System and method for a mobile carousel with power and communication contacts

Abstract

The present disclosure provides a material sorting system adapted to engage with a material handling vehicle. The material sorting system may include a base and a carousel assembly coupled to the base, the base including fork slots adapted to receive a pair of forks from the material handling vehicle. The carousel assembly may include a plurality of storage units and include an actuation mechanism configured to move the plurality of storage units relative to the base. The base may also include at least one electrical contact within the base and electrically connected to the carousel assembly.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is based upon and claims priority to U.S. Provisional Patent Application No. 62 / 927,278 filed on October 29, 2019 and U.S. Provisional Patent Application No. 62 / 992,548 filed on March 20, 2020, which are incorporated herein by reference in their entireties.

[0003] A note about federally funded research

[0004] not applicable. Background Art

[0005] Typically, a warehouse may include numerous material handling vehicles for performing various tasks simultaneously and storage bins / racks for organizing the merchandise stored in the warehouse. Conventionally, material handling vehicles have been used to pick up, transport, and place various types of loads. Summary of the invention

[0006] According to some aspects, the present disclosure provides a material handling vehicle configured to receive a load. The material handling vehicle may include a pair of forks and a clamp assembly disposed between the pair of forks. The clamp assembly may include: a housing; a first handle arm that protrudes from the housing and is movably received by the housing; and a second handle arm that protrudes from the housing and is movably received by the housing. The second handle arm may be laterally opposite to the first handle arm. At least one of the first handle arm or the second handle arm may include an electrical contact that is configured to transmit power or a communication signal.

[0007] According to some aspects, the present disclosure provides a material handling vehicle configured to receive a load. The material handling vehicle may include a pair of forks and a clamp assembly disposed between the pair of forks. The clamp assembly may include: a housing; a first handle arm pivotally coupled to the housing; and a second handle arm pivotally coupled to the housing. The second handle arm may be laterally opposite to the first handle arm. Conductive material may protrude from a surface of one of the first handle arm or the second handle arm to form an electrical contact configured to transmit power or a communication signal.

[0008] According to some aspects, the present disclosure provides a material handling vehicle configured to engage a load. The material handling vehicle may include a pair of forks and a clamp assembly disposed between the pair of forks. The clamp assembly may be configured to secure the load to the material handling vehicle when the pair of forks engage a base of the load. The clamp assembly may include: a housing; a first handle arm pivotally coupled to the housing; and a second handle arm pivotally coupled to the housing. The second handle arm may be laterally opposite to the first handle arm. The first handle arm and the second handle arm may be separated by a gap configured to receive a wall within the base of the load. The clamp assembly may also include at least one electrical contact that may protrude from at least one of the first handle arm or the second handle arm. The at least one electrical contact may be configured to engage with a corresponding electrical contact within the base of the load to transmit power or communication signals between the material handling vehicle and the load.

[0009] According to some aspects, the present disclosure provides a material sorting system adapted to engage with a material handling vehicle. The material sorting system includes a base and a carousel assembly coupled to the base, the base including fork grooves adapted to receive a pair of forks from the material handling vehicle. The carousel assembly includes a plurality of storage units and includes an actuation mechanism configured to move the plurality of storage units relative to the base. The material sorting system further includes at least one electrical contact within the base and electrically connected to the carousel assembly. The at least one electrical contact is adapted to engage with a corresponding electrical contact on a fixture assembly of the material handling vehicle to transmit power or communication signals between the material handling vehicle and the carousel assembly.

[0010] According to some aspects, the present disclosure provides a material sorting system, which includes a base. The base includes: a pair of fork grooves, the pair of fork grooves are suitable for receiving a pair of forks from a material handling vehicle; a top wall; a bottom wall, the bottom wall is separated from the top wall; and a center wall, the center wall is arranged between the top wall and the bottom wall and separates the pair of fork grooves. The material sorting system further includes: a carousel assembly, the carousel assembly is coupled to the base and has a plurality of storage units; and at least one electrical contact, the at least one electrical contact is within the base and is electrically connected to the carousel assembly. The at least one electrical contact is suitable for transmitting power or communication signals between the material handling vehicle and the carousel assembly.

[0011] According to some aspects, the present disclosure provides a material sorting system, the material sorting system includes a carousel. The carousel assembly includes a plurality of storage units and includes an actuation mechanism configured to move the plurality of storage units relative to a base. The material sorting system further includes an electrical contact, the electrical contact being electrically connected to the actuation mechanism. The electrical contact is adapted to engage with a corresponding electrical contact on a material handling vehicle to transmit power or communication signals between the material handling vehicle and the carousel assembly.

[0012] The foregoing and other aspects and advantages of the present disclosure will become apparent from the following description. In the specification, reference is made to the accompanying drawings which form a part thereof and which illustrate preferred configurations of the present disclosure by way of illustration. However, such configurations do not necessarily represent the full scope of the present disclosure, and therefore reference is made to the claims and this document to interpret the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention will be better understood when considering the following detailed description, and features, aspects and advantages other than those set forth above will become apparent.Such detailed description makes reference to the following drawings.

[0014] Figure 1 An exemplary material handling vehicle including a clamp assembly according to one aspect of the present disclosure is illustrated.

[0015] Figure 2 yes Figure 1 Top view of a material handling vehicle.

[0016] Figure 3 is from Figure 2 A top view of a first handle assembly of a material handling vehicle taken at area A.

[0017] Figure 4 It is a bottom view of the first grip assembly.

[0018] Figure 5 is a side view of the first grip assembly.

[0019] Figure 6 is from Figure 2 A top view of a second handle assembly of an example material handling vehicle taken at area B of FIG.

[0020] Figure 7 It is a bottom view of the second grip assembly.

[0021] Figure 8 is a side view of the second grip assembly.

[0022] Fig. 9 is a top view of the first communication contact of the second handle assembly.

[0023] Fig.10 is a partial side view of a load having a base according to one aspect of the present disclosure.

[0024] Fig.11 is a partial side view of a clamp assembly of a materials handling vehicle engaged with a base of a load.

[0025] Fig.12 is a partial side view of a second embodiment of a load.

[0026] Fig.13 is a perspective view of a material sorting system according to one aspect of the present disclosure;

[0027] Fig.14 yes Figure 1 A perspective view of a material sorting system operatively connected to Figure 2 Material handling vehicles;

[0028] Fig.15 is a perspective view of a set of material sorting systems according to another aspect of the present disclosure, wherein the set of material sorting systems is operatively connected to a material handling vehicle; and

[0029] Fig.16 is a perspective view of another set of material sorting systems according to another aspect of the present disclosure.

[0030] Fig.17 is a perspective view of yet another material sorting system according to another aspect of the present disclosure.

[0031] Fig.18 is a perspective view of yet another material sorting system according to another aspect of the present disclosure.

[0032] Fig.19 is aligned with the conveyor system Fig.18 A partial perspective view of the material sorting system. DETAILED DESCRIPTION

[0033] Before explaining any aspect of the present disclosure in detail, it should be understood that the present disclosure is not limited in its application to the construction details and component arrangements set forth in the following specification or shown in the following drawings. The present disclosure can have other configurations, or be implemented or executed in various ways. Moreover, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered restrictive. In this article, "including", "comprising" or "having" and its variants are meant to cover the items listed later and their equivalents and other items. Unless otherwise specified or limited, the terms "install", "connect", "support" and "couple" and their variants are widely used and cover direct and indirect installation, connection, support and coupling. In addition, "connect" and "couple" are not limited to physical or mechanical connections or couplings.

