Wayzim's Parcel Singulator
In high-speed logistics environments, efficiently handling bulk parcels to achieve organized, one-dimensional flow is a game-changer. Wayzim's 2D Parcel Singulator is engineered to transform disorderly parcel streams into perfectly spaced, laminar flow ready for downstream processing. This system integrates advanced sensor technology, independent servo-driven belt modules, and image-based deep learning for precise parcel separation and alignment.
Here’s what we’ll cover in this article:
Input & Detection: Parcel sensing and initial detection by cameras and sensors.
Singulation & Centering: Independent servo-controlled belts for spacing and alignment.
Optional Gapping Section: Increased spacing for high-throughput needs.
Diverging Module: For optimized parcel distribution.
Introduction
The primary function of the 2D parcel singulator is to convert disorderly, two-dimensional bulk flow into a streamlined, laminar one-dimensional flow with consistent spacing between parcels, ensuring optimal preparation according to the specified spacing to enter the DWS or various sorting equipment downstream.
The main body consists of an array of belt modules. Each Belt Module is driven independently via an AC servo motor. For easier and faster maintenance modules are paired together as a set.
Workflow Operation of a Singulator Unit:
1.????? Input Section
Sensors detect the presence of parcels, activating the belt conveyor to feed disorganized parcels into the system.
2.????? Detection
The two WZ-GE cameras mounted on top capture information such as parcel locations and send this data to the Programmable Login Controller (PLC), which controls the servo motors in each module to diverge and singulate the parcels.
3.????? Singulation Section
The PLC controls the servo motors of the belt matrix modules to diverge and singulate parcels, ensuring smooth flow through the system. An equal gap between parcels is created based on the settings configured in the IPC, allowing for a pre-set parcel gap ranging from 300mm to 1,200mm.
4.????? Centering Section
The centering section (centralizer) is designed to align parcels exiting the belt matrices at the end of the singulation area. The separated parcels are aligned to the centre of the conveyor line, ensuring they are properly positioned before leaving the Singulation System.
5.????? Gapping Section (Optional)
An optional gapping belt section can be placed after the singulator to increase the gap between parcels for high throughput applications. Photoelectric sensors measure the gap between parcels. The system adjusts the spacing by increasing the distance between parcels that do not meet the specified gap, ensuring all parcels are evenly spaced and remain in a single row.
Performance & Suitable Product Types
The Singulator is highly versatile, capable of Singulating multiple parcel types and sizes simultaneously. These include cartons, bags, polybags, sacks and envelopes, with parcel dimensions ranging from a minimum of 160x80x1mm to a maximum of 1,200x700x700mm. There are two primary sizes of singulator available (small & large) with sub varieties for each depending on required throughput and configuration.
More detailed specifications and performance details are provided in the table below:
Suitable Product Types:
Modes of Operation
The 2D Bulk Flow Singulator operates in two distinct modes: Singulation Mode and Conveying Mode, which can be toggled via the operation panel knob.
1.????? Singulation Mode:
In Singulation Mode, parcels entering the separation module are laterally redistributed to increase spacing. As they move into the singulator zone, an integrated camera captures real-time images, and the vision system analyses parcel distribution. The belt speeds are then adjusted to the pre-set singulation strategy to ensure precise separation of adjacent parcels. Basically this is the standard operational mode of the unit.
2.????? Conveying Mode:
In conveying mode, there is no synchronized control between upstream and downstream devices, and the singulator’s primary function is bypassed. This mode allows parcels to flow freely through the system without concern for spacing or accuracy, enabling higher throughput.
The singulator can be remotely controlled to switch between modes and supports remote software upgrades for enhanced flexibility.
The Singulator can also switch between an energy-saving mode and a high-speed mode. When the system detects that the parcel flow is less than the set value, the singulator automatically switches to the energy-saving mode to reduce device power consumption.
Input Belt Conveyor
In Singulation mode, when the Singulator issues a no-entry signal, the input belt conveyor immediately halts following the stop of the downstream belt. The input belt automatically resumes operation as soon as the downstream belt restarts, once the no-entry signal is cleared.
In cases of high parcel load within the divergence and singulation section, the system temporarily stops the input section. When the entrance sensors detect that the section is clear of parcels, the input belt promptly resumes conveying items downstream.
