DESC:TITLE: PARCEL SORTING SYSTEM
FIELD OF THE INVENTION
The present invention relates to parcel sorting technology and more particularly it relates to a parcel sorting system for multiple locations for a warehouse.
BACKGROUND OF THE INVENTION
In the conventional parcel distribution system, the parcels were handled manually with a powered conveyor and sorted by hand. It was very difficult to handle a large number of parcels per day to meet the due lines and to maintain its day-to-day operations efficiently with the conventional method. Further, handling parcels in the peak periods such as Diwali, and Christmas is very difficult with the manual parcel sorting process.
The growth of parcel distribution centers is increasing drastically. Many logistic companies reshape their operation to handle the increasing number of parcels and to maintain an efficient and high-speed operation. One efficient way to handle the load of parcels is to sort them automatically with high speed and without human intervention to avoid any error. Hence there is a need of a working environment that provides a comfortable, full automated parcel sorting system that requires less or no physical human effort.
Further, due to online shopping, the shipments pick up and drop destinations are increasing. The destinations are urban as well as rural. So, to sort these parcels for multiple locations manually is a tedious as well as time-consuming job. During manual sorting for a large number of locations, there are chances of errors. Hence, there is a need of an effective and accurate parcel shorting system for multiple destinations/ categories as per users’ or warehouse management requirements.
The existing DWS parcel sorting systems sort the parcels for fewer categories. Parcel sorting for multiple of ‘n’ number of categories is not available. Also, if any fault or error occurs during the parcel sorting process, the machine operation stops, and the technician has to handle the repairing of the machine. This affects the throughput and overall target of the workload of the warehouse. Hence, there is a need for a system that can handle DWS sorting machine faults/ errors and continues the operation without any interrupts.
OBJECTS OF THE INVENTION
One of the object of the present invention is to optimize the parcel handling process with less reliance on manual intervention.
Another object of the present invention is to improve the parcel sorting rate and cut down on delivery time.
Another object of the present invention is to provide a parcel sorting system which is capable for auto fault/ error handling.
Yet another object of the present invention is to increase dispatch accuracy, reliability and speed.
Yet another object of the present invention is labor reduction.
Yet another object of the present invention is to handle parcels in a variety of different sizes and shapes.
Yet another object of the present invention is to capture parcels' required data (dimension, weight & scanning) and prevent revenue leakage.
Yet another object of the present invention is to streamline and fasten the sortation process.
Yet another object of the present invention is to effectively sort parcels based on the captured barcode information.
Yet another object of the present invention is to reduce human intervention.

