Description:
FIELD OF INVENTION
[001] The present invention relates to a system for transferring shipments in two-level cross-belt sorters. Particularly, the present invention relates to a suction cup-based vertical transfer system for two-level cross-belt sorters and method for operation thereof.

BACKGROUND OF THE INVENTION
[002] Efficient material handling is one of the essential requirements in industries such as distribution, manufacturing, and logistics. Cross-belt sorters are employed in these industries to automate the process of sorting and transporting shipments. However, the effective moving of the shipments between the two levels of a cross-belt sorter presents a substantial barrier due to the lack of an efficient method for transporting shipments between the two loops, which leads to bottlenecks and inefficiencies in the sorting process.
[003] The conventional existing cross-belt sorters with two levels of rays comprise induction zones at both levels. However, the presence of induction zones at both levels leads to the complexity of sorter design and operation, significantly increasing maintenance requirements as well as downtime. Further, the requirements for additional induction zones and associated equipment increase the overall cost associated with the sorting system.
[004] A patent application US20100140053A1 titled “Space-saving sorting plant and method for sorting articles” discloses about a sorting plant and method for sorting articles, especially flat mail consignments, include a conveying device, a transfer mechanism and at least one reception device. A conveying transport mechanism of the conveying device transports an article along a conveyor track. The reception device has a plurality of reception components for at least one respective article and a reception transport mechanism. The reception transport mechanism moves the reception components along a reception component track and simultaneously brings one respective reception component of the reception device into a transfer position. The reception component track has a reception segment proceeding vertically or obliquely from the top downward. The transfer mechanism brings an article from the conveying device into one of the reception devices when the article is located at a transfer point on the conveyor track and when this reception component is located in a transfer position with respect to the transfer point.
[005] Another patent application US8037994B2 titled “Apparatus and method for sorting non-sorted containers in an order-picking system” discloses about a method and an apparatus or system for sorting non-sorted containers in a predetermined sequence in an order-picking system includes a main conveying track by means of which the non-sorted containers are transported within the order-picking system, in particular to an order-picking workstation or into a container store, in a main conveying direction. The apparatus includes a conveying-track circuit, which can be connected to the main conveying track via an introduction point, for introducing containers into the conveying-track circuit, and via a discharge point, for discharging containers which are located in the conveying-track circuit. At least one transfer device is arranged within the conveying-track circuit such that containers can be exchanged between a first exchange point and a second exchange point of the conveying-track circuit.
[006] In view of the challenges associated with the above state of the art, there is a need for a cost-effective, simpler, efficient system for transferring shipments between two levels of a cross belt sorter.
OBJECTIVES OF THE INVENTION

[007] The primary objective of the present invention is to provide an efficient, simpler, cost-effective system utilizing suction cups and vertical movement thereof for seamless transfer between levels, thereby improving the efficiency and flexibility of the sorting process while reducing costs and complexity.

[008] Another objective of the present invention is to optimize material handling within the sorting system by providing suction cups to transfer shipments between two levels of a cross-belt sorter.
[009] Yet another objective of the present invention is to decrease downtime, and improve overall cost-effectiveness associated with the use of sorting systems by simplifying the design and operation of the sorter and eliminating the need for additional induction zones.

SUMMARY OF THE INVENTION

[0010] A suction cup-based vertical transfer system for two-level cross belt sorter, comprising a chain driven loop, having a first side and a second side, and the first side disposed with a conveyor drive system to move the chain driven loop between at least two point. A plurality of modular slabs mounted on the second side and moving along the chain driven loop. A tray, having a first surface and a second surface, and positioned on the plurality of modular slabs for carrying a shipment between the at least two points. A number of suction cups installed on the second surface for receiving and carrying the shipment between the at least two points. Further, the first surface of the tray make contact with the plurality of modular slabs. Further, the plurality of modular slabs made of material made of material selected from a group of rubber. Further, the number of suction cups is installed with a plurality of air vent tubes to maintain optimal suction during the transfer process.
[0011] Further, the method of operating the system comprising shipments loading onto modular slabs integrated into a chain-driven loop. Further, the shipments discharged onto a tray equipped with suction cups as the shipments reach the end of the first level. Further, the tray is lifted which is equipped with suction cups vertically upward to a second level of the sorter by the chain-driven loop. Further, the shipments is released on the second level of the sorter by the tray equipped with suction cups as the tray reaches the second level. Further, the empty tray is returned to the first level to repeat the process for the other set of shipments.

BRIEF DESCRIPTION OF DRAWINGS

[0012] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0013] Figure 1 illustrates a perspective view of a suction cup-based vertical transfer system for two-level cross belt sorter;
[0014] Figure 2 illustrates the perspective view of a suction cup-based vertical transfer system for two-level cross belt sorter at level two;
[0015] Figure 3 illustrates a top view of a tray equipped with a number of suction cups; and
[0016] Figure 4 illustrates a flow chart for method of operating the of a suction cup-based vertical transfer system for two-level cross belt sorter.

DETAILED DESCRIPTION OF THE INVENTION

[0017] The following description describes various features and functions of the disclosed system with reference to the accompanying figures. In the figures, similar symbols identify similar components, unless context dictates otherwise. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system can be arranged and combined in a wide variety of different configurations, all of which have not been contemplated herein.

[0018] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0019] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0020] The terms and words used in the following description are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustrative purpose only and not for the purpose of limiting the invention.

[0021] It is to be understood that the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise.

[0022] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
[0023] The phrase “suction cup-based vertical transfer system” and the term “system” may be interchangeably used in the present disclosure.

[0024] The phrase “two-level cross belt sorter” and the term “sorter” may be interchangeably used in the present disclosure.

[0025] The expression “tray equipped with suction cups” and the term “tray” may be interchangeably used throughout the draft.