[0034] The following discussion is provided to enable those skilled in the art to make and use various aspects of the present disclosure. Various modifications to the illustrated configuration will be apparent to those skilled in the art, and the general principles herein may be applied to other configurations and applications without departing from various aspects of the present disclosure. Therefore, various aspects of the present disclosure are not intended to be limited to the configurations shown, but will be given the broadest scope consistent with the principles and features disclosed herein. The following specific embodiments are read with reference to the accompanying drawings, in which similar elements in different drawings have similar reference numerals. The drawings, which are not necessarily drawn to scale, depict selected configurations and are not intended to limit the scope of the present disclosure. Those skilled in the art will appreciate that the non-limiting examples provided herein have many useful alternatives and fall within the scope of the present disclosure.

[0035] Material handling vehicles are designed in various configurations to perform various tasks. The present disclosure is not intended to be limited to any particular material handling vehicle, and various other types of material handling vehicle configurations may also be provided for the systems described herein, including, for example, pallet trucks (e.g., pallet cranes, "tractor trucks," etc.), order pickers, SWING trucks, and the like. Vehicles, and any other lifting or pallet handling vehicles. The various systems and methods disclosed herein are suitable for use with any of the following: driver-controlled material handling vehicles, pedestrian-controlled material handling vehicles, remotely-controlled material handling vehicles, and autonomously-controlled material handling vehicles.

[0036] Material handling vehicles can be used to carry loads, such as pallets, loads with pallet-like bases, specialized carts, or racks. However, conventional material handling vehicles are unable to transmit power to these loads, and the loads themselves are not configured to receive power from the material handling vehicle. Additionally, conventional material handling vehicles are unable to easily exchange information between the material handling vehicle and the load. It may be beneficial to be able to provide power to the load (e.g., to be able to power accessories, carts, or other equipment that the material handling vehicle is carrying) and to be able to transmit information between the load and the material handling vehicle. Some conventional methods of transmitting power or information between a material handling vehicle and a load have been accomplished by installing a cable connection.

[0037] The system or method of the present disclosure provides power and / or communication for a load carried by a material handling vehicle. As used herein, a load can be defined by any structure configured to engage with a material handling vehicle, carried by a material handling vehicle, moved by a material handling vehicle, or transported by a material handling vehicle. For example, a load may include one or more fork slots configured to receive a fork of a material handling vehicle. The fork slots may be separated by a center wall that may be engaged on the material handling vehicle by a clamp. The present disclosure describes a clamp assembly that may make the transmission of power and information available between a material handling vehicle and a load. Specifically, for example, a clamp assembly may be incorporated into or between the forks of a material handling vehicle, such as a pallet clamp. In some cases, a load may have a center wall (e.g., a center longitudinal beam of a pallet) within the base of the load, and the clamp assembly may selectively engage with the center wall to secure the load to the material handling vehicle.

[0038] The clamp assembly may have electrical contacts in the form of electrical power contacts and / or electronic communication contacts. For example, in an example, when the clamp assembly is engaged with the load, the material handling vehicle can provide power and / or communicate electronically with the load. As used herein, an electrical contact may be defined as a structure formed at least in part of an electrically conductive material that can be configured to transmit electrical power or communication signals.

[0039] refer to Figure 1-Figure 2 , the material handling vehicle 100 may include a power source 102, a first fork 103, a second fork 105, a controller 108, and a clamp assembly 110. The power source 102 may be a battery mounted on the material handling vehicle 100. The power provided by the power source 102 may be delivered through a regulating supply device to limit the power drawn from the clamp assembly 100 to a predetermined limit (e.g., 100 watts). The power provided by the power source may also be delivered through various safety and control devices, such as fuses, current limiters, power feeders, and switches.

[0040] The clamp assembly 110 can be configured to selectively engage a load. For example, the clamp assembly 110 can be configured to clamp a center wall (e.g., a center stringer) of a load. The clamp assembly 110 can include a housing 101 having a first arm portion 104, a second arm portion 106, a first grip arm or assembly 114, and a second grip arm or assembly 116. The first grip assembly 114 can be movably or pivotally engaged with the first arm portion 104. The second grip assembly 116 can be pivotally engaged with the second arm portion 106. The first grip assembly 114 and the second grip assembly 116 can be arranged to face away from each other or toward each other.

[0041] In some embodiments, the first grip assembly 114 and the second grip assembly 116 can be biased toward each other (e.g., via a spring). Figure 2 As best illustrated in FIG. 1 , when no external force is applied to the first grip assembly 114 and the second grip assembly 116, they are separated by a lateral distance D1. The lateral distance D1 can define a gap between the first grip assembly 114 and the second grip assembly 116 that is less than a width of a structure (e.g., a center wall) configured to be inserted between the first grip assembly 114 and the second grip assembly 116. When the structure is inserted between the first grip assembly 114 and the second grip assembly 116, they can be displaced away from each other. In such a displaced position, the first grip assembly 114 and the second grip assembly 116 can be biased toward each other (e.g., via a spring) to ensure contact between the first grip assembly 114 and the second grip assembly 116 and the structure to secure and grip the structure. For example, during operation, the material handling vehicle 100 can be maneuvered into a position in front of a load having a fork slot within the base of the load. The first fork 103 and the second fork 105 can then be inserted into the fork slots so that the clamp assembly 110 engages with the center wall disposed between the fork slots. After engaging with the center wall, due to the contact between the center wall and the first grip assembly 114 and the second grip assembly 116, the first grip assembly 114 and the second grip assembly 116 can be displaced away from each other to receive the center wall. The first grip assembly 114 and the second grip assembly 116 can then grip the center wall, thereby securing the load to the material handling vehicle 100. In some embodiments, various other types of mechanical clamps can be used instead of the first grip assembly and the second grip assembly. For example, a hydraulically driven metal plate can be used to engage the load and transmit power and / or communication to the load.

[0042] The clamp assembly 110 can be configured to provide electrical communication between the power source 102 on the material handling vehicle 100 and the load received on the first fork 103 and the second fork 105. The clamp assembly 110 can be in electrical communication with the power source 102. The controller 108 can also be in electrical communication with the clamp assembly 110. In some embodiments, the controller 108 can be configured to selectively articulate the clamp assembly 110. For example, the controller 108 can be configured to selectively rotate the first grip assembly 114 and the second grip assembly 116 between a deployed position and a stowed position. In the stowed position, the first grip assembly 114 and the second grip assembly 116 can be received within the first arm portion 104 and the second arm portion 106 of the housing 101, respectively.

[0043] In some embodiments, the first handle assembly 114 and the second handle assembly 116 may be manually actuated by an operator. For example, the material handling vehicle 100 may have a manually operated foot pedal that, when actuated by an operator, may be configured to selectively rotate the first handle assembly 114 and the second handle assembly 116 between the deployed position and the stowed position. In other embodiments, an electrical switch may be mounted in the operator compartment to selectively rotate the first handle assembly 114 and the second handle assembly 116 between the deployed position and the stowed position.