BRIEF DESCRIPTION OF THE DRAWINGS
The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figure 1 illustrates a block diagram depicting a parcel sorting system, in accordance with the present invention;
Figure 2 illustrates a parcel sorting system, in accordance with the present invention;
Figure 3 (a, b) illustrates a two-way parcel sorting system in accordance with the present invention;
Figure 4 (a, b) illustrates a four-way parcel sorting system, in accordance with the present invention;
Figure 5 (a, b) illustrates an eight-way parcel sorting system, in accordance with the present invention;
Figure 6 (a, b) illustrates a sixteen-way parcel sorting system, in accordance with the present invention;
Figure 7 (a, b) illustrates further a parcel sorting system, in accordance with the present invention;
Figure 8 illustrates the N-way parcel sorting system, in accordance with the present invention.
Figure 9 shows the parcel sorting process, in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION
Disclosed is a parcel sorting system (hereinafter “The system (100)”) used in warehouses or logistic domains. Figure 1 shows a block diagram of the parcel sorting system in accordance with the present invention. The system (100) comprises a DWS (Dimension Weighing Scanning) unit (A), a conveyor unit, and a parcel collecting unit operably connected to each other.
The DWS unit includes a mainframe, a control/PLC unit, a camera to take real time pictures of the received parcel, a VMS for measuring volume, one dimensional and two-dimensional barcode scanner, a plurality of loading conveyors adapted with a static check weigher to capture the weight of the parcels, a Human Machine Interface, a DWS system server that communicates with a customer servers and an ethernet switch to connects all the DWS system components internally and with PLC module; wherein, the DWS system server receives the dimensions, weight, barcode and image of the parcel, saves the information at the database and communicate it host. Parcel sorting process executes at server end for multiple categories. The control unit is configured with a parcel sorting application. A customer ERP is installed at the customer end. The parcel sorting application communicates with the customer ERP via a web server.
The Programmable Logic Control (PLC) module acts as a central controlling unit of the DWS system (20). The PLC module (90) is configured to control the conveyor operation, trigger the Volumetric Measurement System (VMS) (60) and trigger the weighing unit (80), generate alarms, and display it on the Human Machine Interface (HMI) (70). The Human Machine Interface (70) is an interactive surface of the system (100). HMI provides operative command access to the user such as Start, Stop, Reset. The HMI (70) provides an interactive interface for parcel sorting application (30) and displays information such as the predefined alarms saved in the database. It also shows the system rectification message upon pressing the popped-up alarm, thus it makes the system capable of auto error rectification and easily troubleshoot. The HMI unit (70) calculates the length, width, height, and volume of the parcel and sends it to the parcel sorting application (30). The Weighing unit (80) calculates the weight of the parcel and sends it to the parcel sorting application (30). The camera (40) captures the real-time image of the parcel upon receiving the trigger from parcel sorting application (30) and sends the captured image to the parcel sorting application (30). The Barcode scanner (50) scans the barcode of the parcel and sends barcode data to the parcel sorting application (30). The barcode on the parcel has to keep within the range of the scanner so that scanner can capture it. The barcode provides the parcel shipment specification that includes customer details, source details, and destination address. The system server in communication with the host server shares the real-time captured information of the received parcel.
In the preferred embodiment of the invention, the VMS (60) provides the volumetric measurement to the DWS system server. The VMS and weighing unit measure the L X B X H of the parcel if it is in the specified range. If the dimensions and weight of the parcel are not within the specified limits, the loading conveyor stops processing the parcel further or transfers it to the discarded parcel collecting bin, according to user instructions.
The conveyor unit includes a plurality of load carrier belt conveyors that rotate in opposite directions such as on the left and right. The number of load carrier belt conveyors is depend upon the user requirement or categories/destinations. The length and width of the carrier belt conveyor are approximately double the maximum length and width set for a parcel sorting system.
The parcel collecting unit includes a plurality of parcel collecting/ receiving bins. Each bin includes an acknowledgment sensor to acknowledge the receipt of the parcel and a level sensor to indicate the parcel level. The number of parcel collecting bins for a sorting system depends upon the user’s requirements or categories/destinations. Further, the parcel collecting bin includes a level sensor to indicate the bin fill level. The level sensor is connected with the control and processing unit. The alert system of the application invokes a notification alert to the user display when the parcel collecting bin is nearly filled for immediate replacement.
The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in brackets in the following description.
Figure 2 illustrates a parcel sorting system in accordance with the present invention. The mainframe of the DWS unit includes a camera, a control unit, a computing device, and a barcode scanner mounted on it. The mainframe is positioned on the conveyor unit in such a way that the parcel on the conveyor is exposed in the range of the scanner and the camera. The parcel collecting bins are aligned with the loading conveyors to collect the parcels shoot out from the conveyors. Preferably, the conveyor is a static weigher with a scanner having a load capacity up to 30 kg and 60mpm±10% speed. The conveyor is ON as long as it transfers the product onto the next conveyor. The conveyor gets automatically OFF if no parcel is detected. This helps in saving power. The barcode scanner scans one-dimensional as well as two-dimensional codes with approximately 90 codes per second and 3072*2048 resolution. The control unit is connected to the computing device through a switching device. Preferably, the switching device is a relay that isolates or changes the state of the control unit from one state to another. The computing device is a computing and interfacing device electrically coupled with a data converter. The data converter is an analog to digital converter that converts the sensors’ analog output signals into a digital data format and directs to the computing device for further processing. Specifically, the computing device is any one of the devices selected from a computer, tablet and like. The computing device comprises an input/output unit, a processing unit and a memory unit. The memory unit receives and stores the data from the sensors, user requirement details and the number of destinations for sorting the parcels set by the operator. The computing device is configured with a presorting application and connected with a logic function block. The logic function block includes the standard sorter carrier logic function. Based on the scanner output, camera output, and conveyor’s sensor output, the processing unit shoot out the parcels to the respective collecting bins. The memory unit further comprises a set of instructions based on which the processing unit analyses the sensor data and regulates parcel sorting. The computing device is coupled to a server unit using wired or wireless connectivity. This allows the operator to set the parameters related to the sorting for a particular category/ destination and store the data associated with sorted parcels to process further delivery.
