With the rapid growth of e-commerce and express delivery services, traditional manual sorting methods can no longer keep up with the demands of high efficiency and large-scale operations. To support logistics centers, postal systems, and retail warehouses in achieving automation, the cross-belt sorting system has emerged as a powerful solution. This system significantly boosts sorting speed, accuracy, and overall logistics performance—becoming the core equipment for modern intelligent logistics hubs.
System Functions & Working Principle
This express sorting system adopts cross-belt sorting technology, consisting of a main drive belt conveyor line and multiple trolleys equipped with small belt conveyors (referred to as “trolleys”). It enables fully automatic, multi-zone, and high-efficiency parcel sorting operations. Key features include:
- High-Speed Sorting:
Trolleys can accurately align with parcels in motion and quickly rotate their belts to complete the sorting process. - Dynamic Identification and Dispatching:
The system integrates barcode recognition and CCD image detection technology to assign trolleys in real-time based on item information. - Bi-Directional Unloading:
The belts on the trolleys can rotate in both forward and reverse directions, increasing flexibility in site layout. - Modular Structure:
The system can be flexibly expanded according to production line scale and logistics needs.
Application Scenarios
This solution is designed for sorting small items across a wide range of industries, such as:
- E-commerce fulfillment centers (e.g., during Double 11 shopping festivals)
- Express delivery sorting hubs
- Supermarket and retail distribution centers
- Postal service sorting systems
Applicable items include: food, cosmetics, clothing, books, and small parcels.
Workflow Description
- System Initialization: The circular main belt starts, stabilizes speed, and finds its origin point.
- Item Drop-off at Infeed Station: Items are placed into designated zones, and acceleration parameters are set.
- Barcode Scanning & Recognition: Barcode readers detect destination information for each item.
- Trolley Assignment: The system uses CCD cameras to detect vacant trolleys and assigns one accordingly.
- Speed Control: Based on the position of items and trolleys, the system adjusts acceleration and cruising speed to ensure timely matching.
- Docking Position Arrival: Items arrive at the docking point with the assigned trolley.
- Trolley Belt Activation: The trolley’s belt activates to receive the item from the infeed station.
- Arrival at Unloading Port: The trolley carries the item to the designated outlet.
- Forward/Reverse Belt Unloading: The belt rotates in the assigned direction to complete the item delivery.
Key Benefits
- High Speed & Throughput: Handles peak volumes with ease, processing hundreds of thousands of parcels per day.
- Accurate & Stable: Real-time positioning and precise control reduce sorting errors.
- Reduced Labor Costs: Minimizes the need for manual handling and sorting.
- Modular Scalability: Flexible system configuration allows easy expansion of trolley and outlet numbers.
- Seamless System Integration: Compatible with WMS, ERP, and MES systems for complete smart logistics control.
Conclusion
The cross-belt sorter is a vital step in transitioning logistics centers toward full automation and intelligence. With its high-speed, accurate sorting capabilities, it empowers businesses to handle high-volume orders, shorten delivery times, and reduce operational errors. In the competitive logistics landscape, success depends not just on speed, but also on seamless system integration. Ace Pillar’s cross-belt sorter solution is your ideal partner in building the future of intelligent logistics.
