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Technology speeds up parcel distribution
Modern identification systems provide the basis for optimized logistic processes.
Scanning tunnels automate and optimize logistics processes
Companies in the express parcel and mail order industries are realizing a high level of automation in modern sorting equipment for parcels and large-format letters. Advances integrating inline recognition, weighing and label printing are increasing productivity and reducing manual processing costs. Scan tunnel technology being utilized to sort items quickly and accurately for distribution, warehousing and parcel distribution. State-of-the-art systems for multi-sided package identification are being used to read hand-written and machine-written address information, identify barcodes and 2-D codes, measure volume and weight, and enable manual corrections of incomplete address information to be made at video coding terminals. Modern systems can also be programmed to detect “clear spots” for real time automatic print and apply systems.
Identification of address information and codes
High-speed line scan cameras identify text and barcodes with very high reading speeds on up to all six sides of an item‘s surface. This includes hand-written and machine-written address information as well as barcodes, 2-D codes, and specific customer codes. Thus the position of the package makes no difference. Often these systems are utilized to recognize OCR and codes even behind layers of plastic or shrink-wrap.
Images can be recorded on sorting equipment widths of up to 40 inches, a focal length of 4.5 feet, and throughput speeds of up to 9 feet/second on conveyors and sorters. Scanning tunnels utilize a single sensor unit with a high-resolution dynamic autofocus line scan camera, and LED illumination. Fiber-optic cables transmit digitized video data to high-performance computers for analysis. Modern software algorithms extract the necessary information from the digitized images. The result is a data file for each package that can be used to populate manifests, management reports and archival for fast customer service response.
Captured volume data
Volume measurement
Calculating package volumes is sometimes used automate invoicing. Parcel processors utilize this data according to the country-specific certification for revenue recovery and to drive billing activities. In addition, the data that is captured may be used for optimizing logistical processes such as loading. Volume measurement systems can measure all freight items for maximum dimensions in length, width, and height. Using this data, systems can calculate the smallest possible cube that will enclose the consignment. High-end systems can measure packages as small as 2 x 2 x 2 inches or as large as 48 x 24 x 24 inches (L x W x H) to an accuracy of ±0.2 inches.
video coding terminals
Video coding
What about “no reads” or items that cannot be scanned automatically? The industry has discovered that scanning tunnels used together with video coding stations achieve an identification rate approaching 100 percent. Addresses that were not machine-written or have not been fully identified can be transferred by a high-speed, intelligent network to video coding terminals. A grey scale image is sent to a coding desk where trained personnel add the information online or offline. Online video coding means that the information is entered immediately, within a defined time, and provided for sorting and further processing. Offline video coding means that data is required for the database rather than live sortation, therefore coded as a batch process at a later time. The image can be available at the video coding terminal in less than 300 ms. Depending on the video coding requirements, up to 1000 parcels can be processed per hour. Like the tunnels themselves, video coding stations can be scaled from one to multiple stations.
Inline Weighing
Dynamic in-motion weigh-scales determine the weight of packages at any conveyor belt throughput speed up to 8 feet/second without interrupting the material flow or limiting the throughput. If very long packages have to be transported a dual weigh-scale arrangement can be used in which the two weighing surfaces can be combined. In some cases two weighing units of different sizes are set up inline to weigh large or small packages in ranges between 3 ounces and 130 Lbs.
Alibi Storage
Accumulated data such as volume, weight, and address information or barcodes can be passed on to a data-concentrator and alibi-storage unit. This system should be certified according to the international OIML standard so that the volume measurement and the scales can be officially calibrated. The accumulated data and other necessary information can be secured under technical calibration regulations and stored safe from any manipulation. According to Robert King, the Sales and Marketing Manager for VITRONIC in the USA, implementing camera tunnels can make the difference with regards to in customer satisfaction, “Customers increasingly want to know additional information about their parcels and packages, and they want to know that their packages shipped on time and in good condition. The ability to store actual images and provide proof to customers upon request satisfies the most demanding customer inquiry”. This gives the user and their customers’ considerable reassurance:
- The user generates reliable data and can automate invoicing by individual package.
- Customers know that no one can alter the readings after they have been obtained.
- The data cannot be manipulated and are guaranteed to be stored for six months.
Clear spot detection
In some applications such as parcel consolidation, clients may wish to automatically apply a new label or indicia to their parcels prior to dispatch. In such cases it must be ensured that the new label is not applied over any existing information or labels. “Clear-spot detection” is an option with modern line scan cameras. The camera system checks for clear areas on the package surface and sends these co-ordinates to a third-party automated label print and apply system.
Incomplete address information is entered manually with the aid of grey scale images and video coding.
Interfaces
Scan tunnel interfaces have matured and now provide easy interfacing to a wide range of sorter control systems. This is the foundation for integration into existing material handling systems. In this respect scanning technology can be implemented using existing conveyor infrastructure as a base.
Summary
Scanning tunnel technology has matured greatly in the last few years. Hundreds of tunnels have been deployed to warehouse and parcel processors worldwide to reduce cost and improve service levels. Systems are reliable and flexible to the extent that implementers can pick and choose features specific to their operational requirements.