Description:INTEGRATED PARCEL SORTING SYSTEM AND PROCESS WITH REAL-TIME VALIDATION AND INTELLIGENT SORTING

FIELD OF THE INVENTION
The present invention relates in general to a system and process for automated parcel sorting and logistics management. More particularly, the present invention pertains to a system and process for automated processing parcels of varying sizes and types using barcode scanning, weight measurement, real-time data validation, and intelligent sorting with integrated anomaly detection.

TECHNICAL BACKGROUND AND PRIOR ART
Traditional parcel sorting systems suffer from inefficiencies such as mis-sorting errors, labour-intensive manual handling, and inadequate real-time tracking capabilities. These shortcomings lead to operational delays, increased costs, and reduced reliability in parcel delivery networks. Existing solutions often fail to address the diverse needs of sorting large parcels, small parcels/bags, and loose parcels while ensuring accuracy and scalability.
Accordingly, there exists a need for an advanced, automated sorting system that enhances accuracy, minimizes errors, and optimizes workflow through integrated technology and real-time monitoring. The present invention meets this need by providing a system and process for automated processing parcels of varying sizes and types using barcode scanning, weight measurement, real-time data validation, and intelligent sorting with integrated anomaly detection.

OBJECTIVES OF THE INVENTION
The principal objective of the present invention is to provide a system and process for automated processing parcels of varying sizes and types using barcode scanning, weight measurement, real-time data validation, and intelligent sorting with integrated anomaly detection.
It is yet another objective of the present invention to provide a system and process for ensuring an advanced, automated sorting system that enhances accuracy, minimizes errors, and optimizes workflow through integrated technology and real-time monitoring.
How the foregoing objectives are achieved will be clear from the following description. In this context it is clarified that the description provided is non-limiting and is only by way of explanation.

SUMMARY OF THE INVENTION
Accordingly, the present invention provides an integrated parcel sorting system for Real-Time validation and intelligent sorting comprising a put to light (PTL) system, operatively connected to a central processing unit for real time data processing and synchronization with the PTL system and to a hand held PC equipped with in built bar code scanner and software for bag and parcel scanning during coding process, the PC is connected to a weighing machine for receiving parcel weight data and the PTL is equipped with a control panel with programmable logic controller for controlling bin light indicators atop the plurality of parcel receiving bins and for automation and said PTL is also equipped with LCD displays for showing destination hub abbreviation, pin code, parcel category, parcel count and weight.
The present invention also provides a parcel sorting process applying the foregoing integrated parcel sorting system comprising the following steps:
a) arriving of parcels in cage trolleys and categorizing as small Parcels in Bags, loose parcels and large parcels, transferring small parcels to the bag opening and coding station, processing loose parcels individually from bulk mailers and affixing bag labels on large parcels followed by moving to a separate cage trolley,
b) removing bag label and handing over to the Coding Station Operator (CSO), dumping parcels onto bag opening table, logging on to the hand held PC by CSO and selecting “Scan Bag Label” from the main menu and scanning the label and in the event of failing to scan label, CSO manually entering the barcode, printing a replacement via the mini barcode printer, and proceeding,
c) CSO picking a parcel, placing it on the weighing scale, and capturing weight and barcode data automatically via hand held PC, in the event of barcode being unreadable removing the parcel by CSO and entering the barcode manually, printing a new label, affixing it and rescanning followed by fetching of bag manifest and parcel details from the central server by hand held PC, using the barcode,
d) in the event of parcel data being unavailable, the HPC flagging it as a "SHORT PARCEL" and notifying the supervisor, in the event of pin code data missing, flagging it as “NO PIN CODE DATA” for report analysis and then CSO entering the destination pin code, validating against central server data, by checking “Match” pop up or “Not Match, Check the Parcel” pop up for rechecking, CSO selecting parcel category, validating against barcode prefix, upon validation, CSO selecting “Continue to Next Parcel” storing data in the database, the hand held PC in that event suggesting a pre-sort package trolly mapped to a frame group via a web-based sort plan configured by the supervisor, thereafter CSO placing the parcel on the suggested trolley,
e) Sorting Operator (SO) picking a parcel from the trolley being moved to the PTL system and scanning its barcode using the ring scanner, validation of the pin code by the system against the sort plan, activating a green light on the assigned bin and its column’s tower lamp, assigning bins to a pin code for air, surface or express parcels, placing the parcel in the glowing bin by SO, so that green light turns off to certify correct placement and in the event of placement in a wrong bin, persisting of green light of the correct bin, blinking of red light of the wrong bin, the tower lamp turning red, and consequential sounding of an until corrected and logging of Mis-sorts, halting of scanning until the mis-sort is resolved, tracking of parcel count by PTL and cumulative weight per bin, displaying on the bin’s LCD (destination hub abbreviation, hub type, pin code, parcel type, count and cumulative weight) such that at desired threshold cumulative weight, the tower lamp flashes red, an alarm sounds, and the bin locks to prevent exceeding preset threshold,
f) SO pressing the red button on the bin to initiate closure, generating and printing a bag label (sticker) and manifest (A4 sheet) by the system, removing the full bag inserting the manifest, affixing the label affixed, and tying the bag followed by placing the bag on a cage trolley and moving to the staging area and in the event of failing of printing, resolving the issue by SO and repressing the red button and in the event of a new bag being placed without printing, SO scanning the bin’s barcode to reprint.
Preferably, the process involves loose parcel processing comprising selecting “Loose Parcel” from the hand held PC menu, auto filling the bag label as “loose parcel” and following the steps in b) to f).
More preferably, the process involves undertaking category validation by CSO and selecting “Print Bag Label”, affixing on “Large Parcel” and following steps in b) to f).
Even more preferably, the desired threshold cumulative weight is 18Kg and the preset threshold is 20Kg.
The process also involves transferring all PTL bag wise manifest data to the central server/Central Processing Unit and retrieving for tracking inward bag manifests including bag labels, parcel barcodes and details and wherein the supervisor generates all related reports using provided web application.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The nature and scope of the present invention will be better understood from the accompanying drawings, which are by way of illustration of a preferred embodiment and not by way of any sort of limitation. In the accompanying drawings: -
Figures 1a, 1b and 1c show different views of the coding station.
Figures 2a, 2b and 2c represent different views of the PTL system according to the present invention.
Figures 3a, 3b and 3c represent different views of the coding station and PTL system operatively connected.
Figure 4 is a flow chart of the overall process.
Figure 5 is a flow chart of the loose parcel processing.
Figure 6 is a flow chart of the large parcel processing.
Figure 7 is a detailed flow chart of the process.

