Efficient Logistics Sorting Solution: Double Speed Belt Conveyor Line Equidistant Sorting Practice

Hey, have you ever seen the scene of packages piled up in the logistics warehouse? Is not always feel like the sorting line in the "constipation" - things into the fast but out of the slow? Today we will chatter about this logistics people love and hate theDouble Speed Belt Conveyor LineLet's see how it turns a "traffic jam" into a "high-speed toll booth"!

🛞First, the traditional sorting for why always turn over?​

Imagine this: upstream packaging machines spitting out parcels like a chicken, while downstream sorting robots are slow as a grandpa taking a stroll. What's the result? The parcels are packed into a ball, the scanning gun is confused, the robot arm grabs a lonely...
​Here's the root of the problem.::

1. ​Single Speed Hard: the conveyor belt is one speed from end to end, the front section of the parcel is squeezed into sardines, and the back section of the robot is starving and wailing
2. ​runaway spacing: parcels of different sizes, small pieces drilled under the crotch of large pieces, always missed when scanning the code
3. ​Manually fighting fires: 30% Manpower in manual picking and pulling of jammed parcels

An express distribution centre test: single-speed line sorting peak only6000 pieces/hour, also always have to stop the line to clear the congestion!

⚡Second, double speed belts: simple and brutal physical hang-ups​

Don't let the name fool you! This thing is exactly what it says.Two belts running slowly in front of each other::

• ​Foreplay area (low-speed section): Speed approx.0.8-1.2m/sLet's get the parcels lined up first.
• ​High Tide Zone (High Speed Section): the speed is soaring to1.5-2.5m/sSwish and space it out.

​The secret is in the speed difference.::

make a copy of
Packet spacing = (high speed - low speed) × travelling time  
As a chestnut 🌰: 1m/s for low speed belt, 2m/s for high speed belt, it takes 2 seconds for the parcel to go through the low speed belt →Spacing is 2 metres straight away!​

📊Configuration table for different scenario speeds​



Package Type
Low speed section (m/s)
High-speed section (m/s)
spacing effect




Envelopes for small items
0.8
1.8
Stable ≥ 1.2m


Standard Courier Box
1.0
2.0
Stable ≥ 1.5m


Large appliances
1.2
2.5
Stable ≥ 2.0m


Data from industrial measurements








🔧III. Three axes on the ground: don't let the programme become scrap metal​
​▶ Hardware Matching Anti-Rollover​

​Belt Selection: For low speed rangeSerrated non-slip surface(Friction coefficient > 0.4), high speed section withFlat belt noise reduction​
​Transition zone gold 15cm: The area where the two belts overlap should be inclined by 10° to prevent the parcel from jamming and skipping
​Sensor Dual Insurance: Low-speed section outlet mountingOptical + Pressure SensingAvoiding parcel "tailgating"

​▶ Control Logic Life and Death​

​Principle of rigidity of speed difference: High speed/low speed ratio must be >1.5, otherwise the spacing is wasted
​Over-speed protection mechanism: Automatically reduces the speed of the high speed segment to save your life when there is a delay in scanning the code.
​Plugging emergency stop interlock: Low-speed section blocked for 5 seconds → full suspension, 3 times faster than manual response

​▶ Operation​

​Morning and evening speed-testing ceremoniesTake the standard box to run three times, speed fluctuation>0.1m/s immediately adjust the motor
​Belt Life Metaphysics: Align the belts left and right every month and wear life is directly doubled!
​laser marking method: Draw red lines on the ground in the transition area, and the crooked parcels will appear at a glance.


📈Fourth, the true fragrance of the scene: burning equipment how to return to the capital?​
A tawdry operation at a clothing warehouse in Hangzhou:

​pre-conversion: 12 persons/shift on a single line, average daily handling of 40,000 pieces, misclassification rate of 3%
​After the double speed belt is added::

Personnel cut to 6 persons/shift 👉Savings in labour costs of $430,000 per annum​
Sorting Peak21,000 pieces/hour👉 Shipment speeds up by five hours.
Error rate drying up to0.3%👉 Aftermarket costs down $80,000 a month



Even more extreme is a fresh food warehouse in Foshan: in the low-speed section addedWeighing and dynamic labelling machineThe sorting is done at the same time as the charging of weights.Equipment payback cycle reduced from 2 years to 10 months!

🚫V. A guide for novices to avoid the pit: blood and tears for experience​

​The speed difference is not as big as it should be!!! Exceeding 2.5x speed differential will cause small parcels to turn 360° in the air (don't ask how you know that 🙃 )
​Don't skip the transition rollers.: A factory to save money to remove the transition roller, the results of the parcel flying out of the line rate skyrocketed 15%
​anti-skidding earthwork: Sprinkle flour to detect belt slippage?laser tachymeteronly natural
​assassination by lighting: The top of the high speed section must be fitted withstrobe lightOtherwise, the workers will be so dizzy they'll puke.


A logistics park in Suzhou overturned the actual record: did not install vibration isolation → heavy forklifts next door to cross the road → conveyor belt collective bouncy → the whole line downtime for 2 hours → lost the customer 170,000 liquidated damages💸


🔮VI. The Future is Here: Can Dual-Speed Belts Still Be Played Out?​
Personally, I think ah, the next generation is by no means a brainless speed up, butFlexible Sorting! For example:

​AI visual prognosis: Camera identifies parcel size → Dynamic adjustment of speed difference → Automatic speed reduction for large parcels to prevent flying parcels
​Magnetic Levitation Double Speed Belt: Replacement of rollers by electromagnetic force → Speed switching from seconds to milliseconds
​Modular assembly: free combination of passages like Lego → today, the courier, tomorrow, the durian are not panicked!


I've heard that one of the head companies is already testingSelf-regulating two-speed systemIf this is the case, the tuner will cry!


💎The Exclusive Riot Theory​
Double speed belts are essentiallyTrading space for timephilosophy: spend $200,000 on a conveyor line modification and save $2 million worth ofHidden time costs(Customer complaints, pressure charges, compensation for lost items...). Next time you see a warehouse bursting at the seams, don't rush to add more people and cars, feel the temperature of the conveyor belt - maybe it's waiting for you to give a chance to "shift"!
(Note: The practical parameters in the article have been verified by a number of logistics enterprises, and the specific implementation needs to be adjusted in conjunction with the characteristics of the site)