[0044] The clamp assembly 110 may include one or more electrical contacts. The electrical contacts may be configured to transfer power to a load on the material handling vehicle 100. For example, one of the first grip assembly 114 or the second grip assembly 116 may include at least one power contact. Figure 3 , showing a top view of the first grip assembly 114. The first grip assembly 114 may include a first protrusion or clamping arm 120, a first base 122, and a first power contact 124. The first base 122 may be inserted into and supported by the first clamping arm 120. The first base 122 may be substantially flush with the first clamping arm 120. The first base 122 may be constructed of an electrically insulating material (e.g., plastic, rubber, silicone, etc.).

[0045] The first power contact 124 can be configured to engage with a corresponding contact in the base of the load to transfer power from the power supply 102 to the load. The first power contact 124 can be coupled to the first clamping arm 120 through the first base 122 to electrically insulate the first power contact 124 from the first clamping arm 120. The first power contact 124 can be inserted into and supported by the first base 122. In some embodiments, the first power contact 124 can be crescent-shaped, but other shapes are contemplated. The crescent-shaped or arc-shaped first power contact 124 can provide a demagnetizing (wiping) electrical contact. In the illustrated embodiment, the arc-shaped electrical contact can enable the clamp assembly 110 to engage the center wall of the load while maintaining electrical contact between the electrical contact (e.g., the first electrical contact 124) and the corresponding electrical contact in the base of the load, and these center walls have various center wall thicknesses. In some embodiments, the arc of the electrical contact can share a rotation center with the rotation of the first grip assembly 114 and the second grip assembly 116. The first power contact 124 may be made of a conductive material (e.g., metal or carbon). In some embodiments, the power contact may be overmolded into a base that includes leads that may be directed to or from the power contact. The first power contact 124 may be electrically connected to the power supply 102 and the controller 108. The controller 108 may be configured to selectively energize the first power contact 124 using power from the power supply 102.

[0046] refer to Figure 4 , showing a bottom view of the first grip assembly 114. The first grip assembly 114 may also include a second base 126 and a second power contact 128 opposite the first base 122 and the first power contact 124. In the illustrated embodiment, the bottom side ( Figure 4 ) can be substantially similar to the top side ( Figure 3). Unless otherwise noted in the following description or in the accompanying drawings, it should be understood that the bottom of the first grip assembly 114 can be substantially similar, including similar structure and performing similar functions as the top of the first grip assembly 114. For example, the second power contact 128 can be configured to engage with a corresponding contact within the base of the load to transfer power from the power supply 102 to the load. The second base 126 can be inserted into and supported by the first clamping arm 120. The second base 126 can be generally flush with the first clamping arm 120. The second base 126 can be composed of an electrically insulating material and configured to electrically insulate the second power contact 128 from the first clamping arm 120. The second power contact 128 can be inserted into and supported by the second base 126. In some embodiments, the second power contact 128 can be a mirror image of the first power contact 124 and thus be crescent-shaped. It is contemplated that the second power contact 128 can be composed of a conductive material. The second power contact 128 may be in electrical communication with the power source 102 and the controller 108. The controller 108 may selectively energize the second power contact 128. In some examples, the controller 108 may energize the second power contact 128 based on input from an operator. The controller 108 may be configured to selectively energize the second power contact 128.

[0047] Go to Figure 5 , as seen in the side view, the electrical contacts may protrude from the surface of the clamping arm. In some embodiments, the electrical contacts may be arranged on opposite sides of the clamping arm. For example, in the illustrated embodiment, the first power contact 124 may be opposite the second power contact 128. The first power contact 124 and the second power contact 128 may extend away from the first clamping arm 120. In other words, the first power contact 124 and the second power contact 128 may protrude beyond the first clamping arm 120 or protrude from the first clamping arm 120. In some embodiments, a switch may be included to allow an operator to selectively turn on / off the power to the first power contact 124 and the second power contact 128.

[0048] The clamp assembly 110 may include one or more electrical contacts configured to transmit communication signals between the load of the material handling vehicle 100. For example, one of the first grip assembly 114 or the second grip assembly 116 may include at least one signal contact. The signal contact may be configured to engage with a corresponding contact within the load base to transmit information or signals to / from the material handling vehicle 100 to the load.

[0049] Reference now Figure 6, a top view of the second grip assembly 116 is shown. The second grip assembly 116 may include a second protrusion or clamping arm 132, a third base 134, and a first signal contact 136. The third base 134 may be inserted into and supported by the second clamping arm 132. The third base 134 may be generally flush with the second clamping arm 132. The third base 134 may be constructed of an electrically insulating material and configured to electrically insulate the first signal contact 136 from the second clamping arm 132.

[0050] The first signal contact 136 can be inserted into and supported by the third base 134. In some embodiments, the first signal contact 136 can be crescent-shaped, but other shapes are contemplated. The crescent-shaped or arc-shaped first signal contact 136 can provide electrical contact for demagnetization. The first signal contact 136 can be in electrical communication with the controller 108. In some embodiments, the signal contact can be overmolded into a base that includes leads that can be led to or from the signal contact.

[0051] refer to Figure 7 , showing a bottom view of the second grip assembly 116. In the illustrated embodiment, the bottom side ( Figure 7 ) can be substantially similar to the top side ( Figure 6 ). Unless otherwise described in the following description or in the accompanying drawings, it should be understood that the bottom of the second grip assembly 116 can be substantially similar, including a structure similar to the top of the second grip assembly 116 and performing functions similar to the functions performed by the top of the first grip assembly 114. For example, the second grip assembly 116 may include a fourth base 138 and a second signal contact 140. The fourth base 138 can be inserted into and supported by the second clamping arm 132. The fourth base 138 can be generally flush with the second clamping arm 132. The fourth base 138 can be composed of an electrically insulating material and configured to electrically insulate the second signal contact 140 from the second clamping arm 132. The second signal contact 140 can be inserted into and supported by the fourth base 138. In some embodiments, the second signal contact 140 can be a mirror image of the first signal contact 136 and therefore be crescent-shaped. The second signal contact 140 can be electrically connected to the controller 108.

[0052] Check Figure 8 As seen in a side view, the first signal contact 136 may be opposite to the second signal contact 140. The first signal contact 136 and the second signal contact 140 may extend away from the second clamping arm 132 or protrude from the second clamping arm 132. In other words, the first signal contact 136 and the second signal contact 140 may protrude out of the second clamping arm 132.

[0053] refer to Fig. 9 , the first signal contact 136 may include a plurality of signal contacts 136A, 136B, 136C and a plurality of insulators 146. It is contemplated that the plurality of insulators 146 are comprised of electrically insulating material. It is also contemplated that the plurality of signal contacts 136A, 136B, 136C may be comprised of conductive material. The individual insulators of the plurality of insulators 146 may be alternately layered between the individual tracks of the plurality of signal contacts 136A-136C. Thus, the plurality of insulators 146 may electrically insulate the individual tracks of the plurality of signal contacts 136A-136C from one another. Return to view Figure 6 and Figure 7 It should be understood that the first signal contact 136 may be a mirror image of the second signal contact 140. Therefore, the second signal contact 140 may also include a plurality of signal contacts and a plurality of insulators (140A-140C and 146, see Fig.11 ).