DETAILED DESCRIPTION OF THE INVENTION
Having described the main features of the invention above, a brief and non-limiting description of a preferred embodiment will be given in the following paragraphs with reference to the accompanying drawings.
The shape, size and number of the devices shown are by way of example only and it is within the scope of the present invention to change their shape, size and number without departing from the basic principle of the invention.
All through the specification, the technical terms and abbreviations are to be interpreted in the broadest sense of the respective terms and include all similar items in the field known by other terms, as may be clear to persons skilled in art. Restriction or limitation if any referred to in the specification, is solely by way of example and understanding the present invention.
First the present invention is described briefly. The present invention provides an integrated parcel sorting system designed to process parcels with various dimensions ranging and weights. The system comprises a central processing unit (CPU), a handheld PC (HPC) with an inbuilt barcode scanner, a ring scanner, a weighing scale, a programmable logic controller (PLC), and a intelligent sorting mechanism wirelessly connected.
This invention enables automated parcel categorization, real-time validation of parcel data, mis-sorting prevention through bin-specific indicators and alarms, and streamlined bag closing with manifest generation. It is scalable through a multi-frame sorting configuration and ensures secure and efficient handling of parcels of varying sizes and types.
Now the present invention is described with reference to the accompanying drawings.
As stated before, the present system integrates hardware, software, and process workflows to achieve efficient parcel sorting.
Figures 1a, 1b, 1c are different views of the coding station. The diagrams are self-explanatory.
In figures 1a, 1b and 1c the reference numerals used to identify the features are indicated below:
Reference numeral Feature
1 Cage Trolley
2 Bag Opening Table
3 Weighing Machine
4 Hand held PC
5 Adjustable hand held PC stand
6 Weighing Machine Frame
7 Barcode Printer
8 Package trolley
The PTL system according to the present invention is detailed in figures 2a, 2b and 2c which are self-explanatory.
In figures 2a. 2b and 2c the reference numerals used to identify the features are indicated below.
Reference numeral Feature
9 Manifest Printer
10 Bag label Printer
11 Foldable Platform
12 Aluminium Frame
13 Wheel with Brake
14 Green LED
15 Red LED
16 LCD display
17 Tower Lamp
18 Control Panel with PLC
19 Mis Sort Sensor

Frame Description
1. Min No of Bins – 3(R)x3(C) – 9 Bins
2. Max No of Bins – 3(R)x7(C) – 21 Bins
3. Bin Opening Size – 460mm x 460mm and 600mm x 600mm.
4. Frame material – Aluminium anodized frame.
The No of Bins and Bin Sizes are Customizable as per site requirements.
The layout of the coding station and the PTL system operatively connected is shown in figures 3a, 3b, 3c respectively.
1. Each PTL Frame has 21 bins.
2. Frames facing each other (at a gap of 2.2 m) are denoted as FRAME GROUP – this has 42 Bins. The Number of Coding stations, Bins and Frame Groups are Configurable as per site requirements.

