precise sorting of items. This technical advancement allows the sorting machine to reposition and rearrange items with high accuracy, leading to efficient sorting operations and reducing the chances of errors. In another example, the ability of the movable sub-carriages to move laterally provides the machine with greater flexibility in its sorting strategies. It can adapt to varying sorting requirements and accommodate changes in the sorting process as needed. This technical advancement enhances the versatility and adaptability of the modular sorting machine. Furthermore, the lateral movements of the sub-carriages do not interfere with the primary direction of movement along the reference axis until an item reaches to a target sub-carriage. As a result, the sorting machine can operate efficiently even in limited floor space, maximizing its utility in diverse environments. The modular sorting machine does not require long continuous conveyor belt for movement of input items like the conventional sorting machines, which eliminates the problems related jamming of conveyor belt, thereby increasing productivity while sorting.
In another aspect, the present disclosure provides a method for operating a modular sorting machine. The method comprises performing, by one or more controllers, data acquisition of a plurality of input items fed to one or more in-feed carriages of the modular sorting machine. A delivery location of each input item is acquired during the data acquisition of the plurality of input items. The method further comprises identifying, by the one or more controllers, a sorting location for each input item based on the acquired delivery location of each input item. In addition, the method comprises instructing, by the one or more controllers, the one or more in-feed carriages to move the plurality of input items from the one or more in-feed carriage to a movable sub-carriage from a plurality of movable sub-carriages corresponding to the identified sorting location. Moreover, the method comprises instructing, by the one or more controllers, the corresponding movable sub-carriage to move a lateral distance in either left or right direction normal to a reference axis based on the identified sorting location of each input. Moreover, the reference axis is defined normal to a direction of movement of the plurality of movable sub-carriages. The method further comprises depositing each input item into the identified sorting location.
The method achieves all the advantages and technical effects of the modular sorting machine of the present disclosure.
It is to be appreciated that all the aforementioned implementation forms can be combined. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an installation place with multiple modular sorting machines, in accordance with an embodiment of the present disclosure;
FIG. 2A is a schematic view of a modular sorting machine, in accordance with an embodiment of the present disclosure;
FIG. 2B is a diagram illustrating a system for operating a modular sorting machine, in accordance with an embodiment of the present disclosure;
FIGs. 3A and 3B are schematic diagrams of a modular sorting machine, in accordance with a different embodiment of the present disclosure;
FIGs 4A to 4E are schematic diagrams illustrating flow of operations in a modular sorting machine, in accordance with an embodiment of the present disclosure;
FIGs. 5A to 5I are schematic diagrams of a modular sorting machine, in accordance with a different embodiment of the present disclosure; and
FIG. 6 is a flowchart of a method for operating a modular sorting machine, in accordance with an embodiment of the present disclosure.
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those skilled in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
FIG. 1 is a schematic view of an installation place with multiple modular sorting machines, in accordance with an embodiment of the present disclosure. With reference to FIG. 1, there is shown an installation place 102 with six modular sorting machines, such as a first modular sorting machine 100A, a second modular sorting machine 100B, a third modular sorting machine 100C, a fourth modular sorting machine 100D, a fifth modular sorting machine 100E and a sixth modular sorting machine 100F. The modular sorting machines are configured to transfer a plurality of input items (e.g., parcels or delivery items) from one location to another and sort the plurality of input items in a plurality of sorting locations. The modular sorting machine includes multiple compact modules or carriages that sort the plurality of input items repetitively. Due to the compact modules, the modular sorting machine occupies lesser floor area in the installation place 102 as compared to conventional conveyor-belt based sorting machines. For the sake of brevity, here are shown six modular sorting machines in the installation place 102 in an example, however, the number may vary in practice as per need.
FIG. 2A is a schematic view of a modular sorting machine, in accordance with an embodiment of the present disclosure, in accordance with an embodiment of the present disclosure. With reference to FIG. 2A, there is shown a modular sorting machine 200, which includes one or more in-feed carriages 202, a stationary carriage 204 and a movable carriage 206 having a plurality of movable sub-carriages. The stationary carriage 204 is fixedly connected to the one or more in-feed carriages 202 and the movable carriage 206 is movably connected to the stationary carriage 204.
The modular sorting machine 200 is configured to move a plurality of input items 208 from one location to another and further sort the plurality of input items 208 in a plurality of sorting locations 214, for example, based on delivery address of input items (i.e., delivery locations). The plurality of input items 208 may refer to parcels, delivery items, or products that are introduced into the modular sorting machine 200 for sorting in the plurality of sorting locations 214. Examples of the plurality of input items 208 may include, but are not limited to parcels, boxes, finished products, tools, spare parts or any other items capable of sorting. The delivery locations refer to destinations or addresses where the plurality of input items 208 are intended to be delivered. For example, the plurality of input items in a warehouse includes three input items, such as a first input item, a second input item and a third input item. The first input item is to be delivered in the city A, the second input item is to be delivered in the city B and the third input item is to be delivered in the city C. Therefore, the cities A, B and C are the delivery locations for the three input items. The plurality of sorting locations 214 refer to designated areas or spaces within the modular sorting machine 200 where sorting activities take place. In continuation with the previous example, there may be three containers arranged with the modular sorting machine 200, such as container A, B and C. The input items to be delivered in the city A may be sorted and collected within the container A. Similarly, the input items to be delivered to cities B and C may be sorted within the containers B and C respectively. In another example, the plurality of sorting locations 214 may be segregate into five delivery or sorting zones, such as north, south, east, west, and central zones as per the destination city of an input item at which is to be delivered.
The one or more in-feed carriages 202 refers to workstations which are configured to receive the plurality of input items to be sorted in the plurality of sorting locations 214. Further, the stationary carriage 204 is configured to receive the plurality of input items 208 from the one or more in-feed carriages 202. In an example, one input item may be placed at a time over each in-feed carriage from the one or more in-feed carriages 202 during operation of the modular sorting machine 200. With reference to FIG. 2A, one stationary carriage is fixedly connected with one in-feed carriage and configured to receive one input item at a time from the in-feed carriage. In an implementation, each movable sub-carriage from the plurality of movable sub-carriages is a standalone carriage and is capable of performing independent movement with respect to consecutive movable sub-carriage. The movable carriage 206 is configured to receive the plurality of input items 208 from the stationary carriage 204 and transport the plurality of input items from one location to another in a first direction along a reference axis 210.