[0054] As described above, in some embodiments, the fixture assembly 110 may include multiple signal contacts. The multiple signal contacts may provide CAN signal communication capabilities. Typically, CAN communication is a two-way communication based on the CAN standard, which uses three signal contacts (e.g., CAN high, CAN low, ground loop) and a fourth signal contact (e.g., engagement). The "engagement" signal contact may be used as a signal indicating that the fixture assembly has engaged a load.

[0055] The controller 108 may be configured to selectively energize one or more of the power contacts or signal contacts on the first grip assembly 114 or the second grip assembly 116 based on a system check of the material handling vehicle 100. In some embodiments, the material handling vehicle 100 may be equipped with one or more sensors, and the controller 108 may be in electrical communication with the sensors to perform a system check on the material handling vehicle 100.

[0056] In some embodiments, the controller 108 may be configured to perform an engagement system check, which may include determining whether the load is properly engaged by the forks 103, 105, or the clamp assembly 110. In such embodiments, the controller 108 may apply power and make one or more attempts to communicate with the load via power contacts or signal contacts. The power applied may be limited by a fuse or circuit breaker on the material handling vehicle 100. If the controller 108 does not receive an expected response to the communication attempt (e.g., a CAN bus message), the system check may indicate that the load is not properly engaged by the clamp assembly 110.

[0057] In some embodiments, the disengagement system check may include determining whether the load was properly disengaged by the clamp assembly 110. In such embodiments, the controller 108 may continue to communicate with the load after the material handling vehicle 100 attempts to disengage the load. If communication still exists (e.g., via power contacts or signal contacts), the system check may indicate that the load was not properly disengaged. It should be understood that the controller 108 may warn the operator that the load remains engaged before the material handling vehicle 100 drives away.

[0058] In some embodiments, the status system check may include interrogating the load to obtain status information (e.g., via a signal contact). In such embodiments, the controller 108 may query the load to obtain a load identification, a fault code for a mechanism on the load, and a status of the load. Additionally, based on the status information, the controller 108 may instruct the load to perform one or more operations (e.g., rotate a box or actuate a carousel assembly).

[0059] In some embodiments, the loading system check may include interrogating the load to obtain product loading information. In such embodiments, the controller 108 may query sensors mounted on the load (e.g., barcode scanners, 2D barcode processors, RFID chips, position detectors, etc.) to monitor the products loaded or removed from the load. When the load is engaged, the controller 108 may alert the operator to warn of any product count deficiencies.

[0060] In some embodiments, the power draw system check may include monitoring the electrical power drawn by the load using the controller 108. It should be understood that the above system checks are non-limiting examples, and the controller 108 may perform any type of system check.

[0061] It should be understood by those skilled in the art that the clamp assembly described herein or the power contacts and signal contacts provided thereon may be retrofitted into a truck using a pre-existing pallet clamp, or the clamp assembly described herein may directly replace the pallet clamp of a material handling vehicle equipped with a pallet clamp.

[0062] Go to Fig.10 , showing one embodiment of a load assembly having a base. The load assembly 152 may include a base 156 and a load 158. The base 156 may support the load 158. In some embodiments, the base 156 may be a pallet or a shape and structure similar to a pallet. For example, the base 156 may include a center wall 162 (e.g., a center longitudinal beam of a pallet), a top plate or top wall 164, and a bottom plate or bottom wall 166 opposite the top wall 164. The space formed between the top wall 164 and the bottom wall 166 may be divided by the center wall 162 to form a fork groove 163. The fork groove 163 may be configured to receive the first fork 103 and the second fork 105 of the material handling vehicle 100 (see Figure 2 ).

[0063] The base 156 may include electrical contacts configured to engage with electrical contacts on the clamp assembly 110 to transmit power or communication signals between the power supply 102 and the controller 108 to the load 158. In some embodiments, the base 156 may include a plurality of electrical contacts corresponding to and engaging with a plurality of electrical contacts on the clamp assembly 110. The electrical contacts may protrude from the surface of the base 156 into the cavity formed by the fork groove 163. In the illustrated embodiment, the base 156 may include one or more electrical contacts configured to transmit power to the load 158. For example, one of the top wall 164 or the bottom wall 166 may include at least one electrical contact configured to engage with one of the first electrical contact 124 or the second electrical contact 128 of the clamp assembly 110. The base 156 may also include one or more electrical contacts configured to transmit communication signals between the controller 108 and the load 158. For example, one of the top wall 164 or the bottom wall 166 may include at least one signal contact configured to engage with one of the first signal contact 136 or the second signal contact 140 of the clamp assembly 110. In the illustrated embodiment, the base 156 may include a first power pin 170, a second power pin 172, a first signal pin 176, and a second signal pin 178. In the illustrated embodiment, the center wall 162 separates the first power pin 170 and the first signal pin 173 from the second power pin 172 and the second signal pin 178. In other words, the first power pin 170 and the first signal pin 173 are disposed in one of the fork slots 163, and the second power pin 172 and the second signal pin 178 are disposed in the other fork slot 163.

[0064] The center wall 162 may be connected to the top wall 164 and the bottom wall 166 and configured to be received within and engaged by the fixture assembly 110. The first power pin 170 and the first signal pin 176 may extend from the top wall 164 toward the bottom wall 166. The first power pin 170 and / or the first signal pin 176 may be slidably engaged with the top wall 164. In some embodiments, the first power pin 170 and / or the first signal pin 176 may be spring loaded relative to the top wall 164 so that the first power pin 170 and the first signal pin 176 are biased away from the top wall 164. The second power pin 172 and the second signal pin 178 may extend from the bottom wall 166 toward the top wall 164. The second power pin 172 and / or the second signal pin 178 may be slidably engaged with the bottom wall 166. In some embodiments, the second power pin 172 and / or the second signal pin 178 can be spring loaded relative to the bottom wall 166 such that the second power pin 172 and the second signal pin 178 are biased away from the bottom wall 166. The center wall 162 can be disposed between the first power pin 170 and the first signal pin 176. The center wall 162 can be disposed between the second power pin 172 and the second signal pin 178.

[0065] View further Fig.10 , the first power pin 170, the second power pin 172, the first signal pin 176, and the second signal pin 178 can be in electrical communication with the load 158. The first power pin 170 and the second power pin 172 can be sized and configured to provide electrical energy from the power source 102 on the material handling vehicle 100 to the base 156 and / or the load 158 when the clamp assembly 110 is engaged with the center wall 162 (e.g., to support a refrigeration compressor, run a fan, illuminate a lamp, an actuator, a carousel, a light, etc.).

[0066] refer to Fig.11 , the clamp assembly 110 is illustrated as being engaged with the base 156. The first signal pin 176 and the second signal pin 178 may be sized and configured to transmit a signal between the base 156 and / or the load 158 on the material handling vehicle 100 and the controller 108 when the clamp assembly 110 is engaged with the center wall 162. The information may include, for example, an internal temperature of the load 158, inertial motion data of the base 156 and / or the load 158, position data of the base 156 and / or the load 158, time since the load 158 was opened, etc. The first signal pin 176 and the second signal pin 178 may be sized and spaced relative to each other to correspondingly contact one or more of the plurality of signal contacts 140A-140C on the clamp assembly 110.