Referring to all the foregoing figures, the system components are now described.
Central Processing Unit (CPU): A high-performance i7 CPU hosting API services and a database for real-time data processing and synchronization with the PTL system.
Handheld PC (HPC): Equipped with inbuilt barcode scanner and application software for bag and parcel scanning during coding process.
Ring Scanner: Worn by the Sorting Operator (SO) for hands-free barcode scanning during PTL sorting, enabling two-handed parcel handling.
Weighing Scale: Captures parcel weight and transmits data to the HPC for validation.
Programmable Logic Controller (PLC): PLC controlling bin light indicators, tower lamps, and automation processes.
21-Bin Aluminium Anodized Wheel-Mounted Frame: A modular structure with 21 bins per frame, expandable to multiple frame groups per sorting location.
Tower Lamp: Mounted atop each bin column, glowing green to indicate the correct bin or red to signal errors or weight limits.
Sensors: Multiple sensors mounted on each bin to identify the mis-sort activities.
LCD Displays in PTL: 2-line LCD displays showing destination hub abbreviation, hub type (L1 or L2), pin code, parcel type (surface, air, express), parcel count, and cumulative weight.
Bag Label Printer: Prints bag labels for sorted bags.
Manifest Printer: Prints A4 manifests detailing bag contents.
Mini Barcode Printer: Generates 1D/2D replacement barcodes for unreadable labels.
So, the integrated parcel sorting system for Real-Time validation and intelligent sorting comprises a put to light (PTL) system, operatively connected to a central processing unit (CPU) for real time data processing and synchronization with the PTL system and to a hand held PC (4) equipped with in built bar code scanner and software for bag and parcel scanning during coding process.
The PC is connected to a weighing machine (3) for receiving parcel weight data and the PTL is equipped with a control panel with programmable logic controller (18) for controlling bin light indicators atop the plurality of parcel receiving bins and for automation.
The PTL is also equipped with LCD displays (16) for showing destination hub abbreviation, pin code, parcel category, parcel count and weight.
The system is connected to a ring scanner worn by sorting operator for hands free barcode scanning during PTL sorting and transferring the data to the central processing unit.
The weighing machine captures parcel weight and transmits to the PC and there is a tower lamp (17) atop each bin column glowing green to indicate the correct bin or red to signal errors or weight limits and multiple sensors (19) are mounted on each bin to identify the mis-sort activities. The PTL system is equipped with bag label printer (10), manifest printer (9) and mini barcode printer.
Referring to figures 1a, 1b and 1c again the coding station is a part of the integrated parcel system comprising of at least one caging trolley (1), and at least one bag opening table (2) adjacent to said trolley, a weighing machine (3) adjacent to said table and a hand held PC (4) atop said weighing machine resting on the weighing machine frame (6). At least a barcode printer (7) is located at the bottom portion of the frame while at least a package trolley (8) is located adjacent to the frame.
Now the process is described elaborately with reference to figures 4, 5, 6 and 7.
Bag Arrival - Cage Trolley:
Referring to figure 4, parcels arrive in cage trolleys and are categorized as: a) Small Parcels in Bags: Transferred to the bag opening and coding station. b) Loose Parcels: Processed individually from bulk mailers. c) Large Parcels: Bag labels affixed and moved to a separate cage trolley.
Bag Opening and Coding:
a) Bag Opening:
• Bag label is removed and handed to the Coding Station Operator (CSO).
• Parcels are dumped onto the bag opening table.
• CSO logs into the HPC, selects "Scan Bag Label" from the main menu, and scans the label.
• If the label fails to scan, CSO manually enters the barcode, prints a replacement via the mini barcode printer, and proceeds.
b) Parcel Scan:
• CSO picks a parcel, places it on the weighing scale, and captures weight and barcode data automatically via HPC.
• If the barcode is unreadable, CSO removes the parcel, enters the barcode manually, prints a new label, affixes it, and rescans.
• HPC fetches bag manifest and parcel details from the central server using the barcode.
Error Handling:
• If parcel data is unavailable, the HPC flags it as a "SHORT PARCEL" and notifies the supervisor.
• If pin code data is missing, it is flagged as "NO PINCODE DATA" for report analysis.
• CSO enters the destination pin code, validated against central data.
• If matched, a "MATCH" popup appears.
• If unmatched, a “NOT MATCH. CHECK THE PARCEL” popup prompts rechecking.
• CSO selects parcel category, validated against barcode prefix.
• Upon validation, CSO selects "Continue to Next Parcel," storing data in the database. The HPC suggests a pre-sort package trolley mapped to a frame group via a web-based sort plan configured by the supervisor.
• CSO places the parcel on the suggested trolley.
Pre-Sorting and Trolley Movement:
After coding, the pre-sort package trolley is moved to the PTL section’s frame group.
Sorting at PTL:
• Sorting Operator (SO) picks a parcel from the trolley and scans its barcode using the ring scanner.
• The system validates the pin code against the sort plan, activating a green light on the assigned bin and its column’s tower lamp.
• Multiple bins may be assigned to a pin code for air, surface or express parcels.
• SO places the parcel in the glowing bin.
• Green light turns off upon correct placement.
• If placed in the wrong bin, the correct bin’s green light persists, the wrong bin’s red light blinks, the tower lamp turns red, and an alarm sounds until corrected. Mis-sorts are logged.
• Scanning is halted until the mis-sort is resolved.
• The PTL tracks parcel count and cumulative weight per bin, displayed on the bin’s LCD (destination hub abbreviation, hub type, pin code, parcel type, count and cumulative weight).
• At 18 kg cumulative weight, the tower lamp flashes red, an alarm sounds, and the bin locks to prevent exceeding 20 kg.
Bag Closing:
• SO presses the red button on the bin to initiate closure.
• The system generates and prints a bag label (sticker) and manifest (A4 sheet).
• The full bag is removed, the manifest inserted, the label affixed, and the bag tied.
• The bag is placed on a cage trolley and moved to the staging area.
• If printing fails, SO resolves the issue and represses the red button. If a new bag is placed without printing, SO scans the bin’s barcode to reprint.
Loose Parcel Processing is described with reference to figure 5 in particular. CSO selects "Loose Parcel" from the HPC menu, auto-filling the bag label as "Loose Parcel."
The process follows the standard coding and sorting steps mentioned above, similar to small parcel handling.
Large parcel processing is described with reference to figure 6 in particular. Large parcels bear both bag and parcel labels.
CSO selects "Large Parcel" from the HPC menu, scans the bag label, and follows the coding process.
After category validation, CSO selects "Print Bag Label," affixes it to the parcel, and processes all large parcels before printing the manifest.
Data Synchronization:
To Server: All PTL manifest details (bag-wise) are transmitted to the central server. Anytime the supervisor can generate the all the related reports using provided web application.
From Server: Inward bag manifests, including bag labels, parcel barcodes, and details, are retrieved for tracking.
The overall process flow chart is shown in figure 7 which should be clear when construed with reference to the foregoing description. It is also possible according to the process of the present invention to handle unreadable barcodes by manually entering data and printing replacement labels.