[0026] Accordingly, the present invention relates to a system (100) for transferring shipments in two-level cross-belt sorters. Particularly, the present invention relates to a suction cup-based vertical transfer system for two-level cross-belt sorters and method for operation thereof.

[0027] Figure 1 illustrates a perspective view of a suction cup-based vertical transfer system (100) for two-level cross belt sorter. Further, the suction cup-based vertical transfer system (100) comprises a chain-driven loop (102), at least two level (106, 108), a conveyor drive system (108), a plurality of modular slabs (110), a tray (112), a number of suction cups (114). The components are described herein in detail.

a) Chain-driven loop (102): The chain-driven loop (102) serves as a main conveyor for transporting shipments along a sorting path. The chain-driven loop (102) runs horizontally and is responsible for moving the tray (112), equipped with suction cups, which is carrying the shipments between two levels of the sorter. Further, the chain driven loop (102) having a first side and a second side.

b) A conveyor drive system (108): The system (108) comprises a conveyor drive system (108) disposed in the first side of the chain-driven loop (102).Further, the conveyor drive system (108) is connected to supply power for regulating the functioning of the chain-driven loop (102).

c) A plurality of modular slabs (110): The plurality of modular slabs (110) are integrated with the chain-driven loop (102), serving as a platform on which the shipments are placed during the transfer process. Further, the plurality of modular slabs (110) are installed on the second side of the chain driven loop (102). Each modular slab (110) may be arranged adjacent to one another, in a sequential manner, forming a continuous conveyor path for the movement of shipments between the at least two point (106, 108) as they travel along the conveyor path.

d) A tray (112) equipped with suction cups: The system (100) comprises at least one tray (112) equipped with the number of suction cups (114) positioned at the end of each level. The tray (112) may be equipped with the number of suction cups (114) arranged in a series to facilitate the transfer of the shipments between the at least two level (106, 108). The number of suction cups (114) is equipped with a plurality of air vent tubes to maintain optimal suction during the transfer process. The air vent tubes ensure that the suction cups maintain a strong grip on the shipments, preventing any accidental dislodging during transfer of the shipment.

[0028] In an embodiment, when a shipment reaches the end of first level (106) of the sorter, it is discharged onto the tray (112) which is equipped with the number of suction cups (106), moves vertically upwards to the second level (108) of a sorter, as shown in figure 2. Further, the upward movement of the tray (112) is facilitated by the chain-driven loop (102). Once the tray (112) reaches a higher level, the number of suction cups (114) release the shipment, allowing it to be transferred onto the second level (108) of the sorter. The tray (112) then returns to the first level (106) to repeat the process for another set of shipments.

[0029] In an exemplary embodiment, the conveyor drive system (108) may be selected from, such as, but not limited to, end drive.

[0030] In another exemplary embodiment, the number of suction cups (114) equipped on the tray (112) may vary depending on the manufacturer.

[0031] Figure 4 illustrates a flow chart for method (200) of operating the suction cup-based vertical transfer system for two-level cross belt sorter. In an embodiment, the present invention also provides a method for operating a suction cup-based vertical transfer system for two-level cross-belt sorters. The method (200) comprises the following steps:

[0032] At first step, the shipment is loaded onto the plurality of modular slabs (110) integrated into a chain-driven loop (102).

[0033] At second step, the shipment is discharged onto the tray (112) equipped with the number of suction cups (114) as the shipments reach the end of the first level (106) which includes lower level.

[0034] At third step, the tray (112) equipped with the number of suction cups (114) is lifted vertically upward to the second level (108) which includes higher level of the sorter by the chain-driven loop (102).

[0035] At fourth step, the shipment is released on the second level (108) of the sorter by the tray (112) equipped with the number suction cups (114) as the tray (112) reaches the second level (108) which is including higher level; and

[0036] At fifth step, the empty tray (112) is returned to the first level (106) which includes lower level (106) to repeat the process for the other set of shipments.

[0037] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
, Claims:WE CLAIM:
1. A suction cup-based vertical transfer system (100) for two-level cross belt sorter, comprising:

(a) a chain driven loop (102), having a first side and a second side, and the first side disposed with a conveyor drive system (104) to move the chain driven loop (102) between at least two level (106, 108);
(b) a plurality of modular slabs (110) mounted on the second side and moving along the chain driven loop (102);
(c) a tray (112), having a first surface and a second surface, and positioned on the plurality of modular slabs (110) for carrying a shipment between the at least two points (106, 108); and
(d) a number of suction cups (114) installed on the second surface of the tray (112), and carrying the shipment between the at least two points.

2. The system (100) as claimed in claim 1, wherein the at least two points include a lower point (106) and an upper point (108).

3. The system (100) as claimed in claim 1, wherein the first surface of the tray make contact with the plurality of modular slabs (110).

4. The system (100) as claimed in claim 1, wherein the plurality of modular slabs (110) made of material made of material selected from a group of rubber.

5. The system (100) as claimed in claim 1, wherein the number of suction cups (114) is installed with a plurality of air vent tubes to maintain optimal suction during the transfer process of the shipment.

6. The method (200) of operating the system (100) comprising;
Step 1: loading shipments onto the plurality of modular slabs (110) integrated into a chain-driven loop (102);
Step 2: discharging of the shipments onto the tray (112) equipped with the number of suction cups (114) as the shipments reach the lower point (106);
Step 3: lifting of the tray (112) equipped with the number of suction cups (114) vertically upward to the second level (108) of the sorter by the chain-driven loop (102);
Step 4: releasing the shipments on the second level (108) of the sorter by the tray (112) equipped with the number of suction cups (114) as the tray (112) reaches the upper point (108); and
Step 5: returning of the empty tray (112) to the first level (106) to repeat the process for the other set of shipments.