[0067] Reference again Fig.11In operation, the first arm portion 104 and the second arm portion 106 of the clamp assembly 110 may be inserted between the top wall 164 and the bottom wall 166 such that the central wall 162 may be received between the first grip assembly 114 and the second grip assembly 116. The controller 108 may direct the first grip assembly 114 to pivot outwardly relative to the first arm portion 104 and the second grip assembly 116 to pivot outwardly relative to the second arm portion 106 to actuate the first grip assembly 114 and the second grip assembly 116 from the stowed position to the deployed or clamped position. In other words, the controller 108 may cause the first grip assembly 114 to selectively pivot relative to the first arm portion 104 and the second grip assembly 116 to selectively pivot relative to the second arm portion 106 to grasp and secure the central wall 162. Thus, the central wall 162 may be securely compressed and gripped between the first clamp arm 120 and the second clamp arm 132, thereby securing the base 156, and thus the load 158, to the material handling vehicle 100. The material handling vehicle 100 and base 156 may be collectively referred to as a material handling system 190.

[0068] In an example, when the first grip assembly 114 is pivoted outwardly relative to the first arm portion 104, the first power contact 124 can contact the first power pin 170 and can slide over the first power pin 170. Therefore, the first power contact 124 can press the first power pin 170 into the top wall 164, and the first power contact 124 can be placed in electrical communication with the first power pin 170. In an example, when the first grip assembly 114 is pivoted outwardly relative to the first arm portion 104, the second power contact 128 can contact the second power pin 172 and can slide over the second power pin 172. Therefore, the second power contact 128 can press the second power pin 172 into the bottom wall 166, and the second power contact 128 can be placed in electrical communication with the second power pin 172.

[0069] In an example, when the second grip assembly 116 is pivoted outwardly relative to the second arm portion 106, the first signal contact 136 can contact the first signal pin 176 and can slide over the first signal pin 176. Therefore, the first signal contact 136 can press the first signal pin 176 into the top wall 164, and the first signal contact 136 can be placed in electrical communication with the first signal pin 176. In an example, when the second grip assembly 116 is pivoted outwardly relative to the second arm portion 106, the second signal contact 140 can contact the second signal pin 178 and can slide over the second signal pin 178. Therefore, the second signal contact 140 can press the second signal pin 178 into the bottom wall 166, and the second signal contact 140 can be placed in electrical communication with the second signal pin 178. Thus, the controller 108 may electronically send and receive information to and from the base 156 and / or the load 158 via the first signal contacts 136 and / or the second signal contacts 140 .

[0070] Go to Fig.12 , showing a second embodiment of a load assembly having a tray or tray-like base. The load assembly 252 may be Fig.10 and Fig.11 In general, the second embodiment of the load assembly 252 can be substantially similar to Fig.10 and Fig.11 The load assembly 252 may be similar to the load assembly 152 of FIG. 1 , except that the power contacts and the signal contacts are located along the center wall 162 instead of opposite the top wall 164 and the bottom wall 166. The load assembly 252 may include a base 156 and a load 158. The base 156 may support the load 158. Additionally, the base 156 may include the center wall 162, the top wall 164, the bottom wall 166, the first power pin 170, the second power pin 172, the first signal pin 176, and the second signal pin 178.

[0071] The center wall 162 may be connected between the top wall 164 and the bottom wall 166. Fig.10 and Fig.11In contrast to the load assembly of the embodiment of the present invention, any one of the first power pin 170, the second power pin 172, the first signal pin 176, and / or the second signal pin 178 may extend outwardly from the center wall 162 between the top wall 164 and the bottom wall 166 in a manner perpendicular to the center wall 162. Any one of the first power pin 170, the second power pin 172, the first signal pin 176, and the second signal pin 178 may be slidably engaged with the center wall 162 and spring-loaded relative to the center wall 162. The first power pin 170 and the second power pin 172 may extend opposite to each other. The first signal pin 176 and the second signal pin 178 may extend opposite to each other. The center wall 162 may be between the first power pin 170 and the first signal pin 172. The center wall 162 may be between the first signal pin 176 and the first signal pin 178.

[0072] View further Fig.12 , the first power pin 170, the second power pin 172, the first signal pin 176, and the second signal pin 178 can be in electrical communication with the load 158. The first power pin 170 and the second power pin 172 can be sized and configured to provide electrical energy to the base 156 and / or the load 158 (e.g., to support a refrigeration compressor, run a fan, illuminate a lamp, an actuator, a carousel, a lamp, etc.).

[0073] In general, the fixture assembly 110 may be modified or arranged in alternative embodiments to align the power pins and the signal pins with each other. Fig.10 and Fig.11 The load assembly 252 is engaged. For example, return to reference Figure 5 , as seen in the side view, the first clamping arm 120 includes a first side 262 facing the second clamping arm 132. Additionally or alternatively, the first clamping arm 120 may include a third power contact and a third signal contact (not shown) mounted along the first side 262. The third signal contact may include a plurality of signal contacts and a plurality of insulators. It is contemplated that the third power contact and the third signal contact may be comprised of a conductive material and mounted in an electrically insulating material. The third power contact may be in electrical communication with the power supply 102 and the controller 108. The controller 108 may selectively energize the third power contact. The third signal contact may be in electrical communication with the controller 108.

[0074] The third power contact and the third signal contact can extend laterally from the first clamp arm 120. In other words, the third power contact and the third signal contact can protrude beyond the first side 262. A switch can be included to allow an operator to turn on power to the third power contact and the third signal contact. The first clamp arm 120 can be connected to the third power contact and the third signal contact via the third power contact and the third signal contact. Fig.12The load assembly 252 of the embodiment of the present invention is operated together. In operation, the third power contact can contact and compress the first power pin 170 and the third signal contact can contact and compress the first signal pin 176.

[0075] Return to reference Figure 8 , as seen in the side view, the second clamping arm 132 may include a second side 266 facing the first clamping arm 120 and opposite the first side 262. Additionally or alternatively, the second clamping arm 132 may include a fourth power contact and a fourth signal contact (not shown) mounted along the second side 266. The fourth signal contact may include a plurality of tracks and a plurality of insulators. It is contemplated that the fourth power contact and the fourth signal contact may be comprised of a conductive material and mounted in an electrically insulating material. The fourth power contact may be electrically connected to the power supply 102 and the controller 108. The controller 108 may selectively energize the fourth power contact. The fourth signal contact may be electrically connected to the controller 108.

[0076] The fourth power contact and the fourth signal contact can extend laterally from the second clamping arm 132. In other words, the fourth power contact and the fourth signal contact can protrude beyond the second side 266. The switch can allow an operator to turn on power to the fourth power contact and the fourth signal contact. The second clamping arm 132 can communicate with the fourth power contact and the fourth signal contact via the fourth power contact and the fourth signal contact. Fig.12 The fourth power contact may contact and compress the second power pin 172 during operation. Additionally, the fourth signal contact may contact and compress the second signal pin 178 during operation.

[0077] As described previously herein, the clamp assembly 110 (see Figure 2 ) enables the material handling vehicle to provide power and / or communication signals to the load 158 (see Fig.11 ). For example, the load 158 cab is a load support container, a material sorting system, etc. The load can have a base to receive power and / or communication signals from the material handling vehicle. As described previously herein, the load can be embodied in various ways. As described below, the material sorting system can be coupled to a base that can be engaged by the material handling vehicle.