Following are the non-limiting advantages of the present invention as it would be clear from the foregoing.
• Enhances PTL system reliability with intelligent surveillance.
• Reduces dependency on manual supervision.
• Detects and predicts operational anomalies proactively.
• Provides tamper-proof visual evidence for auditing and disciplinary action.
• Enables compliance enforcement with minimal human intervention.
From the foregoing description and the appended claims it would be clear that all the objectives of the present invention have been met.

The present invention has been described with reference to some drawings and a preferred embodiment purely for the sake of understanding and not by way of any limitation and the present invention includes all legitimate developments within the scope of what has been described herein before and claimed in the appended claims.
, Claims:We claim:

1. An integrated parcel sorting system for Real-Time validation and intelligent sorting comprising a put to light (PTL) system, operatively connected to a central processing unit (CPU) for real time data processing and synchronization with the PTL system and to a hand held PC (4) equipped with in built bar code scanner and software for bag and parcel scanning during coding process, the PC is connected to a weighing machine (3) for receiving parcel weight data and the PTL is equipped with a control panel with programmable logic controller (18) for controlling bin light indicators atop the plurality of parcel receiving bins and for automation and said PTL is also equipped with LCD displays (16) for showing destination hub abbreviation, pin code, parcel category, parcel count and weight.

2. The integrated parcel sorting system as claimed in claim 1, wherein system is connected to a ring scanner worn by sorting operator for hands free barcode scanning during PTL sorting and transferring the data to the central processing unit.