The modular sorting machine 200 is operational in two states – a rest state and an activated state. In the rest state, each movable sub-carriage of the plurality of movable sub-carriages is configured to rest at a predefined location along the reference axis 210 to form a unitary carriage arrangement. This arrangement ensures that the sub-carriages are well-aligned and synchronized, providing stability, and preventing misalignment during the sorting process. The unitary carriage arrangement contributes to the overall robustness and reliability of the modular sorting machine 200. The unitary carriage arrangement refers to the arrangement of the plurality of movable sub-carriages in a linear sequence to form an array of movable sub-carriages. In the rest state, the plurality of movable sub-carriages do not move physically from their original position and act as a single unit, which transfer the plurality of input items by using in-built rollers from one location to another in one direction along the reference axis 210. With reference to FIG. 2A, the reference axis 210 is parallel to a sequence of arrangement of the plurality of movable sub-carriages in the unitary carriage arrangement. In the activated state, each movable sub-carriage of the plurality of movable sub-carriages is configured to move laterally in either left or right direction normal to the reference axis 210. The lateral movement of the plurality of sub-carriages is based on the positions of the plurality of sorting locations 214. Each movable sub-carriage is moved either right - left to sort the plurality of input items 208 in respective sorting locations. In an implementation, the modular sorting machine 200 includes a plurality of lateral rails 214A fixedly connected to each movable sub-carriage from the plurality of movable sub-carriages. Each lateral rail from the plurality of lateral rails 214A is looped with a belt driven by a first rotary actuator 216A. In an example, the sorting location is at a definite distance in right direction of the reference axis 210. In such case, the first rotary actuator 216A is rotated to move the movable sub-carriage having the input item in the right direction up to respective sorting location.
In accordance with an embodiment, the modular sorting machine 200 includes one or more controllers. The one or more controllers is a computational element which is configured to operate the one or more in-feed carriages 202, the stationary carriage 204 and the movable carriage 206 to sort the plurality of input items 208. Examples of the one or more controllers may include but are not limited to, a hardware processor, a digital signal processor (DSP), a microprocessor, a microcontroller, a complex instruction set computing (CISC) processor, an application-specific integrated circuit (ASIC) processor, a reduced instruction set (RISC) processor, a very long instruction word (VLIW) processor, a state machine, a data processing unit, a graphics processing unit (GPU), and other processors or control circuitry.
In operation, the plurality of input items 208 are placed over the one or more in-feed carriages 202. After receiving the plurality of input items 208, the modular sorting machine 200 operates in the rest state. During the rest state, the one or more in-feed carriages 202 are configured to perform the data acquisition of the plurality of input items 208. In an implementation, the data acquisition involves scanning a barcode printed on the plurality of input items 208, measuring weight and dimensions of the plurality of input items 208. Based on the data acquired by the one or more in-feed carriages 202, the one or more controllers are configured to determine the delivery location of each input item. Further, based on the delivery location, the one or more controllers are configured to determine the sorting location of each input item. After determining the sorting location of each input item, the one or more in-feed carriages 202 transfer the plurality of input items 110 to the stationary carriage 204. Further, the stationary carriage 204 transfers the plurality of input items 208 in the first direction towards the movable carriage 206. The stationary carriage 204 transfers the input item to a first movable sub-carriage 206A (nearest to the stationary carriage 204). Based on the sorting location, the one or more controllers are configured to direct the movable carriage 206 to move each input item from the first movable sub-carriage to a target movable sub-carriage which is positioned at a predefined distance along the reference axis 210.
The target movable sub-carriage refers to a movable sub-carriage in which an input item is reached before movement of the movable sub-carriage in the left or right. In the rest state, the movable carriage is in the form of the unitary carriage arrangement (i.e., the plurality of movable sub-carriages are in line to form a single movable carriage) and the plurality of input items 208 are transferred from the first movable sub-carriage to the target movable sub-carriage. After the input item is reached up to the target movable sub-carriage, the modular sorting machine 204 gets transitioned in the activated state. In the activated state, the one or more controllers are configured to activate the target movable sub-carriage to move either to left or right direction normal to the reference axis 210 in order to reach towards corresponding sorting location of the input item. After reaching in proximity of the sorting location, the one or more controllers are configured to direct the target movable sub-carriage to drop the input item in the corresponding sorting location. After dropping the input item into the corresponding sorting location, the target movable sub-carriage gets returned to its original position. The sequence of operations of the modular sorting machine 200 is explained in detail with the FIG. 5.
In an example, there are multiple combinations of the one or more in-feed carriages and corresponding sorting locations are used in the modular sorting machine 200 as per requirement, as follows: a) Single in-feed carriage with 24 sorting locations; b) Two in-feed carriages with 24 sorting locations; c) Single in-feed carriage with 48 sorting locations; d) Two in-feed carriages with 48 sorting locations; e) Single in-feed carriage with 72 sorting locations; f) Two in-feed carriages with 72 sorting locations; g) Single in-feed carriage with 96 sorting locations; and h) Two in-feed carriages with 96 sorting locations.
In an implementation, each of the one or more in-feed carriages 202 and the stationary carriage 204 includes a set of rollers and a belt looped around the set of rollers such that the belt is driven by the set of rollers. After the data acquisition of each input item by the one or more in-feed carriages 202, the set of rollers in the one or more in-feed carriages 202 are rotated by rotary actuators that drive the belt to move the input item towards the stationary carriage 204. After receiving the input item, the set of rollers in the stationary carriage are rotated by rotary actuators to move the input item towards the movable carriage 106.
In accordance with an embodiment, each movable sub-carriage includes a set of rollers and a belt looped around the set of rollers such that the belt is driven by the set of rollers along the reference axis 210 to transport the plurality of input items 208 from one location to another in the first direction along the reference axis 210 using the belt and the set of rollers. In an example, each movable sub-carriage is having two rollers and the belt is looped around rollers in such a way that the two rollers are spaced apart at a predefined distance. In an implementation, each roller from the set of rollers is actuated by separate rotary actuators such as motors or through one rotary actuator. During operation, when the stationary carriage transfers the input item to the first movable sub-carriage, the set of rollers of each movable carriage between the first movable sub-carriage and the target movable sub-carriage get rotated and corresponding belts cause the movement of the input item from the first movable sub-carriage up to the target movable sub-carriage.