[0078] In large storage warehouses storing objects such as consumer goods to be purchased, goods can be picked up from shelves and the like and sorted before being shipped out to consumers for purchase. In order to pick up and organize these goods, conventional "put walls" and order picking carts are often used. However, these conventional "put walls" are fixed and the order picking carts are manually pushed by workers. In addition, conventional order picking often includes workers placing items on pallets or in carts.

[0079] The present disclosure provides a material sorting system that can be configured to travel or move to a location of stored goods within a warehouse. The material sorting system can be configured to be operably attached to a material handling vehicle. The operably attached member can include an electrical attachment member, such as the clamp assembly previously described herein having the above-mentioned electrical power contacts and / or electronic communication contacts (see Figure 1 ).

[0080] In some embodiments, the material sorting system can be driven by an internal drive system and can be configured to be driven autonomously or by an operator. In some embodiments, the material sorting system can indicate a predetermined position for storing goods in the material sorting system. In some embodiments, the material sorting system can be a carousel with a storage rack or container that moves along the track of the carousel. In some embodiments, the track can be oriented vertically relative to the ground. In other embodiments, other track orientations (such as horizontal tracks or rotating tracks) are considered. For example, certain features and combinations of features presented for a specific embodiment in the above discussion can be appropriately used in other embodiments and other combinations. As will be described in this article, when using the material sorting system described herein, order picking can be improved. For example, the system and method described herein can increase the placement density. This can enable operators or workers to complete more orders. Ergonomics can also be improved, for example, the carousel system can place appropriate totes or boxes in areas, heights or positions that are convenient for workers.

[0081] refer to Fig.13 , the material sorting system 310 can be coupled to the base 156 (see Figure 10-12 ). The material sorting system 310 may include a carousel assembly 318.

[0082] In the illustrated embodiment, the base 156 may include a drive system 312. The drive system 312 may operate the wheels 314 to move the base 356 and the carousel assembly 318 in a forward and rearward direction along the Z axis, such as in FIG. Fig.13 The drive system 312 can be configured to rotate the wheels 314 in the opposite direction, for example, similar to tank-steering, to rotate the base 156 about the Y axis. The drive system 312 can be powered by an onboard power source (e.g., one or more batteries). Casters 322 can be attached to the base 156, shown here as corners 324 of the rectangular base 156, and can provide additional support and stability for the material sorting system 310 when the base 156 is not carried by the material handling vehicle.

[0083] As previously described herein, the base 156 may be sized and shaped similar to a pallet and may be configured to dock with a material handling vehicle. For example, the base 156 may have a center wall 162 and openings or fork slots 163 on each side of the center wall 162. Fig.14 As best shown in FIG. 1 , a material handling vehicle 100 (eg, a high lift forklift) may include a pair of forks (not shown, see FIG. Figure 1 ), the fork being configured to be received in the fork slot 163 of the base 156. The fork slot 163 in the base 156 can enable a material handling vehicle to carry and move the material sorting system 310. As mentioned earlier in this document, the configuration of a material handling vehicle engaged with the base 156 can be referred to as a material handling system 190. In some embodiments, the base 156 can take other shapes and configurations. For example, the base 156 can be substantially circular. In autonomous embodiments, a circular base can be advantageous and provide better maneuverability.

[0084] The carousel assembly 318 may be a vertical carousel and include one or more storage units that are configured to be movable relative to the base 156 to receive items picked by an order picker. In the illustrated embodiment, the carousel assembly includes a plurality of storage units 320 that are movable along a track 326 on a set of opposing posts 328 coupled to the base 156. In the illustrated embodiment, the carousel assembly 318 may include an actuation mechanism 327 that is operably coupled to the track 326 and configured to move the plurality of storage units 320 along the track 326. In some embodiments, the actuation mechanism 327 may include a motor that is configured to drive a belt, chain, or gear drive system (not shown) to move the plurality of storage units 320 along the track 326. In other embodiments, the actuation mechanism 327 may include a linear actuator or any other mechanical, electrical, or hydraulic mechanism capable of moving the plurality of storage units 320. The column 328 can be coupled to the base 156 and extend upward from the base 156. In the illustrated embodiment, the column 328 can be generally arranged on the wheel 314 and extend vertically along the Y-axis. The position of the column 328 on the wheel 314 can distribute the weight of the carousel assembly 318 more directly to the wheel 314 in a direction substantially perpendicular to the ground (e.g., in the direction of the y-axis). This arrangement can enhance the stability and control of the material sorting system 310.

[0085] It is contemplated that although the track 326 can provide a continuous path for the storage units 320 to traverse along the column 328. In some embodiments, different stop positions along the continuous path can be provided. The column 328 can further include indicators 330 at different stop positions along the column 328. The indicator 330 can be a light or other identification mark, and can provide information to the operator 340. In some embodiments, the indicator 330 can be a multi-color light. For example, during operation, the indicator 330 can be normally lit as a red light. In order to indicate that the goods are placed in one of the multiple storage units 320 at one of the different stop positions, one of the indicators 330 corresponding to each storage unit 320 can be lit green to alert the operator to the respective storage box 320 for placing the picked goods. Other embodiments using indicators along the column 328 to specify the placement of goods in a particular storage unit 320 are also within the scope of the present disclosure. In some embodiments, each of the multiple storage boxes 320 may include an indicator to specify the placement of goods in a particular storage unit 320. In some embodiments, each of the plurality of storage bins 320 may include a smart barcode label. The smart barcode label may be integrated with a controller or warehouse management system to specify the placement of goods within a particular storage unit 320.

[0086] Fig.14 An example movement of the storage unit 320 along the column 328 is shown (as indicated by arrow 329). The storage unit 320 can be configured to be accessible along the entire length of the track 326. Fig.14 , the actuation mechanism 327 can be configured to move the storage unit 320 closest to the operator 340 in an upward direction relative to the base 156. It should be understood that the direction of motion can also be reversed to move the storage unit 320 closest to the operator 340 in a downward direction relative to the base 156 (e.g., the motor of the actuation mechanism can be reversed). The movement of the storage units 320 can be automated (i.e., programmed to position a particular storage unit 320 at a particular different stop position based on remote input or local input), mechanically driven and controlled by an operator using a switch or control panel, or manually moved by an operator on the track 326. As described below, the carousel assembly 318 can be powered by the power supply 102 on the material handling vehicle 100 via electrical contacts on the clamp assembly, which can also provide power to the drive system 312 and / or the actuation mechanism 327. In some embodiments, the carousel assembly 318 can include a separate power supply (not shown).

[0087] Return to reference Fig.11, the base 156 may include one or more electrical contacts configured to receive power signals or communication signals from corresponding electrical contacts on the clamp assembly 110. As previously described herein, the clamp assembly 110 may be configured to transmit power signals and communication signals from the material handling vehicle 100 (such as a material handling vehicle 100) via one or more electrical contacts within the base 156. Fig.14 material handling vehicle) delivered to Fig.14 The material sorting system 310 shown in . The clamp assembly 110 can be positioned between a pair of forks on a material handling vehicle and can include a first gripping arm or assembly 114 and a second gripping arm or assembly 116. The first gripping assembly 114 and the second gripping assembly 116 can include at least one power contact (e.g., a first power contact 124 and a second power contact 128). In some embodiments, the first gripping assembly 114 and the second gripping assembly 116 can include at least one signal contact (e.g., a first signal contact 136 and a second signal contact 140). Additional power contacts and signal contacts or alternative arrangements of power contacts and signal contacts are contemplated (e.g., see Fig.12 ).