Diverging Module
The Diverging Module employs narrow belts to distribute incoming parcels evenly across the singulator’s width, optimizing throughput by fully utilizing the available space within the singulator.
The diverging module belts are positioned to form a radial distribution, with a slight angle difference between each of the adjacent belts.
During operation, if the parcels are in close proximity to one another, as each parcel comes? into contact with the belts of the diverging module, its motion trajectory is altered, creating slight angle variations. This increases the distance between parcels, effectively separating them to the left and right. This separation enhances the accuracy of the Singulator’s camera recognition system.
*The diverging module is only available on the larger size singulators, and not a required feature on the smaller models.
Singulator Vision System
The vision system on the singulator unit incorporates image-based deep learning, image stitching, and advanced algorithms for precise parcel detection and analysis, achieving an accuracy rate of over 99%. It is capable of detecting a wide range of items with high precision. The system features an integrated, compact camera with a built-in light source and is designed with IP65-rated protection, ensuring reliability in industrial environments.
Vision System
The recognition system in Wayzim’s 2D Bulk Flow Singulator consist of two WZ-GE cameras and one industrial computer. The cameras, positioned above the belt matrices, transmit real-time images to the industrial computer’s software system. Using advanced visual object recognition technology, proprietary image processing, and deep learning algorithms, the system precisely identifies parcels and controls the independent motion of each belt module.
?This software-driven control architecture ensures parcels are automatically singulated, spaced, and intelligently queued.
Belt Module Matrix
The belt matrix of the singulator features a modular design, allowing for quick and easy removal of belt modules for maintenance and replacement. The replacement process is highly efficient, with an estimated time of less than 5 minutes per module.
Each module within the matrix consists of a belt, each belt is independently controlled and driven by a 220V AC Servo Motor. The paired design structure allows for optimal maintenance efficiency.
Alignment after Singulation
After singulation is completed by the belt matrices the parcels will travel onto the centering conveyor.
Two centering conveyor options are available: the centering conveyor and the side alignment conveyor.
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Centering Conveyor
The centering section (centralizer) is designed to align parcels exiting the belt matrices at the end of the singulation area. The centering conveyor operates as a standalone machine, complete with its own dedicated control cabinet. However, it is also an integral part of the overall singulator system.
Using advanced mechanical and automated control technology, the centering conveyor automatically adjusts objects to align them precisely in the centre of the belt. This ensures consistent positioning for downstream processes, enabling efficient and accurate handling.
Alignment Conveyor
The side alignment conveyor is designed to output parcels along one side of the belt. Its rollers are arranged in a single row at a specified angle, guiding parcels perpendicular to the rollers direction. As parcels reach the side of the conveyor, they are transferred in a straight line under the action of the powered side belt, ensuring organized and uniform output.
Controls & Setup
The Singulator System features its own IPC unit, which manages the entire operation. This design streamlines setup and integration, enabling the system to function as a standalone, plug-and-play device without the need for additional controls or external configurations. Gap parameters, speed, and system settings can be easily adjusted through the IPC interface using the provided user-friendly software. Moreover, external reporting and SCADA interfaces can be seamlessly exported from the IPC to the host system for monitoring purposes.
The image below illustrates the user interface of the Singulator software which provides real time information on operation, performance and set parameters. This software is capable of receiving remote upgrades and troubleshooting.
The below image illustrates the system architecture of the singulator and its connections to its various sub-systems and components.
Maintenance
Each belt module within the matrix consists of two independently controlled belts, each belt powered by a 220V AC Servo Motor. Replacing a belt module is a quick and straightforward process, taking just less than five minutes to complete. No specialized tools are required for removal; the module can be easily lifted and detached from the frame, the driver extension cable is unplugged. Once the old module is removed, the new module is plugged in, and repositioned.
This simple replacement procedure minimizes system downtime, ensuring continuous operation with minimal interruptions.
The faulty module can then be taken to the maintenance room, where the belt or servo can be easily replaced at a more convenient time.
3D Stack Separator
The 3D Stack Separator is an add-on module for the singulator, designed to transform 3-dimensional stacked parcel flows into 2-dimensional de-stacked flow. In situations where parcels are bulk tipped onto a takeaway conveyor line, the stack separator is required in order to prepare parcels for the singulator, which then converts the flow into a laminar, one-dimensional format.