In accordance with an embodiment, in order to perform the data acquisition of the plurality of input items 208, the one or more in-feed carriages 102 is configured to scan a barcode and measure a weight and dimensions of the plurality of input items 208. In an implementation, a barcode scanner, a camera, and a weight sensor are positioned over the one or more in-feed carriages 202 to scan the barcode, measure dimensions and weight respectively. In accordance with an embodiment, the one or more controllers are configured to obtain the delivery location of each item during the data acquisition of the plurality of input items 208. The barcode printed over each input item includes information about the delivery location of the corresponding input item. In an implementation, the correlation between the delivery location and the corresponding sorting location is predefined and stored in a memory associated with the one or more controllers.
In accordance with an embodiment, the modular sorting machine 200 includes a plurality of trolleys 216. Moreover, each trolley of the plurality of trolleys 216 includes a plurality of sorting locations 214, and each trolley is configured to receive one or more sorted input items at the corresponding sorting location. With reference to FIG. 1, each trolley from the plurality of trolleys 216 includes three sorting locations. During operation of the modular sorting machine 200 in the activated state, the target movable carriage is configured to drop the one or more sorted input items into the corresponding sorting location. In an example, each trolley is having a plurality of wheels and is capable of moving inside and outside of the modular sorting machine 200.
In accordance with an embodiment, the modular sorting machine 200 includes a plurality of position sensors disposed proximate to each trolley to identify a predefined position of each trolley and detect overhanging of each input item over the plurality of trolleys 216. During operation of the modular sorting machine 200 in the activated state, the target movable sub-carriage along with the input item is moved to either right or left direction to move towards the corresponding sorting location and drops the input item in the corresponding sorting location. The plurality of position sensors are configured to detect the presence of the input item within the trolley. Further, the plurality of position sensors transmits a signal regarding a sorting completion status to the one or more controllers. The sorting completion status of each input item is indicative of a successful deposition of each input item in the identified sorting location. Further, the one or more controllers are configured to update a database associated with status of the input items, such as whether the sorting of a particular input item is completed or not. In an implementation, the plurality of sensors includes at least one of a weight sensor, a proximity sensor, and an image sensor. In an example, the modular sorting machine 200 may include a through beam sensor to detect the overhanging of the plurality of input items 208.
In accordance with an embodiment, the modular sorting machine 200 includes an exception handling component configured to identify one or more ineligible input items from the plurality of input items that meet one or more ineligibility criteria. In an implementation, the exception handling component is a hardware component which is connected with the one or more controllers and is configured to receive information regarding the barcode, weight and dimensions acquired by the one or more in-feed carriages 202. Further, the exception handling component is configured to check the barcode, weight, and dimensions with respect to the sorting criterion. Examples of the ineligibility criterion may include, but not limited to, following list of criteria:
1) Input item with weight less than 50 g
2) Odd-shaped input items (Odd-shaped items can be round, uneven, and oblong in shape)
3) Input items with height greater than length and width
4) Input items having low center of gravity.
5) Input items having dimensions less than 50 x 50 x 10 mm (LxBxH)
6) Input items weighing more than 20 Kg.
7) Input items weighing less than 50 g.
8) Input items has no label or barcode at all.
9) The barcode is damaged or otherwise unreadable due to a number of reasons: the contrast is too low, there are ratio problems; or the bar code width or height does not comply with specifications.
10) Barcodes that are covered with foil can also sometimes be hard to read due to reflections.
11) The barcode is readable, but the structure of the data contained in the barcode is not compliant.
12) The barcode is readable but doesn’t contain sufficient data that enables further processing.
13) Input items with barcode size lesser than 8 mill.
14) Input items placed with barcode outside matrix shown over carriage.
15) Input items having multiple barcodes.
16) Input items with dimensions 50 x 50 x 10 mm and weight 5 kg
17) Input item that is enclosed in a soft-sided pack, such as a bubble mailer.
18) Input item enclosed in a plastic shrink wrap or stretch wrap.
19) Input item bound using a plastic, metal, or cloth banding, or items with wheels, straps, handles, and casters.
20) Input items with long tail.
In an implementation, the exception handling component is connected to a linear actuator arranged with the one or more in-feed carriages 102. If any input item is determined as ineligible by the exception handling component, then the exception handling component actuates the linear actuator to discard the corresponding input item away from the one or more in-feed carriages.
In an implementation, the modular sorting machine 200 includes a plurality of sensors for detecting position of the plurality of input items 202 throughout the modular sorting machine 200. In an implementation, the plurality of sensors are inductive proximity sensors. The plurality of sensors are arranged over each movable sub-carriage to detect the presence of the plurality of items along the movable carriage 206. During operation of the modular sorting machine 200, the one or more controllers 220 determines the sorting location for a definite input item based on the delivery location of the corresponding input item. Further, based on the sorting location of the input item, the one or more controllers 220 determine the movable sub-carriage, which is needed to be moved in either left or right direction perpendicular to the reference axis 210 in order to deposit the input item into the identified sorting location. Further, in case the input item is reached to the target movable sub-carriage, the sensor mounted over the target movable sub-carriage detects the presence of the input item and transmit signals to the one or more controllers 220. Based on the information received from the sensors in the target movable sub-carriage, the one or more controllers 220 are configured to actuate the first rotary actuator 216A to operate the lateral rail 214A corresponding to the target movable sub-carriage, which in turn causes lateral movement of the target movable sub-carriage in either left or right direction in order to drop the input item into the identified sorting location. In an implementation, the modular sorting machine 200 includes a limit switch that prevents overtravel of the first rotary actuator 216A during corresponding operation. In an implementation, each sorting location from the plurality of sorting locations associated with the plurality of trolleys 216 includes a stand for hanging one or more bags. The bags refer to a covering layer, which is to be wrapped around the plurality of input items 208 deposited into each sorting location.
