Delta Motion Control Solution for Matrix Sorting Systems–Enhanced Efficiency and Convenience

As the E-commerce business flourishes in this era of global communications, customers' requirements have become more diverse. There are also new trends such as smaller parcels and various packaging types in the logistics industry. However, with increasing demand and labor shortages, the logistics industry is facing severe challenges. The key to elevating the warehouse logistics industry to the next level starts from the total management and efficiency optimization of good information flows. To minimize labor and increase overall efficiency, many enterprises are implementing smart automation processes integrated with information technology and conveyor equipment in their logistics segments.

Delta has a customer with a huge warehouse that manages massive amounts and categories of parcels and goods. The logistics flow volume was not affordable using a traditional labor-intensive linear sorting system, so the customer adopted Delta's advanced matrix sorting system. The matrix sorting system is divided into upper and lower lines: the upper line consists of one main conveyor belt and many swing devices, and the lower line includes many branch conveyor belts that correspond to the swing devices of the upper line and convey the sorted goods.

The upper line is comprised of different modules. When the trucks arrive at the warehouse, workers transfer the goods into feeders, which are then conveyed to the measurement section for the article number scanning and weighing process. Once scanned, the goods' information is automatically identified by the system which is connected to the database of the logistic company. The system immediately determines the good's category and where it should go. A conveyor belt directs the parcels to the main line, and then gradually carries them to different sorting ports. The swing devices sort the parcels down to a lower line when they arrive at their corresponding ports. The parcels that can't be sorted automatically are rerouted to a branch line for manual processing. If the flow volume is too high for the main line to carry during peak hours, the upper lines nearby are connected with a diagonal conveyor belt for mutual support. The goal of the system is for highly efficient and flexible warehousing.

Delta developed a smart motion control system solution for the customer's matrix sorting system. The solution applies the Compact Modular Mid-range PLC AS300 Series as master controller for the conveying and sorting process in the upper lines. The Delta AC Servo Drive ASDA-A2 Series and servo motors drive the motion and speed of different modules and swing devices. The Photoelectric Sensor PS-R Series is equipped at different modules and swing devices to sense the parcel conveying status. The 7-inch Widescreen Ethernet HMI DOP-107WV offers real-time monitoring for the entire system to ensure the completion of the sorting process. The automated sorting system substantially increased its sorting efficiency by 20% after integration with Delta's smart IA products.

In actual applications, Delta's matrix sorting solution brings the following benefits to our customer:

• High positioning accuracy: The AC Servo Drive ASDA-A2 Series applied in the different modules and swing devices send control commands to the ECMA series servo motors directly. The full-closed loop function reduces the effects of backlash and vibration from the machine and ensures the accuracy of positioning. The ECMA series servo motors feature incremental encoders with 20-bit resolution that can eliminate unstable commands at low speed, smooth motor operation and enhance the accuracy of swing devices and conveyor belts. They also support an absolute 17-bit encoder and are able to maintain motor position when the power is off.

• Superior sensing performance: The Photoelectric Sensors PS-R Series are equipped at different modules and swing devices to sense the parcel conveying status. They send the sensed information back to the master controller to eliminate manual labor. The PS-R Series features a slim design and easy-to-install M3 mounting holes. With CE and IP 67 certification, it is stable and suitable for long hours of performance in the sorting system.

• Flexible, convenient and efficient sorting solution: The matrix sorting system consists of Delta's smart IA products with the Compact Modular Mid-range PLC AS300 Series as master controller. The AS300 series is equipped with 32 I/O inputs and outputs to lower the costs for I/O module extension. With the AS-FCOPM card, it delivers up to 8-axis positioning control via fast CANopen communication. There is no need for users to look up parameters or use additional software to configure the ASDA-A2 Series positioning. It is easy to maintain axis control by instructions, and it also provides high PLC program readability. By deploying Delta's smart solution, the customer saves 20% of parcel sorting time and achieves the goal of having a convenient and efficient parcel sorting system.

Delta's motion control solution for the matrix sorting system integrates controllers, motion systems and sensing devices to develop a convenient, efficient and automated parcel sorting solution for logistics and warehouse industries. Our solution not only optimizes customer's parcel sorting efficiency, but it also solves the issue of labor shortages and elevates the logistics industry to the next level. Delta continues to offer comprehensive solutions to meet our customer's diverse requirements, and to ensure an outstanding future together.