When packages are stacked, using a singulator alone is not sufficient. In such cases, a stack separation device is required. The singulator’s front input belt is replaced with this stack separation unit, which effectively separates the stacked packages before they enter the singulator for further processing.
The stack separator is composed of multiple sections of horizontal belt conveyors and inclined belt conveyors, of which the angle of incline belt is 22 degrees to achieve optimal separation. The Stack Separator is composed of three incline segments, and two horizontal transition segments and a horizontal output segment. The separation of packages carried out by combining a camera and motion control algorithm.
The main component structure of the stack separator is listed below:
3D Stack Separator Operation
The operation of the 3D stack separator is divided into 4 main processes, These processes are explained in more detail below:
1)????? Input Section: The system receives bulk flow via the incoming conveyor line, the Stack separator sends a stop/start signal to the connecting conveyor line to manage and balance the flow of incoming parcels.
2)????? Vision System: Wayzim’s vision system automatically detects the presence of stacked parcels, the information is then sent to the IPC and PLC.
3)????? Belt Modules: After receiving the parcel positioning information acquired by the camera system the conveyor belt modules intelligently stop-start to de-stack the parcel flow. Basically parcels are de-stacked as they travel along the system through differential speed belt conveyors controlled by the camera as well as the height drop between the gapping section and the transition section.
4)????? Outbound Section: After stack separation the outbound flow is directly connected to the infeed section of the 2D parcel singulator, for further refinement of flow into laminar 1D flow.
Integration of the 3D Stack Separator with the 2D Singulation System
By integrating the 3D Stack Separator with the 2D Singulator, full automation can be achieved from the initial tipping of bulk flow onto the takeaway line, all the way to the final sortation of parcels.
Additionally, the 3D Bulk Flow Singulator features a smart energy-saving function. When the system detects a pause in parcel flow, it automatically switches to sleep mode, reducing power consumption and extending the device’s operational lifespan.
Vision System
The visual recognition system comprises of several cameras and an industrial computer. Positioned above the belt modules, the camera captures real-time images of the parcels on the system. These images are processed by the industrial computer’s software, utilizing visual and motion control algorithms to manage the movement of individual modules. As parcels enter the system, the cameras continuously capture data, which is analyzed by the vision system to assess parcel characteristics. Based on predefined control strategies, the speed of each individual belt module is adjusted independently to handle the parcel de-stacking process efficiently.
Wayzim stacked-parcel separator is based on WZ-ZG020-GM intelligent camera as the core, which is embedded with high-performance hardware processing platform and combined with deep learning technology to realize multi-area express parcel positioning and area calculation. Combined with the intelligent control system, it can precisely control the amount of goods in each section of the parcel infeed area, separating large quantities of express parcels that are stacked together, avoiding undesirable situations such as stacked parcels and collision parcels, ensuring smooth parcel infeed and improving sorting efficiency.
User Interface
The image below illustrates the user interface of the 3D Stack Separator & 2D Singulator (combined) software which provides real time information on operation, performance and set parameters. This software is capable of receiving remote upgrades and troubleshooting.
Warranty
All of Wayzim’s Singulators are accompanied by a comprehensive one-year warranty as standard, which encompasses the provision of replacement parts and associated installation services. This warranty ensures that any defective or malfunctioning components will be promptly addressed, thereby guaranteeing optimal performance and longevity of the equipment.
Manufacturing and Lead Times
Thanks to the extensive scale and advanced capabilities of Wayzim’s manufacturing facility in Anhui, we are able to produce Singulators to the highest standards with remarkably short lead times. From the moment an order is placed, we can complete the manufacturing process and prepare the Singulator for shipment within just six weeks.
Why Choose the Singulator System ? Here are some of the key benefits
Wayzim Singulator Systems have a number of self-developed technologies and patents with international project technology level and experience. At present, there are project cases in many countries around the world, and it has CE certification.
Technical Advantages
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Product Advantages
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If you’re interested in our Singulator Systems and would like to receive more information please don’t hesitate to contact us.
Pouyan Korouei
London, UK based Senior Automation Solutions Engineer at Wayzim
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3 周This is a perfect product introduction that has given me a deep understanding of Wayzim's Singulator. ??