The modular sorting machine 200 includes multiple carriages, such as the one or more in-feed carriages 202, the stationary carriage 204, and the movable carriage 206, which are separate modules and are detachably attached with each other. The modular design of the machine 200 makes it easy to scale up or down as needed. For example, if the volume of input items increases, more in-feed carriages and movable carriages can be added to the machine 200. The use of the plurality of movable sub-carriages within the movable carriage 206 introduces a modular approach to the design. Each sub-carriage can function as an independent unit that contributes to the overall operation of the modular sorting machine 200. The lateral movement of each movable sub-carriage in either left or right direction, perpendicular to the reference axis, enables precise sorting of items. This technical advancement allows the modular sorting machine 200 to reposition and rearrange items with high accuracy, leading to efficient sorting operations and reducing the chances of errors. In another example, the ability of the movable sub-carriages to move laterally provides the machine with greater flexibility in its sorting strategies. It can adapt to varying sorting requirements and accommodate changes in the sorting process as needed. This technical advancement enhances the versatility and adaptability of the modular sorting machine 200. Furthermore, the lateral movements of the sub-carriages do not interfere with the primary direction of movement along the reference axis until an item reaches to a target sub-carriage. As a result, the sorting machine can operate efficiently even in limited floor space, maximizing its utility in diverse environments. The modular sorting machine 200 does not require long continuous conveyor belt for movement of input items like the conventional sorting machines, which eliminates the problems related jamming of conveyor belt, thereby increasing productivity while sorting.
FIG. 2B is a diagram illustrating a system for operating a modular sorting machine, in accordance with an embodiment of the present disclosure. FIG. 2B is described in conjunction with elements of FIG. 2A. With reference to FIG. 2B, there is shown a system 200 which includes a server 218 connected with a database 232 and the one or more in-feed carriages 214 through a communication network 230. Further, the server 218 includes one or more controllers 220, a memory 222 and a network interface 228. Further, the memory 222 includes a plurality of delivery locations 224 and a plurality of sorting locations 214 of the plurality of input items. Further,
The database 232 is a storage device or storage server, which is configured to store the details of correlation between the plurality of delivery locations 224 and the plurality of sorting locations 226. In an implementation, the database 232 includes a sorting completion status 234, that is details regarding whether a particular input item is sorted or not. In an implementation, the database 232 is a remote cloud-based server.
The server 218 is configured to identify the plurality of sorting locations 214 based on the plurality of delivery locations, operate the modular sorting machine to sort the plurality of input items in corresponding sorting locations and update the sorting completion status in the database. In an implementation, the server 218 may be a master server or a master machine that is a part of a data center that controls an array of other cloud servers communicatively coupled to it for load balancing, running customized applications, and efficient data management. Examples of the server 218 may include, but are not limited to a cloud server, an application server, a data server, or an electronic data processing device.
The memory 222 is configured to store the plurality of delivery locations 224 acquired by the one or more in-feed carriages 202 and the plurality of sorting locations 214 identified by the one or more controllers 220. Examples of implementation of the memory 126 may include, but are not limited to, an Electrically Erasable Programmable Read-Only Memory (EEPROM), Dynamic Random-Access Memory (DRAM), Random Access Memory (RAM), Read-Only Memory (ROM), Hard Disk Drive (HDD), Flash memory, a Secure Digital (SD) card, Solid-State Drive (SSD), and/or CPU cache memory.
The network interface 228 refers to a communication interface to enable communication of the server 218 with the database 232. Examples of the network interface 124 include, but are not limited to, a network interface card, a transceiver, and the like.
In operation, the one or more controllers 220 are configured to obtain a delivery location of each input item during the data acquisition of the plurality of input items 208. Further, the one or more controllers 220 is configured to identify a sorting location from a plurality of sorting locations 214 for each input item based on the obtained delivery location of each input item. More specifically, the one or more controllers 220 are configured to receive the data acquired regarding the plurality of input items 208 by the one or more in-feed carriages and identify corresponding sorting locations based on the correlation stored in the database 232.
In an implementation, the one or more controllers 220 are configured to retrieve the details regarding the plurality of sorting locations 214 of the plurality of input items 208 from the database 232 based on the plurality of delivery locations 224.
In addition, the one or more controllers 220 are configured to cause each input item to reach a movable sub-carriage from the plurality of movable sub-carriages corresponding to the identified sorting location of each input item. In an implementation, the one or more controllers 220 are configured to determine the target movable sub-carriage corresponding to the identified sorting location. After identifying the target movable sub-carriage, the one or more controllers 220 actuate the set of rollers in the stationary carriage 204 (of FIG. 2) to transfer the input item to the first movable sub-carriage. Further, the one or more controllers 220 are configured to rotate the set of rollers of all the moving sub-carriages from the first movable sub-carriage up to the target movable sub-carriage to transfer the input item up to the target movable sub-carriage. Furthermore, the one or more controllers 220 are configured to instruct the corresponding movable sub-carriage to move a lateral distance in either left or right direction normal to the reference axis 210 based on the identified sorting location of each input item to sort each input item in the identified sorting location. By moving the corresponding target movable sub-carriage laterally or vertically in either the left or right direction normal to the reference axis 210, the modular sorting machine 200 can achieve precise item placement into the target trolley. This technical advancement enhances the accuracy of the sorting process, reducing the likelihood of misplacement or errors in sorting. In an implementation, after the input item is reached at the target movable sub-carriage, the one or more controllers 220 is configured to rotate the first rotary actuator 216A (of FIG. 2A) of the lateral rails 216 to move the target movable sub-carriage towards the identified sorting location and operate the set of rollers in the target movable sub-carriage to drop the input item into the identified sorting location. In an implementation, the one or more controllers 220 is configured to detect the presence of input item in the corresponding sorting location and update the sorting completion status 234 of the plurality of input items 208 in the database 232. In an example, before dropping an input item into the plurality of sorting locations, the one or more controllers 220 are configured to change the sorting completion status 234 for the corresponding input item as “incomplete”. After depositing the input item into the corresponding sorting location, the one or more controllers 220 are configured to change the sorting completion status 234 for the corresponding input item as “complete”.
