The application of Solidot's integrated I/O module in the logistics circular cross-belt sorting system

The cross-belt sorter system is a highly efficient and accurate logistics automation solution. Through the coordinated operation of the circular conveyor belt and sorting carts, it rapidly completes the scanning, sorting, and bagging of parcels. Featuring high throughput, high sorting accuracy, and strong flexibility, the system is widely used in e-commerce warehousing, express transfer centers, and other fields, significantly improving logistics efficiency and reducing labor costs.

1. Production process overview

Cross-belt sorter system workflow: scan and feed — automatic sorting — bagging

[scan and Feed]

Parcels enter the sorting system via the conveyor line. The scanning equipment automatically identifies parcel information (such as destination, dimensions, and weight), classifies them accordingly, and uploads the data to the control system to prepare for subsequent automatic sorting.

[automatic Sorting]

Parcels are placed on the conveyor belt of the cross-belt sorter system. Based on preset sorting rules, the system controls the rotation direction and speed of the belts to accurately convey parcels to the corresponding sorting chutes.

[Bagging]

Sorted parcels enter the bagging area via chutes, where manual workers or robotic arms complete bagging and sealing before they proceed to the outbound process.

2. I/O module Application mode

The system uses the PROFINET protocol for communication. The overall I/O points are distributed and relatively few in number (typically within 20 points). A single Solidot integrated I/O module PN4-1616BW provides 16 digital input points and 16 digital output points, meeting the system's input/output point requirements without stacking multiple modules, thus reducing space usage.

16 digital input points: some channels acquire photoelectric sensor signals to detect parcel positions in real time (e.g. scanning zone trigger, sorting chute in position); some channels receive safety signals (e.g. emergency stop button, safety door status); and some channels obtain sorting commands from equipment (e.g. target chute, parcel priority).

16 digital output points: based on control system commands, signals are output to various actuators. Some assist in starting/stopping conveyor line motors and reversing sorting cart belt direction, while others assist in turning on/off audible and visual alarms and Fault indicators.

3. Solidot integrated I/O module Series Products

Solidot integrated I/O modules support multiple bus protocols, featuring a compact size, high speed, and easy wiring. With a high-speed ARM plus dedicated ASIC, configuration is simple and Cascading is supported. Available in three form factors — vertical, horizontal, and IP67 — they adapt to various complex production environments.