Figure 3 illustrates a two-way parcel sorting system in accordance with the present invention. For two-way parcels, at least two collecting bins and one load carrier are required. The sorting parameters are set by the operator for two destinations. The parameter can be a particular region or parcel category or any parameter as per the user’s requirements. For exemplary purposes, the sorting parameter is ‘state’. The parcel has to sort for two states, ‘State 1’ and ‘State 2’. The operator sets Bin1 for State 1 and Bin2 for State 2. The operator loads the parcels on the weighing conveyor in static mode. The parcel detector triggers the weighing conveyor to measure the weight. The barcode scanner scans the barcode on the parcel. The conveyor sensor such as a diffuse sensor or a retro-reflective sensor detects the loaded parcel on it and sends the parcel information to the processing unit. The camera captures the parcel image. The image includes parcels’ real-time barcode, length, width, height, weight, volume and date time. The image is processed to the host by handshaking data. The handshake methods are such as Web API, DB to DB communication, AWS, FTP communication, File handling. The processor sends image data, barcode, weight, and dimension information to the server. A processing application has been configured at the server end that process the received information and generates a sort id for a parcel. The processing application is adapted to compute a sorting algorithm to sort the parcels. The application provides short id to the PLC. The application checks the status of the bin. If the bin is full or 75% filled, an alert pops up on the interface to replace the bin. The operator replaces the bin and rescans the parcel. The PLC sends a command to the conveyor to shoot out the parcel in the respective bin as per the sort id. Further, the collecting bin acknowledges the receipt of the parcel.
Based on the received information, parcels are sorted in their respective bin. The level sensor provides parcel level status to the operator on interactive display of the computing device. If the collecting bin is full, the system pop ups the message that the bin is full and needs to be replace/ empty. The system operation resume once the bin is empty.
Figure 4 illustrates a four-way parcel sorting system, in accordance with the present invention. The 4-way parcel sorting system includes at least four collecting bins for four categories/destinations and three load carriers. The operator loads the parcel on the weighing conveyor. The weighing conveyor detects the parcel and triggers the weighing unit to measure the weight. The VMS measures the volume and dimension. The camera capture the image including parameters length, width, height, dimension, barcode. The system saves the data in the database and communicates data with the host server. The application computes the received data and generates the sort id and shares that short id with the PLC. PLC sends the received inputs to the control and processing unit. Based on the received data, the presorter application is executed and the carrier conveyors shoot out the parcels in the respective bins. Further, the collecting bin acknowledges the receipt of the parcel.
Figure 5 illustrates 8- way parcel sorting system. The 8-way parcel sorting system includes at least 9 carriers and 8 collecting bins. Figure 6 illustrates 16-way parcel sorting system for sorting parcels to 16 destinations. The 16 way sorting system is implemented with atleast 21 carrier conveyors and 16 bins. Same way 32-way parcel sorting system can be implemented in accordance with the present invention. Further, Figure 6 shows N-way sorter arrangement for N number of destinations. The required number of stations are added with Zig Zag formation. In an N-way sorter a DWS station, N number of carriers, and N numbers of collecting bins are used. Thus, using a single DWS unit, multiple destination sorting is achieved.
In another aspect of the invention, the parcel sorting system includes a discarded parcel collecting bin for collecting the parcels with the damaged barcode, overweight, not in specified dimensions etc. When the system receives no read input for a parcel, the presort application is configured to transfer the parcel to the discarded parcel collecting bin. These discarded items are further recollected and processed manually by the operator.
Further, the system is configured for auto-correction. If any error occurs while parcel measurement, VMS or weighing unit generates an error code. VMS sends error codes to the parcel sorting application. These error codes get saved in the local database. The parcel sorting application obtain rectification data from the database or server. If any new error is detected, VMS or weighing unit generates a new error code. Control and processing unit read new error code from VMS and weighing unit on the server.The system (100) is configured with a machine learning module. The system (100) obtains rectification by the processing unit for new error using learning methods. The user addresses the new error following the provided rectification action and resolves it. This makes the system (100) automated, thus increasing system efficiency and throughput. The system (100) is capable of calculating the frequency of error occurrence and managing its tracking. Maximum frequency errors are highlighted using RED color.
The weighing unit provides weight details to the DWS system server. The weighing unit (80) includes a plurality of force transducers. The parcel sorting application (30) reads the error generated by the weighing unit on the web server and obtains the solution from the database if the error code is already available. For new error codes, the system finds a solution using machine learning. The HMI shows the error and corresponding rectification action/solution. The user addresses the error by following the provided rectification action and resolves the error.
Figure 9 shows the parcel sorting system process flow. The parcel sorting system receives the parcel on the loading conveyor. The loading conveyor detects the parcel and triggers the weighing unit to capture the parcel weight. In the next step, the VMS system will measure the parcel dimension. The barcode reader/ scanner scans the shipment barcode/details. This captured information barcode, weight, and dimension will be saved into the database. If the parcel dimension and volume are within the specified range and the barcode on the parcel is in the scanning range of the barcode scanner, the scanner reads the barcode successfully else the scanner shows no reads and moves the parcel to the discard bin. The parcel sorting application generates a sorter id for a successfully scanned parcel and communicate it with the PLC. The parcel sorting application feeds the scanned parcel shipment details such as barcode, length, width, height, weight, real volume and date time into the database as well as displays the details on the image of the parcel. The processed image will be uploaded to the server. In the next step, the parcel will move to the read sorter. The system receives the shipment location details. The system checks the status of the bin for that location. If the bin is not full, the sorter system transfers the parcel to a bin specified for that location. If the bin is full, the system pops up a “Bin full” message. The operator has to replace the bin and rescan the shipment. The parcel sorting application updates the database with sorted parcel details and sends notifications including shipment details to the customer ERP.
The parcel sorting application installed on the control unit facilitates parcel information management. The interactive surface/ dashboard of the parcel sorting application displays the sorting status in real-time. The parcel sorting application includes system alerts, alarms, DWS statistics reports, and user management. The alarms indicate the bin status. If the bin is full or 75% filled with parcels, the application pops up an alarm for the same. The operator has to replace it with an empty bin. The system alerts include a list of all possible sorting system faults. The active fault is highlighted with red color. A few system faults are enlisted in Table 1, Table 2 and Table 3.