FIGs. 3A and 3B are schematic diagrams of a modular sorting machine, in accordance with a different embodiment of the present disclosure. With reference to FIG.3A and 3B, there is shown a modular sorting machine 300 having two in-feed carriages, such as a first in-feed carriage 302A and a second in-feed carriage 302B, a stationary carriage 304, a first movable carriage 306 and a second movable carriage 308. The first movable carriage 306 and the second movable carriage 308 are in line as shown in FIG. 3B. The stationary carriage 304 includes a plurality of stationary sub-carriages. The stationary carriage 304 is perpendicular to both the first movable carriage 306 and the second movable carriage 308. Further, the modular sorting machine 300 includes a plurality of sorting locations 310.
In operation, at the rest state, each input item from the plurality of input items 208 is placed either on the first in-feed carriage 302A or the second in-feed carriage 302B or both. Further, the first in-feed carriage 302A or the second in-feed carriage 302B is configured to perform data acquisition on the corresponding input item, such as by scanning barcode, measuring weight and dimensions of the input item. Based on the data acquired by the first in-feed carriage 302A or the second in-feed carriage 302B, the one or more controllers 220 (of FIG. 2) are configured to determine the sorting location of the corresponding input item. After determining the sorting location, the one or more controllers 220 are configured to transfer the input item from either the first in-feed carriage 302A or the second in-feed carriage 302B to the stationary carriage 304. Further, the one or more controllers 220 are configured to move the input item along a first reference axis 312A from the stationary carriage 304. More specifically, the input item is transferred to a first stationary sub-carriage 304A. The first stationary sub-carriage 304A is positioned between the first in-feed carriage 302A and the second in-feed carriage 302B as shown in FIG. 3B. Further, the one or more controllers 220 are configured to move the input item along from the first stationary sub-carriage 304A to a second stationary sub-carriage 304B. The second stationary sub-carriage 304B is a part of the stationary carriage, which is positioned between the first movable sub-carriage 306 and the second movable sub-carriage 308.
After transfer of the input item over the second stationary sub-carriage 304B, the one or more controllers 220 are configured to actuate the second stationary sub-carriage 304B to transfer the plurality of input items to either the first movable carriage 306 or the second movable carriage 308 based on the identified sorting location. Further, the one or more controllers are configured to actuate the first movable carriage 306 or the second movable carriage 308 to transfer the plurality of input items 208 from the second stationary sub-carriage 304B to a target movable sub carriage of the first movable carriage 306 or the second movable carriage 308 along a second reference axis 312B.
The target movable sub-carriage of the first movable carriage 306 or the second movable carriage 308 refers to a movable sub-carriage in which the plurality of input items 208 are reached before movement of the movable sub-carriage in the left or right direction of the second reference axis 312B. After the plurality of items 208 are reached over the target movable sub-carriage, the modular sorting machine 300 gets transitioned from the rest state to the activated state. In the activated state, the target movable sub-carriage moves either to a left or right direction perpendicular to the second reference axis 312B along a lateral or vertical rail from a plurality of lateral rails 314. In an implementation, the plurality of lateral rails 314 are actuated by a plurality of rotary actuators 314A. The plurality of lateral rails 314 are structurally and functionally similar to that the plurality of lateral rails 214A. Further, the plurality of lateral rails 314 cause movement of the target movable sub-carriage towards an identified sorting location from the plurality of sorting locations 310. After the target movable sub-carriage is reached towards the identified sorting location, the one or more controllers 220 are configured to operate the target movable sub-carriage to drop the plurality of input items 208 into the identified sorting location.
FIGs 4A to 4E are schematic diagrams illustrating flow of operations in a modular sorting machine, in accordance with an embodiment of the present disclosure. With reference to FIGs 4A to 4E, there is shown schematic diagrams illustrating flow of operations in the modular sorting machine 200 and 300. FIGs 4A, 4B and 4C illustrate the operations of the modular sorting machine 200 and 300 in the rest state, whereas the FIGs. 4D and 4E illustrate the operations of the modular sorting machine 200 and 300 in the activated state.
During operation of the modular sorting machine 200 and 300 in the rest state, the plurality of input items 208 are placed over the one or more in-feed carriages 202 as shown in FIG. 4A. The one or more controllers 220 (of FIG. 2B) are configured to perform data acquisition of the plurality of input items 208. Further, based on the data acquired, the one or more controllers 220 are configured to determine the delivery locations of the plurality of input items 208. In addition, the one or more controllers 220 are configured to obtain the sorting location for the plurality of input items 208 based on the acquired delivery locations. Further, the one or more controllers 220 are configured to transfer the plurality of input items 208 to the stationary carriage 204 as shown in FIG. 4B. Further, the one or more controllers 220 are configured to operate the stationary carriage 204 to move the plurality of input items 208 towards a target movable sub-carriage 206 from the moving carriage 206 along the reference axis 210 in a first direction 210A. Further, the one or more controllers 220 are configured to move the target movable sub-carriage 206B in the left direction 210B towards identified sorting location from the plurality of sorting locations 208 as shown in FIG. 4D. After reaching towards the plurality of sorting locations 214, the one or more controllers 220 are configured to operate the target movable sub-carriage 206B to drop the plurality of input items 208 into the identified sorting locations 214 as shown in FIG. 4E.
In accordance with an embodiment, in the rest state, although each movable sub-carriage of the plurality of movable sub-carriages is configured to rest at its corresponding predefined location to form a unitary carriage arrangement 210A (as shown in FIG. 4A), one or more input items of the plurality of input items 208 moves in the first direction from the first movable sub-carriage 206A to a corresponding target movable sub-carriage (i.e., the target movable sub-carriage 206B) using the set of rollers along the first direction. By moving the corresponding target movable sub-carriage laterally in either the left or the right direction normal to the reference axis, the sorting machine can achieve precise item placement into the target trolley. This technical advancement enhances the accuracy of the sorting process, reducing the likelihood of misplacement or errors in sorting. In other words, in the rest state, the set of rollers of the plurality of movable sub-carriages are actuated by the one or more controllers 220 to move the plurality of input items 208 from the first movable sub-carriage 206A to the corresponding target movable sub-carriage along the first direction 210A. Further, upon reaching the corresponding target movable sub-carriage, the corresponding target movable sub-carriage becomes activated to move laterally in either the left or right direction normal to the reference axis 210 for dropping corresponding input item in a target trolley. This feature introduces dynamic activation of the corresponding target movable sub-carriage upon reaching the target position. In conventional conveyor sorting machines, the sorting process is often fixed and predetermined, with items moving along a static path. However, with this advancement, the target movable sub-carriage is activated based on real-time feedback, allowing for a more dynamic and adaptive sorting process. The target trolley corresponds to a trolley from the set of trolleys 216, which includes sorting location for particular input item. Each trolley includes multiple sorting locations. The dynamic target activation requires real-time tracking of the input items as they move along the first reference axis 210. This technical advancement involves incorporating sensors or tracking mechanisms to precisely monitor the position and movement of the items. The real-time data enables the sorting machine to make quick decisions and accurately direct each item to its designated target trolley. With reference to FIG. 4E, each input item from the plurality of input items 208 is dropped into the target trolley corresponding to the identified sorting location.
