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18
2019
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03
Application of Servo Systems in Intelligent Parcel Sorting
Currently, developed countries—represented by Europe, the U.S., and Japan—are increasingly adopting automation in their parcel sorting systems. Intelligent sorting systems have become an indispensable component of large and medium-sized logistics centers, distribution hubs, and express transit stations, with widespread applications also seen in the postal industry. Compared to the broader international logistics landscape, China's sorting technology still lags behind that of developed nations. Manual sorting operations remain highly prevalent, while the use of auxiliary picking technologies such as electronic tags and RF systems is relatively limited. Even more rare are fully automated, intelligent picking systems. Overall, China's sorting system applications currently show a mix of automated systems and…
Currently, developed countries—represented by Europe, the U.S., and Japan—are increasingly adopting automation in the application of parcel sorting systems. Intelligent sorting systems have become an indispensable part of large and medium-sized logistics centers, distribution hubs, and express transit stations, and they are also widely used in the postal industry.
Compared to the broader international logistics industry, China still lags behind developed countries in terms of technology used in sorting systems. Manual sorting operations remain highly prevalent, while the adoption of auxiliary picking technologies such as electronic tags and RF is still limited. Even more rare are the implementation of intelligent picking systems. Overall, the application of sorting systems in China is characterized by the limited scope of automated systems and equipment, as well as a low level of integration and efficiency.
Our company leverages our proprietary core technological advantages to accurately grasp the latest trends in internationally advanced servo drive technology, successfully launching the TS full-digital high-performance servo drive system. Targeting the growing domestic market and development trends in intelligent sorting systems, we have seamlessly integrated the TS AC servo drive system into control applications within the sorting industry. The TS full-digital high-performance servo drive system has achieved significant breakthroughs in areas such as communication capabilities, fully closed-loop servo control, high-precision positioning, and on-site servo debugging—mirroring the cutting-edge advancements and technical sophistication of leading international high-performance servo systems.
1. Operating Principle and Schematic Diagram of the Automated Sorting System
Each parcel is affixed with a barcode. The upper device transports the parcels to the sorting mechanism, where a belt conveyor—driven by a chain—moves along the sorting track. As each parcel passes by the barcode scanner, the scanning device captures the parcel’s sorting information and sends it directly to the computer-controlled system for data analysis and processing. A microcontroller then calculates precisely how long it will take for the parcel to reach its designated sorting chute. Once the parcel arrives at the correct chute, the computer system issues a signal, activating the electrically powered roller to start the belt conveyor, thereby guiding the parcel into the intended compartment and achieving the ultimate goal of efficient sorting. As illustrated in the diagram below.
2. Application Selection for TS Servo Drive Systems
Drive Model: TS0040A22
Motor Model: 60CB040C
Control Mode: Internal Speed Mode
Transmission method: Synchronous belt drive with a 1:5 reduction gear
Maximum load (maximum package weight): 35 kg
Maximum motor speed: 2600 rpm
Time Acceleration: 500ms
Deceleration time: 500ms
3. Outstanding Advantages of TS Servo Drives
CANopen communication functionality: Implemented the CANopen communication protocol for use in servo systems, defining four standard communication interfaces: SDO (Service Data Object), PDO (Process Data Object), NMT (Network Management Command), and special objects. These interfaces enable functions such as communication, network management, and emergency handling, with the physical medium adhering to the ISO 1189 standard.
Servo full closed-loop control: Designed for equipment requiring high positioning accuracy or rapid dynamic response, this system addresses precision errors caused by intermediate transmission stages, ultimately achieving highly accurate and highly responsive positioning.
High-precision positioning: Equipped with a 23-bit (8-million-line) high-precision absolute encoder, the servo system ensures control accuracy and overall performance that keep pace with those of leading international brands, effectively breaking free from the current situation of low-level competition and price wars plaguing domestic servo products.
Servo field debugging: An oscilloscope function has been added to the TS servo drive, allowing users to monitor characteristic curves and modify drive parameters via a PC, making on-site servo parameter adjustments much more convenient.
4. Main Features of the Automated Sorting System
(1) Achieved continuous, large-scale sorting of goods
Due to the assembly-line automated operations employed in large-scale production, the automatic sorting system is not limited by factors such as weather, time, or physical stamina—it can run continuously for extended periods. Moreover, the system boasts a high sorting capacity, handling thousands of packaged items per hour. In contrast, manual sorting would allow only about 100 items to be processed each hour, and even then, human sorters cannot sustain such intense labor for prolonged durations.
(2) Extremely low sorting error rate
The accuracy of the sorting error rate in an automated sorting system primarily depends on how precise the input sorting information is—this, in turn, hinges on the input mechanism used. If manual keyboard entry or voice recognition is employed, the error rate can exceed 3%. However, when barcode scanning is utilized for input, errors are virtually eliminated—provided, of course, that the barcodes themselves are printed without defects. That’s why automated sorting systems today predominantly rely on barcode technology to identify goods.
(3) Sorting operations have largely achieved unmanned operation.
One of the primary goals in establishing an automated sorting system is to reduce manpower, ease the physical strain on employees, and enhance overall workforce efficiency. As a result, the automated system can minimize human involvement to the greatest extent possible, essentially achieving full automation. In fact, the sorting process itself no longer requires manual intervention—human presence is now limited solely to the following tasks:
Operation of the manually operated sorting system.
When the delivery vehicles arrive at the inbound end of the automated sorting line, goods are received manually.
At the end of the sorting line, workers manually collect the sorted goods and load them onto vehicles.
Operation, management, and maintenance of the automated sorting system.
Material sorting is controlled by a programmable logic controller (PLC) or related circuit boards. Moreover, the sorting system can seamlessly integrate flexibly with other logistics equipment, enabling efficient allocation and management of material information flows. Its design adopts a modular and standardized assembly approach, offering features such as flexible layout and convenient maintenance and inspection.
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