Fixed Lane Assignment Sortation

The fixed lane assignment sortation method is normally accomplished with a PLC reading a lane number barcode previously applied in the pick area. This barcoded carton travels to the fixed lane sortation system where it is diverted to the fixed lane assignment on the barcode. With any sorter, the parts per minute rate depends upon the item lengths, weights, conveyor speed, and required gap.

 

 

 

System Operation

Typical Fixed Lane Sortation Barcode

The picker applies a barcode label on the carton and puts it on the conveyor where it travels to the gapping conveyor.

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 the PLC. The PLC can use a fixed lane number, SKU number or strip characters out that provide it with the sortation lane.

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.

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