3. The integrated parcel sorting system as claimed in claim 1, wherein the weighing machine captures parcel weight and transmits to the PC and there is a tower lamp (17) atop each bin column glowing green to indicate the correct bin or red to signal errors or weight limits and multiple sensors (19) are mounted on each bin to identify the mis-sort activities and wherein the PTL system is equipped with bag label printer (10), manifest printer (9) and mini barcode printer.

4. The integrated parcel sorting system as claimed in claim 1, wherein the coding station is a part of the integrated parcel system comprising of at least one caging trolley (1), and at least one bag opening table (2) adjacent to said trolley, a weighing machine (3) adjacent to said table and a hand held PC (4) atop said weighing machine resting on the weighing machine frame (6) and at least a barcode printer (7) is located at the bottom portion of said frame while at least a package trolley(8) is located adjacent to said frame.

5. Parcel sorting process applying the integrated parcel sorting system as claimed in any one of the claims 1 to 4 comprising the following steps:
a) arriving of parcels in cage trolleys and categorizing as small Parcels in Bags, loose parcels and large parcels, transferring small parcels to the bag opening and coding station, processing loose parcels individually from bulk mailers and affixing bag labels on large parcels followed by moving to a separate cage trolley,
b) removing bag label and handing over to the Coding Station Operator (CSO), dumping parcels onto bag opening table, logging on to the hand held PC by CSO and selecting “Scan Bag Label” from the main menu and scanning the label and in the event of failing to scan label, CSO manually entering the barcode, printing a replacement via the mini barcode printer, and proceeding,
c) CSO picking a parcel, placing it on the weighing scale, and capturing weight and barcode data automatically via hand held PC, in the event of barcode being unreadable removing the parcel by CSO and entering the barcode manually, printing a new label, affixing it and rescanning followed by fetching of bag manifest and parcel details from the central server by hand held PC, using the barcode,
d) in the event of parcel data being unavailable, the HPC flagging it as a "SHORT PARCEL" and notifying the supervisor, in the event of pin code data missing, flagging it as “NO PIN CODE DATA” for report analysis and then CSO entering the destination pin code, validating against central server data, by checking “Match” pop up or “Not Match, Check the Parcel” pop up for rechecking, CSO selecting parcel category, validating against barcode prefix, upon validation, CSO selecting “Continue to Next Parcel” storing data in the database, the hand held PC in that event suggesting a pre-sort package trolly mapped to a frame group via a web-based sort plan configured by the supervisor, thereafter CSO placing the parcel on the suggested trolley,
e) Sorting Operator (SO) picking a parcel from the trolley being moved to the PTL system and scanning its barcode using the ring scanner, validation of the pin code by the system against the sort plan, activating a green light on the assigned bin and its column’s tower lamp, assigning bins to a pin code for air, surface or express parcels, placing the parcel in the glowing bin by SO, so that green light turns off to certify correct placement and in the event of placement in a wrong bin, persisting of green light of the correct bin, blinking of red light of the wrong bin, the tower lamp turning red, and consequential sounding of an until corrected and logging of Mis-sorts, halting of scanning until the mis-sort is resolved, tracking of parcel count by PTL and cumulative weight per bin, displaying on the bin’s LCD (destination hub abbreviation, hub type, pin code, parcel type, count and cumulative weight) such that at desired threshold cumulative weight, the tower lamp flashes red, an alarm sounds, and the bin locks to prevent exceeding preset threshold,
f) SO pressing the red button on the bin to initiate closure, generating and printing a bag label (sticker) and manifest (A4 sheet) by the system, removing the full bag inserting the manifest, affixing the label affixed, and tying the bag followed by placing the bag on a cage trolley and moving to the staging area and in the event of failing of printing, resolving the issue by SO and repressing the red button and in the event of a new bag being placed without printing, SO scanning the bin’s barcode to reprint.

6. The process as claimed in claim 5, wherein it involves loose parcel processing comprising selecting “Loose Parcel” from the hand held PC menu, auto filling the bag label as “loose parcel” and following the steps in b) to f).

7. The process as claimed in claim 5, wherein it involves undertaking category validation by CSO and selecting “Print Bag Label”, affixing on “Large Parcel” and following steps in b) to f).

8. The process as claimed in any one of claims 5 to 7, wherein in step f) the desired threshold cumulative weight is 18Kg and the preset threshold is 20Kg.

9. The process as claimed in any one of the claims 5 to 8 comprising transferring all PTL bag wise manifest data to the central server/Central Processing Unit and retrieving for tracking inward bag manifests including bag labels, parcel barcodes and details and wherein the supervisor generates all related reports using provided web application.

Dated this 29th day of July, 2025

(SUBHASISH GHOSH)
IN/PA – 212
Applicants’ Agent
for seenergi IPR