FIGs. 5A to 5I are diagrams of a modular sorting machine, in accordance with a different embodiment of the present disclosure. With reference to FIGs. 5A to 5I, there is shown a modular sorting machine 500, which includes the one or more in-feed carriages 200 (of FIG. 2A), the stationary carriage 204 (of FIG. 2A), a movable carriage 502, a secondary movable sub-carriage 504, a supporting rail 506 and a plurality of trolleys 508. In addition, with reference to FIGs. 5A, 5B and 5C, there is shown a modular sorting machine 500 in a first operational state. With reference to FIGs. 5D, 5E and 5F, there is shown the modular sorting machine 500 in a second operational state. In addition, with reference to FIGs. 5G, 5H, and 5I, there is shown the modular sorting machine 500 in a third operational state. Further, with reference to FIGs. 5A, 5B and 5C, there are shown top view, front view and side view respectively of the modular sorting machine 500 in the first operational state. Moreover, with reference to FIGs. 5D, 5E and 5F, there are shown top view, front view and side view respectively of the modular sorting machine 500 in the second operational state. Further, with reference to FIGs. 5A, 5B and 5C, there are shown top view, front view and side view respectively of the modular sorting machine 500 in the third operational state.
In this embodiment, the movable carriage 502 refers to a vertical structure, which is configured to perform translational motion from one location to another location in the first direction along the reference axis 210. The supporting rail 506 is a horizontal structure on which the movable carriage 502 is configured to perform translational motion. In accordance with an embodiment, the secondary movable sub-carriage 504 is movably connected to the movable carriage 502. The movable carriage 502 is further movably connected to the supporting rail 506. In such embodiment, the plurality of trolleys 508 are arranged one above the other as a vertical sequence as shown in FIGs. 5A to 5I. Each trolley from the plurality of trolleys 508 includes a plurality of sorting locations. In an example, the secondary movable sub-carriage 504 is connected to the movable carriage 502 through a long-distance transmission mechanism, for example, a chain and sprocket mechanism operated by a rotary actuator. In an example, the movable carriage 502 is connected to the supporting rail 506 through a chain and sprocket mechanism (operated through a rotary actuator coupled to a sprocket) or through a belt drive mechanism (operated through a rotary actuator coupled to a pulley). The operation of the modular sorting machine 500 is explained as follows:
During operation of the modular sorting machine 500, at the rest state, the one or more in-feed carriages 202 (of FIG. 2A) perform the data acquisition of the plurality of input items 208 and transfer the plurality of input items 208 (of FIG. 2A) to the stationary carriage 204 (of FIG. 2A). Based on the data acquired from the plurality of input items 208, the one or more controllers 220 (of FIG. 2B) are configured to identify the sorting location of the plurality of input items 208. After arrival of the plurality of input items 208 to the stationary carriage 204, the one or more controllers 220 are configured to operate the modular sorting machine 500 into the activated state. In the activated state, the secondary movable sub-carriage 504 is configured to move either up or down direction normal to the reference axis 210. The up direction is along a second direction 510 (as shown in FIGs. 5A to 5I) and the down direction is opposite to the second direction 510.
In such embodiment, the activated state includes the first operational state, the second operational state and the third operational state. The transition of the modular sorting machine 500 from within the first, second and third operational states takes place based on the identified sorting locations of the plurality of input items 208. At the first operational state (as shown in FIGs. 5A, 5B and 5C), when the plurality of input items 208 are on the stationary carriage 204, the one or more controllers 220 are configured to operate the supporting rail 506 to move the movable carriage 502 along the reference axis 210 as well as to operate the movable carriage 502 to move the secondary movable sub-carriage 504 in either up direction (i.e., along the second direction 510) or down direction (i.e., opposite to the first direction) so that the secondary movable sub-carriage 504 is aligned with the stationary carriage 204. In case, the sorting location of an input item from the plurality of input items 208 is in line with the secondary movable sub-carriage 504 in the first operational state, the one or more controllers 220 are configured to operate the secondary movable sub-carriage 504 to transfer the corresponding input item in the corresponding sorting location.
In case, the sorting location of an input item is on a trolley positioned above the secondary movable sub-carriage 504 in the first operational state, the modular sorting machine 500 operates in the second operational state. At the second operational state (as shown in FIGs. 5D, 5E and 5F), the one or more controllers 220 are configured to operate the supporting rail 506 to move the movable carriage 502 along the reference axis 210 and to operate the movable carriage 502 to move the secondary movable sub-carriage 504 in the up direction, that is along the second direction 510 until the secondary movable sub-carriage reaches adjacent to the corresponding sorting location of the input item. After the secondary movable sub-carriage 504 reaches the corresponding sorting location, the one or more controllers 220 are configured to operate the secondary movable sub-carriage 504 to transfer the input item to the corresponding sorting location. In case, the sorting location of an input item is on a trolley positioned below the secondary movable sub-carriage 504 in the first operational state, the modular sorting machine 500 operates in the third operational state. At the third operational state (as shown in FIGs. 5D, 5E and 5F), the one or more controllers 220 are configured to operate the supporting rail 506 to move the movable carriage 502 along the reference axis 210 and to operate the movable carriage 502 to move the secondary movable sub-carriage 504 in the down direction, that is opposite to the second direction 510 until the secondary movable sub-carriage 504 reaches adjacent to the corresponding sorting location of the input item. After the secondary movable sub-carriage 504 reaches the corresponding sorting location, the one or more controllers 220 are configured to operate the secondary movable sub-carriage 504 to transfer the input item to the corresponding sorting location. The above operation of the modular sorting machine 500 is explained with a single secondary movable sub-carriage. However, the modular sorting machine 500 may include more than one secondary movable sub-carriage.