Table 1

Table 2

Table 3
The system provides a rectification action for every fault/ error. When an operator clicks on the fault alert, a rectification action displays on the interface. The operator resolves the fault by following the rectification action. The DWS statistic report provides an overview of the sorted parcels for a particular date and time. The user management interface manages the operator/ user interaction with the parcel sorting system. It manages users, user groups and page-level access to the user and groups.
Advantages of the invention:
• The system is useful for sorting parcels for multiple destination at a time. Presorting for Highway lines to avoid multiple handling.
• The system helps in reducing the human intervention and increases accuracy. Less Strain on the operators to check for barcode and capture weight
• The system fastens the sorting process and increases the throughput.
• The system enables the warehouse to meet the deadline in peak seasons and be ready to receive next-day parcels.
• The system automatically detects the system faults/errors and helps to rectify them by providing the rectification action.
• Due to the autoregulation of the system error/alert, the system throughput increases significantly.
• Dimensioning weighing and scanning in one station.
• Modular design where any carrier can be placed anywhere.
• Scalable design with 4-way, 6-way, 8-way, and 16-way sorting with a single operator.
• ‘N’ number of sorters can be added in Zig zag pattern with minimum space.
• Visually challenged and physically challenged people can be employed.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or the scope of the present invention.
,CLAIMS:We Claim:

1. A parcel sorting system (100), characterized in that; said system comprises of;

a dimension weighing scanning (DWS) unit includes a mainframe, a control/PLC unit, a camera to take real time pictures of the received parcel, a VMS for measuring volume, one dimensional and two-dimensional barcode scanner;

a plurality of loading conveyors adapted with a static check weigher to capture the weight of the parcels;

a Human Machine Interface, a DWS system server adapted communicates with a customer servers and an ethernet switch to connects all the DWS system components internally and with PLC module;

wherein, the DWS system server receives the dimensions, weight, barcode and image of the parcel, saves the information at the database and communicate it host;

wherein the parcel sorting process executes at server end for multiple categories;

a control unit is configured with a parcel sorting application; a customer ERP is installed at the customer end; the parcel sorting application communicates with the customer ERP via a web server.

2. The parcel sorting system (100) as claimed in claim 1 wherein the programmable Logic Control (90) is configured to control the conveyor operation, trigger the Volumetric Measurement System (VMS) (60) and trigger the weighing unit (80), generate alarms, and display it on the Human Machine Interface (HMI) (70) which provides operative command access to the user such as Start, Stop, Reset said HMI unit (70) calculates the length, width, height, and volume of the parcel and sends it to the parcel sorting application (30).

3. The parcel sorting system (100) as claimed in claim 1 wherein the VMS (60) provides the volumetric measurement to the DWS system server; the VMS and weighing unit measure the L X B X H of the parcel if it is in the specified range; if the dimensions and weight of the parcel are not within the specified limits, the loading conveyor stops processing the parcel further or transfers it to the discarded parcel collecting bin, according to user instructions.

4. The parcel sorting system (100) as claimed in claim 1 wherein the conveyor unit includes a plurality of load carrier belt conveyors that rotate in opposite directions such as on the left and right.

5. The parcel sorting system (100) as claimed in claim 1 wherein the parcel collecting unit includes a plurality of parcel collecting/ receiving bins and each bin includes an acknowledgment sensor to acknowledge the receipt of the parcel and a level sensor to indicate the parcel level; the parcel collecting bin further includes a level sensor to indicate the bin fill level; said parcel collecting bin connected with the control and processing unit.