[0088] As previously described herein, the first grip assembly 114 and the second grip assembly 116 can be configured to selectively and removably engage the two sides of the base 156 via the center wall 162 when a pair of forks are received within the fork slots 163. In the engaged position, electrical contacts can be disposed in the base 156 within one or both of the two fork slots 163 and can be configured to contact one or both of the power contacts and the signal contacts (e.g., the first power contact 124 and the second power contact 128 and / or the first signal contact 136 and the second signal contact 140). For example, the base 156 can include the first power pin 170, the second power pin 182, the first signal pin 176 and the second signal pin 178 within the fork slots 163 and adjacent to the center wall 162. When in electrical contact, power and communications can be transferred between the material handling vehicle 100 and the material sorting system 310.

[0089] The carousel assembly 318, including the actuation mechanism 327 and the indicator light 330, can be in electrical communication with one or more of the first power pin 170 and the second power pin 182 and the first signal pin 176 and the second signal pin 178. For example, when power is provided from an external source, the carousel assembly 318 can receive power from the first power pin 170 and the second power pin 182. In operation, when the clamp assembly 110 of the material handling vehicle is engaged with the base 156, the carousel assembly 318 can be powered by the power source 102 on the material handling vehicle 100 via the first power pin 170 and the second power pin 182. The carousel assembly 318 can also receive communication and / or command signals from the first signal pin 176 and the second signal pin 178. In operation, when the clamp assembly 110 of the material handling vehicle is engaged with the base 156, the carousel assembly 318 can receive communication and / or command signals from the controller 108 on the material handling vehicle 100 via the first signal pin 176 and the second signal pin 178.

[0090] As described above, the actuation mechanism 327 of the carousel assembly can be in electrical communication with one or more of the first power pin 170 and the second power pin 182 and the first signal pin 176 and the second signal pin 178. For example, when the clamp assembly 110 of the material handling vehicle is engaged with the base 156, the actuation mechanism 327 can receive power from the power source 102 on the material handling vehicle via the first power pin 170 and the second power pin 182. The actuation mechanism 327 can also receive communication signals and / or command signals from the first signal pin 176 and the second signal pin 178. In operation, when the clamp assembly 110 of the material handling vehicle is engaged with the base 156, the actuation mechanism 327 can receive a communication signal from the controller 108 on the material handling vehicle to initiate an actuation command. The actuation command can include positioning the plurality of storage units 320 in different stop positions along the track 326 of the carousel assembly 318.

[0091] Similarly, the indicator 330 of the carousel assembly can be in electrical communication with one or more of the first power pin 170 and the second power pin 182 and the first signal pin 176 and the second signal pin 178. When the material handling vehicle is engaged with the base 156, the indicator 330 can receive power from the power source 102 on the material handling vehicle via the first power pin 170 and the second power pin 182 to turn the indicator light on / off. The indicator 330 can also receive communication and / or command signals from the first signal pin and the second signal pin. In operation, when the clamp assembly 110 of the material handling vehicle is engaged with the base 156, the indicator 330 can receive a communication signal from the controller 108 on the material handling vehicle to issue a lighting command (e.g., to change the color of the indicator 330, etc.).

[0092] As described above, the controller 108 on the material handling vehicle 100 can actuate and control the material sorting system 310. In some embodiments, the material handling system 190 including the material handling vehicle 100 and the material sorting system 310 can be used with a warehouse management system (not shown). The warehouse management system can generate and issue a picking command to the operator 340 of the material handling vehicle 100 (e.g., via a personal device or handheld device) and simultaneously to the controller 108 of the material handling vehicle 100. When the clamp assembly 110 is engaged with the base 156 and electrically communicates with the electrical contacts within the base 156, the picking command can be generated via the electrical contacts within the clamp assembly 110 (see Fig.11 ) transmits the picking command to the material sorting system 310. When the controller 108 receives the picking command, the controller can trigger the actuation mechanism 327 on the material sorting system 310 to position the appropriate storage unit 320 to an ergonomic placement position for the operator 340. The controller 108 can convey a signal to illuminate the indicator light 330 adjacent to the storage unit 320 to indicate to the operator which storage unit 320 to place the picked goods or items. When the order picking operation is completed, the operator 340 can transport the material sorting system 310 to an area within the warehouse via the material handling vehicle 100. In some embodiments, the material sorting system 310 can be driven autonomously between areas within the warehouse. In some embodiments, the carousel assembly 318 can include an onboard controller (not shown). The onboard controller can receive the picking command from the warehouse management system, and the onboard controller can trigger the actuation mechanism 327 on the material sorting system 310 to position the appropriate storage unit 320 to an ergonomic placement position for the operator 340.

[0093] In some embodiments, the carousel assembly 318 may include an electrical switch in electrical communication with the actuation mechanism 327. The electrical switch may be actuated by an operator of the material handling vehicle to trigger the actuation mechanism 327 on the material sorting system 310 to position the appropriate storage unit 320 to the placement location desired by the operator. In other embodiments, the carousel assembly 318 may include a hand crank or flywheel assembly mechanically coupled to the actuation mechanism 327. The hand crank may be actuated by an operator of the material handling vehicle to manually actuate the actuation mechanism 327 on the material sorting system 310 to position the appropriate storage unit 320 to the placement location desired by the operator.

[0094] Fig.15Another embodiment of a material sorting system 410 is shown. In many respects, the material sorting system 410 is similar to the material sorting system 310 described above, and similar numbers in the 400 series are used for the material sorting system 410. For example, the material sorting system 410 includes a carousel assembly 418. The base 156 may include casters 422 at corners 424, and the carousel assembly may include a column 428 with an indicator 430 and a track 426 along which the storage unit 420 can move. The material sorting system 410 may also be configured to be electrically coupled to the present invention. Fig.15 100 is shown as a material handling vehicle 100 of a low lift forklift, wherein the forks 103, 105 extend through the openings or fork slots 163 in the base 156. Electrical coupling can provide power and communication between the material handling vehicle 100 and the material sorting system 410. In some aspects, however, the material sorting systems 310, 410 are different from each other. For example, the carousel assembly 418 can be rotated 90 degrees on the base 156 relative to the orientation of the carousel assembly 318 on the base 156 of the material sorting system 310. This arrangement can provide access from the side of the material handling vehicle 100 to the storage unit. The arrangement can also allow a combination of more than one material sorting system per material handling vehicle. For example, they can be modularly stacked side by side on the forks of the material handling vehicle. In an embodiment incorporating multiple material sorting systems, multiple fixture assemblies can be integrated between the forks to accommodate multiple material sorting systems. In some embodiments, adjacent material sorting systems can be electrically coupled together (e.g., via cables, etc.).