FIG 6 is a flowchart of a method for operating a modular sorting machine, in accordance with an embodiment of the present disclosure. With reference to FIG. 5, there is shown a method 600 for operating the modular sorting machine 200 (of FIG. 1). The method 600 includes steps from 602 to 610.
At step 602, the method 600 includes performing, by one or more controllers 220 (of FIG. 2B), data acquisition of a plurality of input items fed to one or more in-feed carriages of the modular sorting machine. Moreover, a delivery location of each input item is acquired during the data acquisition of the plurality of input items. In an implementation, the data acquisition performed by the one or more controllers 220 includes scanning barcode over each input item by a barcode scanner, measuring weight of each input item by a weight sensor and measuring dimensions of each input item.
At step 604, the method 600 includes identifying, by the one or more controllers 220, a sorting location for each input item based on the acquired delivery location of each input item. In an implementation, based on the data acquisition from the barcode attached over each input item, the one or more controllers 220 are configured to determine the sorting location of each input item based on the delivery location.
At step 606, the method includes instructing, by the one or more controllers 220, the one or more in-feed carriages 202 (of FIG. 2A) to move the plurality of input items 208 (of FIG. 2B) from the one or more in-feed carriages 202 to a target movable sub-carriage from a plurality of movable sub-carriages corresponding to the identified sorting location. After identifying the sorting location for each input item, the one or more controllers 220 are configured to transfer the input item to the stationary carriage 204 (of FIG. 2A) and further to the movable sub-carriage next to the stationary carriage 204, that is the first movable sub-carriage. Further, the one or more controllers 220 are configured to actuate the set of rollers of the first movable sub-carriage to transfer the input item from the first movable sub-carriage to the target movable sub-carriage. In order to move to the target movable sub-carriage, a real-time tracking of the input items is carried out as they move along the reference axis 210 along the plurality of movable sub-carriages. This involves incorporating sensors or tracking mechanisms to precisely monitor the position and movement of the items. The real-time data enables the sorting machine to make quick decisions and accurately direct each item to its designated target trolley.
At step 608, the method 600 includes instructing, by the one or more controllers 220, the corresponding movable sub-carriage to move a lateral distance in either left or right direction normal to the reference axis 210 based on the identified sorting location of each input item. Moreover, the reference axis 210 is defined normal to a direction of movement of the plurality of movable sub-carriages. During operation, the input item is transferred from the first movable sub-carriage to the target movable sub-carriage along the reference axis 210. After identifying the sorting location, the one or more controllers 220 are configured to actuate the first rotary actuator 216A of the lateral rails 216 to move the target movable sub-carriage in either left or right direction along the lateral rails 216 until the target movable sub-carriage is positioned near to the identified sorting location of the corresponding input item. The dynamic activation of target sub-carriages and lateral movement capability allows the modular sorting machine 200 and 300 to adapt its sorting strategy on-the-fly. It can adjust the sorting path or destination based on changing conditions or requirements, such as varying item sizes, different target trolley availability, or sorting priority changes. With real-time tracking and dynamic activation, the modular sorting machine 200 or 300 can maintain a higher throughput rate as compared to conventional systems with same size of machines. It can quickly process a continuous stream of items without unnecessary delays, leading to increased productivity and efficiency in the sorting operation.
At step 610, the method 600 includes depositing, by the one or more controllers 220, each input item into the identified sorting location. In operation, the one or more controllers 220 are configured to rotate the set of rollers in the target movable sub-carriage to drop the input item into the identified sorting location. The adaptive nature of the sorting process reduces the likelihood of jams or backlogs, where if one target trolley is temporarily unavailable or full, the machine can redirect the item to an alternative target in a same zone, avoiding potential bottlenecks and ensuring smooth operation.
In accordance with an embodiment, the method further includes causing, by the one or more controllers 220, a plurality of sensors to detect a presence of each input item in the identified sorting location. Moreover, the plurality of sensors includes at least one of a weight sensor, a proximity sensor, and an image sensor. Examples of the weight sensor may include, but are not limited to, a strain gauge, a capacitance-based weight sensor, a hydraulic weight sensor, a pneumatic weight sensor and the like. Examples of the proximity sensors may include, but are not limited to inductive sensor, capacitive sensor, ultrasonic sensor, photoelectric sensor, and the like. Examples of image sensor may include, but are not limited to camera, infrared sensor, charge coupled device (CCD) sensor, complementary metal oxide semiconductor (CMOS) sensor and the like.
In accordance with an embodiment, the method 500 further includes updating, by the one or more controllers 220, the sorting completion status 234 of each input item in the database 232. Moreover, the sorting completion status 234 of each input item is indicative of a successful deposition of each input item in the identified sorting location. The updating of the sorting completion status enables the one or more controllers to track progress of sorting and determine sorting efficiency (no. of input items sorted in unit time) of the modular sorting machine 200 or 300.
The modular sorting machine 200 or 300 provided in the method 600 includes multiple carriages, such as the one or more in-feed carriages 202, the stationary carriage 204, and the movable carriage 206, which are separate modules and are detachably attached with each other. The modular design of the machine 200 or 300 provided in the method 600 makes it easy to scale up or down as needed. For example, if the volume of input items increases, more in-feed carriages and movable carriages can be added to the machine 200 or 300. The use of the plurality of movable sub-carriages within the movable carriage 206 introduces a modular approach to the design. Each sub-carriage can function as an independent unit that contributes to the overall operation of the modular sorting machine 200 or 300 provided in the method 600. The lateral movement of each movable sub-carriage in either left or right direction, perpendicular to the reference axis, enables precise sorting of items. This technical advancement allows the modular sorting machine 200 or 300 provided in the method 600 to reposition and rearrange items with high accuracy, leading to efficient sorting operations and reducing the chances of errors. In another example, the ability of the movable sub-carriages to move laterally provides the machine with greater flexibility in its sorting strategies. It can adapt to varying sorting requirements and accommodate changes in the sorting process as needed. This technical advancement enhances the versatility and adaptability of the modular sorting machine 200 or 300 provided in the method 600. Furthermore, the lateral movements of the sub-carriages do not interfere with the primary direction of movement along the reference axis until an item reaches to a target sub-carriage. As a result, the sorting machine can operate efficiently even in limited floor space, maximizing its utility in diverse environments. The modular sorting machine 200 or 300 provided in the method 600 does not require long continuous conveyor belt for movement of input items like the conventional sorting machines, which eliminates the problems related jamming of conveyor belt, thereby increasing productivity while sorting.
