Enhancing Merge Conveyor Utilization in a Line-Sorter Sortation System by Introducing a New Control Algorithm

Abstract

The parcel transport industry utilizes automated parcel sorting systems to effectively manage incoming parcels. These systems typically comprise multiple infeed conveyors that converge onto a single merge conveyor for parcel merging. However, the conventional First-Come-First-Serve merging method results in reduced utilization of the merge conveyor and throughput. To address this, a novel approach is proposed in this study, combining a dynamic programming-based control algorithm with a maximum heap algorithm. This approach aims to enhance the utilization of the merge conveyor and achieve a balanced load among the infeeds. To optimize utilization, an additional imaginary segment is introduced ahead of the merge conveyor, synchronously moving with the merge conveyor's speed. This segment is intelligently populated with parcels using dynamic programming, eliminating unnecessary empty spaces. Results demonstrate that the dynamic programming approach outperforms other techniques in terms of utilization. This research presents an initial investigation into implementing dynamic programming as a control algorithm to improve merge conveyor utilization in the parcel transport industry.