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High-speed linear cross-belt sorting system
From item singulation to dual-side chute discharge · Turnkey full-line delivery

Automatic induction · item singulation → DWS dynamic weighing and scanning → cross-belt sorting. All full-line equipment is developed and produced in-house, rated at 5500 parcels/h, with up to 40 chutes on both sides, configured flexibly to the customer's site and volume. This page provides online solution configuration and process simulation modelled on actual dimensions, as a reference for model selection.

5500 parcels/hRated sorting throughput
≈1.5 m/sConstant speed across the line (centering machine outlet)
Dual-side 40 chutesChute size (maximum)
100×200~300×400Compatible parcel range mm
PROCESS

1. Full-line process flow

Seven-section inline layout, with section widths stepping down along the line. Parcels move from untidy infeed to a single constant-speed stream and then into chutes one by one, with no manual handling.

Induction section→ Induction section→ Item singulator 4×4→ Centering unit 800→600→ Induction section→ Weighing and scanning DWS→ Cross-belt sorter⇉ Dual-side chutes
  • Sorting mechanism:Each turning unit in the middle sorting section turns independently (wheel-diverter style). When a parcel arrives it is thrown sideways, and the unit returns to position automatically. The parcel keeps its axial momentum and falls on a diagonal into the chute, whose centreline sits 400 mm downstream of the turning unit, so it lands accurately without impact.
  • Item singulation 4×4:4 rows along the line × 4 columns across = 16 independent servo modules (4×200=800 mm across, exactly matching an 800 mm belt width). Differential speed per row pulls clustered parcels apart front to back; in the same lane the following carrier yields and slows down while the leading one accelerates away, and once the clear gap is stably ≥500 mm the parcels enter DWS.
  • Start/stop metering against stacking:Install start/stop metering gates on the induction / pulling section: when incoming parcels are too dense, the whole group is held and queued, and released only after clear spacing is restored, preventing parcel stacking at the source; it copes with real operating conditions such as throughput fluctuations and manual bulk dumping.
  • Full line at constant speed 1.5 m/s:From the centering unit outlet the whole line runs at the same speed; DWS scanning and cross-belt sorting share the same takt time, rated throughput 5500 parcels/h.
  • Compatible parcels:100×200 ～ 300×400 mm (lateral × longitudinal); the longest side must not exceed the belt width
CASE REFERENCE

II. Reference to actual project cases

The footage below shows the cross-belt sorting system running at a customer site, for a direct view of the equipment configuration, chute layout and operating rhythm; a top-view layout drawing customised to the customer's site and chute count is provided with the proposal.

High-Speed Linear Cross-Belt Sorting System · Customer SiteActual project footage · loop playback
CONFIGURE

3. Online solution configuration

Select chutes and induction configuration according to the facility and business volume; the total line length, footprint, structure drawing and simulation are recalculated instantly, so the whole line for each configuration is clearly visible.

The induction section length is selectable from 2~5 m according to the customer's facility; total length of the central sorting section = chute length × number of chutes per side; footprint is estimated from the rectangular envelope. After switching configurations, the structure diagram and simulation below are recalculated automatically according to the actual full-line proportions.

LAYOUT

4. Full-line structure drawing (top view · to actual dimensions)

Drawn to scale at real mm dimensions: belt width narrowing along the line (800→600→500), 4×4 item singulation grid, funnel convergence at the centering unit, multi-face scanning frames and chutes on both sides, all clearly shown.

SIMULATION

5. Full-line process simulation

Modeled to actual equipment dimensions (mm), with real working conditions including inbound flow fluctuation, paired inbound items and manual batch dumping; differential-speed item singulation, start/stop metering in the induction section, and diverting into chutes are fully visualized, with sorting throughput displayed in real time.

Infeed flow rate
Medium Induction / pulling: start (release)
Parcels 0 · Sorted 0 · Exceptions 0
Induction section Item singulator 4×4 Module at low speed Module at normal speed Module acceleration (spacing out) Centering unit (narrowing) Weighing and scanning section Steering unit (returning) Steering unit (sorting) Ejection trajectory Dual-side chutes
SPECIFICATION

6. Equipment dimensions and configuration

Full-line section dimensions and key configuration items, such as scanning method and pulling stage count, can be selected according to business volume and facility conditions.

Full-line section dimensions (width × length, mm)

SectionWidthLengthDescription
Induction8002000Horizontal belt, length 2–5 m depending on the customer's site
Induction section (within item singulation)8001600Combined with the induction section into a start/stop metering queue zone (anti-overlap, 200 mm gap); singulation is completed by the separator at 500 mm
Item singulator 4×480016004 rows × 4 columns, differential speed per row + same-lane yielding, clear gap pulled to ≥500 mm
Centering unit800 → 6001200Diagonal rollers converge in a herringbone pattern, while the following section narrows to 600 width
Induction section (after the centering unit)600800Pull spacing again to guarantee the clear gap entering the DWS
Weighing and scanning section600800Dynamic weighing + barcode scanning; external multi-side scanning frame
Cross-belt · Head section5001750Built-in centering function
Cross-belt · Central sorting section500750 × 6 = 4500Section length = chute length, includes 1 diverter unit
Cross-belt · Tail section5001250Main ring motor, driving the chain slats along the cross-belt

Chute and parcel

itemsValueDescription
Chute length (along the conveying direction)750 mmOptions: 750 / 1000 / 1200 / 1500 / 2000
Chute lag diverting unit400 mmAfter a parcel is thrown off, axial inertia is retained and the landing point lags behind
Chute layoutDual-sideSymmetrical top/bottom layout (up to 40 per side), type = small chute
Parcel dimensions100×200 ～ 300×400Lateral × longitudinal (mm); the longest side must not exceed the belt width
Rated throughput5500 parcels/hConstant speed at the centering unit outlet, 4×4 item singulation induction

Configuration and selection

  • Scanning method:Top scanning (single side) is integrated with the weighing section; multi-side scanning = external frame + cameras on each side; six-side = full coverage of top / bottom / front / back / left / right.
  • Six-side camera configuration:5+1 (standard) / 6+1 / 8+1 optional; 8K line scan on the base + belt cutout light-transmission solution.
  • Induction stages:With item singulation, use a single pulling section; without item singulation, select the stage by throughput — single stage below 3000 parcels/h, two stages for 3000~5000, three stages above 5000; where floor space is tight, prefer single or two stages.
  • Buffer section:Not required when connecting to a cross-belt sorter (the head section includes 1750 mm); required when connecting to a wheel divert sorter.
  • All full-line equipment is self-developed and self-manufactured, supporting non-standard customization to fit the site.

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