Logistics sorting system
Intelligent logistics conveying and sorting systems are the core subsystems of material handling and warehousing. They are key equipment for performing functions such as goods entering/leaving the warehouse, picking, verification and packaging, and route sorting, acting like the main artery running through the entire logistics process.
With the rapid development of e-commerce, the operational efficiency, accuracy, stability, online rate, and processing capacity of conveyor and sorting systems and equipment are crucial factors determining the operational efficiency, cost, quality, and customer satisfaction of warehousing and distribution centers and modern logistics systems. Intelligentization, modularization, and standardization have become key factors and development trends influencing the performance of conveyor and sorting systems and equipment.
01. Logistics Sorting Process
A logistics sorting system consists of a series of various types of conveyors, auxiliary facilities and control systems, and can be roughly divided into four stages: merging, sorting signal input, sorting and distribution.
The intelligent automated sorting system includes a straight cross-belt sorting system and a circular cross-belt sorting system (single-layer single-cart, double-layer single-cart, single-layer double-cart, etc.), and is equipped with an independently developed electronic control system and information management system.
01. Convergence
Materials picked from different locations according to picking instructions are sent to pre-processing equipment in a certain way, and then collected by the pre-processing equipment onto the main conveyor line. This process is called merging.
02. Sorting
When a signal input arrives at the material on the main conveyor line, the basic information of the material is read by an automatic identification device (such as a barcode scanner). The computer then processes the read material information accordingly. This process is called sorting signal input.
03. Diversion
After the material information is read into the computer system, it continues to move on the main conveyor line. The warehouse racking sorting system detects the position of the material movement in real time. When the material reaches the corresponding sorting gate, the control system sends a sorting instruction to the sorting mechanism. The sorting mechanism immediately generates the corresponding action to make the material enter the corresponding sorting gate. This process is called diversion.
04. Distribution
Materials entering the sorting lanes eventually reach the end of the sorting system, where they are transported to the appropriate areas by manual or mechanical handling tools.
02. Module Application
Option 1:
The project site uses Siemens S7-1200 PLC, Decker EX series Profinet and Modbus-TCP adapters, and expands digital I/O modules to connect to field sensors and actuators. By collecting and analyzing data through the PLC, the project can accurately and quickly sort packages on-site.
Application Highlights:
• Replacing a large amount of manual sorting with distributed remote I/O reduces human resource input and significantly improves efficiency;
Low cost, high stability, and short delivery cycle;
Option 2:
This project is primarily used in a large domestic logistics distribution center, employing a conveyor-sorting method for express parcel distribution. On-site, Siemens 1500 series PLCs and 12 Deckerwell FS integrated I/O units per line are used in the conveyor lines and rotary conveyors.
Application Highlights:
• High response time requirements: Able to unload goods and sort them according to their destination in the shortest possible time;
• High precision: These goods are transported to designated packaging points via fully automated conveyor lines;
• Strong signal speed and stability: Delivery is made to different regional distribution stations according to the delivery location, and then centrally loaded and delivered.
In addition, the upcoming LS series discrete I/O products from Deckerwell can also be well applied to the logistics industry.
The LS series is a distributed I/O module developed based on WELLBUS, a self-developed bus by Dekwell. This series of modules transmits signals and supplies power simultaneously by superimposing signals on power. The topology can be freely selected. In addition, the compact module structure provides customers with more design space and can be applied to occasions with dispersed locations and flexible layouts, such as logistics and warehousing.
03. Equipment Topology Diagram
04. Features of Deckwell Remote I/O Modules
Features of EX series card-type I/O products:
1. Stable communication, fast response, convenient operation, and high efficiency;
2. It supports a rich set of bus protocols, including EtherCAT, PROFINET, DeviceNet, CC-Link, EtherNET/IP, Modbus-RTU, CC-Link IEF Basic, etc.
3. Offers a wide range of signal types to meet the needs of factory automation and process automation control. Supports digital signals, analog signals, temperature modules, encoder modules, and free communication modules;
4. Compact structure, small module size, and a single I/O module supports up to 32 digital signal points;
5. Strong expandability; a single adapter can be expanded to include up to 32 I/O modules; fast coupler scanning speed;
6. Simple and easy to use, standard DIN35 rail mounting, plug-in terminals, tool-free installation.
Features of the FS series integrated I/O products:
The FS series remote I/O has advantages such as rich bus protocols, stable communication, and compact structure. It is widely used in logistics, education, automated stand-alone equipment, and robot workstations, and supports mainstream industrial bus protocols such as EtherCAT, PROFINET, DeviceNET, CC-Link, and CC-LinkIE Field Basic.
