Continuous Sortation System

Sorting products on a continuous basis based upon a table lookup based upon the order. This method requires SolidComm™ to control the legacy host connection and SolidRoute™ to continuously assign lane numbers to the cartons. With any sorter, the parts per minute rate depends upon the item lengths, weights, conveyor speed, and required gap.

Typical System Components

Hardware

• Data Logic Fixed Position Barcode Scanners
• CASI-1050 System Controller
• Electrical Control Panel
• Exception Station PC & Hand Held Barcode Scanner
• Sortation System
• BudgetMaster™ Transportation Conveyor
• Product Gapping belts
• ZoneMaster™ Accumulation Conveyor

Software

• SolidComm™ Legacy Host Interface tool
• SolidRoute™ Routing & Sortation Software
• SolidSuite™ System Manager Maintenance HMI
• Conveyor Controls

Information Download

For cartons with barcodes that do not have an embedded destination lane require an interface to the host system that initiated the order. This is normally the WMS or ERP system the customer uses for shipping. An interface to this legacy host system where the relational data for the barcode identifier is kept will be made using SolidComm™. The details of this interface will be worked out during the functional specification process and will be outlined in detail in the System Requirements Document (SRD). Once this interface is established, cartons can be identified using a barcode scanner, RF Tag reader or other custom method.

Carton Gapping

In order to properly divert the cartons, proper carton gap is required. This gap is created by a series of belt conveyors that run at at increasing speed. This metering belt generates the gap necessary to sort cartons that have been transported in a slug or have become too close during the transportation process.

 

 

 

Carton Identification (Barcode Scanning)

As the carton moves past the fixed position barcode scanner, the barcode is read and transmitted to SolidRoute™. A lookup to the legacy host is performed by the SolidComm™ module and the carton is assigned a lane number. At the sorter induct, this destination lane is transmitted to the sortation PLC as the carton blocks the sorter induct photoeye.

Sortation system typically use omnidirectional barcode scanners like the Datalogic DS6300-GFX shown above. Typical configuration is to have the barcode on top, so the barcode can be read easily if the carton rotates or the carton skews while traveling down the conveyor. Sortation systems can also use scan tunnels when multi-side barcode reading is required.

Tracking

For belt & shoe sortation systems, the tracking is simplified by the use of tachometers. The carton is tracked to the appropriate location on the sorter and the divert fired when the correct number of tachometer pulses is counted. For sorters using roller conveyor, the system must account for slippage by using update photoeyes. In these systems a carton is expected to arrive in a window of time corresponding to a programmable window around the carton. When the carton blocks the update photoeye, the system updates the carton's position and corrects for any slippage.

Divert Process

When the carton reached the divert location, the carton blocks the product present photoeye and the carton is diverted. The carton blocks the divert acknowledge photoeye as it leaves the sorter and the system report is updated.

Exception Processing

Some cartons cannot be sorted due to unreadable barcodes, no lane assigned , etc. These cartons are treated as exceptions and either diverted to a jackpot lane or recirculated.

Systems Integration Services

The pre-engineered design of SolidRoute™ ensures that installation occurs on-time and on budget. The SolidRoute™ solution includes all the control hardware and software functionality needed to ensure accurate, consistent and verifiable sortation and control.

System Benefits

Incorporating an Automatic Sortation System into your distribution center will enable your enterprise to increase productivity by reducing labor and eliminating shipping errors and costly returns and customer complaints. Orders are processed more rapidly with the constancy that can only come from an automated multi-carrier small parcel shipping system.

Contact us for more information and a free consultative analysis of the feasibility of an automatic sortation system for your operation.

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