The steps 602 to 610 are only illustrative and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein. Various embodiments and variants disclosed with the aforementioned machine (such as the modular sorting machine 200) apply mutatis mutandis to the aforementioned method 600.
Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure. , Claims:1. A modular sorting machine (200, 300) comprising:
one or more in-feed carriages (202, 302A, 302B) configured to perform data acquisition of a plurality of input items (208);
a stationary carriage (204, 304) fixedly connected to the one or more in-feed carriages (202, 302A, 302B) and configured to receive the plurality of input items (208) from the one or more in-feed carriages (202, 302A, 302B); and
a movable carriage (206, 306, 308) movably connected to the stationary carriage (204, 304) and configured to receive the plurality of input items (208) from the stationary carriage (204, 304) and transport the plurality of input items (208) from one location to another in a first direction along a reference axis (210),
wherein the movable carriage (206, 306, 308) comprises a plurality of movable sub-carriages,
wherein, in a rest state, each movable sub-carriage of the plurality of movable sub-carriages is configured to rest at a predefined location along the reference axis (210) to form a unitary carriage arrangement,
wherein, in an activated state, each movable sub-carriage of the plurality of movable sub-carriages is configured to move laterally in either left or right direction normal to the reference axis (210), and wherein the reference axis (210) is defined normal to a direction of movement of the plurality of movable sub-carriages.

2. The modular sorting machine (200, 300, 500) as claimed in claim 1, wherein each movable sub-carriage comprises a set of rollers and a belt looped around the set of rollers such that the belt is driven by the set of rollers along the reference axis (210) to transport the plurality of input items (208) from one location to another in the first direction along the reference axis (210) using the belt and the set of rollers.

3. The modular sorting machine (200, 300, 500) as claimed in claim 2, wherein in the rest state, although each movable sub-carriage of the plurality of movable sub-carriages is configured to rest at its corresponding predefined location to form the unitary carriage arrangement, one or more input items of the plurality of input items (208) moves in the first direction from a first movable sub-carriage (206A) to a corresponding target movable sub-carriage using the set of rollers along the first direction and upon reaching the corresponding target movable sub-carriage, the corresponding target movable sub-carriage becomes activated to move laterally in either the left or right direction normal to the reference axis (210) for dropping corresponding input item in a target trolley.

4. The modular sorting machine (200, 300, 500) as claimed in claim 1, wherein in order to perform the data acquisition of the plurality of input items (208), the one or more in-feed carriages (202, 302A, 302B) are configured to scan a barcode and measure a weight and dimensions of the plurality of input items (208).

5. The modular sorting machine (200, 300, 500) as claimed in claim 1, further comprising a plurality of trolleys (216, 508), wherein each trolley of the plurality of trolleys (216, 508) comprises a plurality of sorting locations (214, 310), and each trolley is configured to receive one or more sorted input items at the corresponding sorting location.

6. The modular sorting machine (200, 300, 500) as claimed in claim 1, further comprising a plurality of position sensors disposed proximate to each trolley to identify a predefined position of each trolley and detect overhanging of each input item over the plurality of trolleys (216, 508).

7. The modular sorting machine (200, 300, 500) as claimed in claim 1, further comprising an exception handling component configured to identify one or more ineligible input items from the plurality of input items (208) that meet ineligibility criteria.

8. The modular sorting machine (200, 300, 500) as claimed in claim 1, further comprising one or more controllers (220) configured to:
obtain a delivery location of each input item during the data acquisition of the plurality of input items (208);
identify a sorting location from a plurality of sorting locations (214) for each input item based on the obtained delivery location of each input item;
cause each input item to reach a movable sub-carriage from the plurality of movable sub-carriages corresponding to the identified sorting location of each input item; and
instruct the corresponding movable sub-carriage to move a lateral distance in either left or right direction normal to the reference axis (210) based on the identified sorting location of each input item to sort each input item in the identified sorting location.

9. The modular sorting machine (200, 300, 500) as claimed in claim 1, wherein in the activated state, the plurality of movable sub-carriages in the movable carriage are configured to move either up or down direction normal to the reference axis (210).

10. A method (600) for operating a modular sorting machine (200, 300, 500), the method (600) comprising:
performing, by one or more controllers (220), data acquisition of a plurality of input items (208) fed to one or more in-feed carriages of the modular sorting machine (200, 300), wherein a delivery location of each input item is acquired during the data acquisition of the plurality of input items (208);
identifying, by the one or more controllers (220), a sorting location for each input item based on the acquired delivery location of each input item.
instructing, by the one or more controllers (220), the one or more in-feed carriages to move the plurality of input items (208) from the one or more in-feed carriages (202, 302A, 302B) to a target movable sub-carriage (206B) from a plurality of movable sub-carriages corresponding to the identified sorting location;
instructing, by the one or more controllers (220), the corresponding target movable sub-carriage (206B) to move a lateral distance in either left or right direction normal to a reference axis (210) based on the identified sorting location of each input item, wherein the reference axis (210) is defined normal to a direction of movement of the plurality of movable sub-carriages; and
depositing, by the one or more controllers (220), each input item into the identified sorting location.

11. The method (600) as claimed in claim 8, further comprising causing, by the one or more controllers (220), a plurality of sensors to detect a presence of each input item in the identified sorting location, wherein the plurality of sensors comprises at least one of a weight sensor, a proximity sensor, and an image sensor.

12. The method (600) as claimed in claim 8, further comprising updating, by the one or more controllers (220), a sorting completion status (234) of each input item in a database (232), wherein the sorting completion status (234) of each input item is indicative of a successful deposition of each input item in the identified sorting location.