[0095] In other embodiments, other configurations are possible. For example, see Fig.16 , another embodiment of a material sorting system 510 is shown. In many respects, the material sorting system 510 is similar to the material sorting system 410 described above, and similar numbers in the 500 series are used for the material sorting system 510. For example, the material sorting system 510 includes a carousel assembly 518 having a column 528 with an indicator 530 and a track 526 along which the storage unit 520 can move. Similarly, the material sorting system 510 can be configured to be electrically coupled to the material handling vehicle 100, such as Fig.16Shown as a low-lift forklift. However, in some aspects, the material sorting systems 410, 510 may be different. For example, the base 156 may be a fixed base without powered wheels or driven wheels. The base 156 may have movable casters, or casters may not be provided. In these embodiments, the material sorting system 510 may be located, for example, at the end of an aisle and positioned so that a vehicle (e.g., a material handling vehicle 100) engages with it and moves the material sorting system 510 as needed. Additionally or alternatively, the material sorting system 510 may be placed on top of an automated guided vehicle (AGV) that can move the material sorting system 510 from one location to another. As previously described herein, the material sorting system 510 may be powered by the on-board power supply 102 via a fixture assembly (not shown) on the material handling vehicle.

[0096] In other embodiments, other configurations are possible. For example, see Fig.17 , another embodiment of a material sorting system 610 is shown. In many respects, the material sorting system 610 is similar to the material sorting system 510 described above, and similar numbers in the 600 series are used for the material sorting system 610. For example, the material sorting system 610 includes a carousel assembly 618 with a plurality of storage units 620. Similarly, the material sorting system 610 can be configured to be electrically coupled to the material handling vehicle 100. However, in some aspects, the material sorting systems 510, 610 can be different. For example, the material sorting system 610 can be a horizontal or rotating carousel and include a single central column 628 extending vertically from the base 156. The carousel assembly 618 can be configured to rotate around the base 156 about an axis generally defined by the column 628. In the illustrated embodiment, the material sorting system 610 can include an outer cage or structure 644 that at least partially surrounds the carousel assembly 618. As previously described herein, the material sorting system 610 may be powered by an onboard power source via a clamp assembly (not shown) on the material handling vehicle.

[0097] In other embodiments, yet further various configurations are possible. For example, see Fig.18 , another embodiment of a material sorting system 710 is shown. In many aspects, the material sorting system 710 is similar to the material sorting systems 310 and 410 described above, and similar numbers in the 700 series are used for the material sorting system 710. For example, the material sorting system 710 includes a carousel assembly 718. The base 156 may include a column 728 extending from the base 156 and a track 726 along which the storage unit 720 can move. The actuation mechanism 727 can be configured to move the storage unit 720 along the track 726. The material sorting system 710 can also be configured to be moved via the clamp assembly 110 (see Fig.11) is electrically coupled to the material handling vehicle 100. The electrical coupling can provide power and communication between the material handling vehicle 100 and the material sorting system 710. However, in some aspects, the material sorting systems 310, 710 are different from each other. For example, the sides of the posts 728 on the carousel assembly 718 may include openings 746 to allow loading / unloading of the storage units 720 from the sides of the carousel assembly 718. In the illustrated embodiment, the storage units 720 may include a conveyor track 748 having a plurality of rollers 750 along the base of each storage unit 720. In some embodiments, the rollers 750 can be powered and activated (e.g., instructed to roll in a first direction or a second direction) by a connection provided between the base 156 and the clamp assembly 110.

[0098] Reference now Fig.19 , the opening 746 in the column 728 together with the conveyor track 748 in the storage unit 720 can allow loading and unloading operations from an external conveyor system 760 within a warehouse environment. That is, the material handling vehicle 100 can be driven to the conveyor system 760, and the side of the material sorting system 710 can be aligned with the conveyor system 760 so that the storage unit 720 on the carousel assembly 718 is adjacent to the end of the conveyor system 760. Then, the goods can be loaded onto the conveyor system 760 or unloaded from the storage unit 720. In some embodiments, the conveyor track 748 and the roller 750 can be rotated via a conveyor actuator (not shown). In some embodiments, the conveyor actuator can be electrically connected to the electrical contacts in the base 156 to receive power and communication signals.

[0099] Certain features and combinations of features presented in the above discussion with respect to specific embodiments may be utilized in other embodiments and in other combinations as appropriate. In this regard, for example, different configurations of a base (e.g., electrical contacts) or a carousel assembly (e.g., orientation of a column), etc., presented with respect to a particular one of the material sorting systems 310, 410, 510, 610, 710 may be implemented in conjunction with any number of other material sorting systems 310, 410, 510, 610, 710 or others.

[0100] Although various spatial and directional terms such as top, bottom, lower, middle, lateral, horizontal, vertical, front, etc. may be used to describe examples of the present disclosure, it is understood that such terms are used only relative to the orientation shown in the drawings. The orientation may be reversed, rotated, or otherwise changed so that upper is lower and vice versa, horizontal becomes vertical, etc.

[0101] In this specification, the embodiments of the present specification have been described in a manner that enables a clear and concise description to be written, but it is intended and will be understood that the embodiments may be combined or separated in different ways without departing from the present invention. For example, it should be understood that all preferred features described herein are applicable to all aspects of the invention described herein.

[0102] Therefore, although the invention has been described in conjunction with particular embodiments and examples, the invention is not necessarily so limited, and many other embodiments, examples, uses, modifications, and deviations from the described embodiments, examples, and uses are intended to be covered by the appended claims. The entire disclosure of each patent and publication cited herein is incorporated herein by reference, as if each such patent or publication was individually incorporated herein by reference.

[0103] Various features and advantages of the invention are set forth in the following claims.

Claims

1. A material sorting system, the material sorting system being adapted to be coupled to a material handling vehicle, the material sorting system comprising: a base including a first fork slot and a second fork slot adapted to receive a pair of forks from the material handling vehicle; A carousel assembly coupled to the base, the carousel assembly comprising: a plurality of storage units; and an actuation mechanism configured to move the plurality of storage units relative to the base; at least one power contact within the first fork slot of the base and in electrical communication with the carousel assembly, the at least one power contact adapted to engage a corresponding power contact on a clamp assembly of the material handling vehicle to transfer power between the material handling vehicle and the carousel assembly; and at least one signal contact within the second fork slot of the base and in electrical communication with the carousel assembly, the at least one signal contact adapted to engage with a corresponding signal contact on the clamp assembly to transmit a communication signal between the material handling vehicle and the carousel assembly, Wherein the clamp assembly is positioned between the forks on the material handling vehicle.

2. The material sorting system according to claim 1, wherein: The at least one power contact and / or the at least one signal contact protrudes from a surface of the base into a cavity formed by the fork groove.

3. The material sorting system according to claim 1, wherein: The at least one power contact and / or the at least one signal contact are spring loaded.

4. The material sorting system according to claim 1, wherein: The carousel assembly further comprises: a set of columns extending from the base, and A movable track on each post, the plurality of storage units being coupled along the movable track.

5. The material sorting system according to claim 4, wherein: The actuation mechanism is configured to move the plurality of storage units along the movable track between stop positions.

6. The material sorting system according to claim 5, wherein: The set of columns includes an indicator light adjacent to the stop position of the plurality of storage units and configured to indicate a placement location of the picked merchandise.

7. A material sorting system, comprising: A base, the base comprising: a first fork pocket and a second fork pocket adapted to receive a pair of forks from a material handling vehicle; top wall; a bottom wall spaced apart from the top wall; and a central wall disposed between the top wall and the bottom wall and separating the pair of fork grooves; a carousel assembly coupled to the base and comprising a plurality of storage units; at least one power contact within the first fork slot of the base and in electrical communication with the carousel assembly, the at least one power contact adapted to engage with a corresponding power contact on a clamp assembly of the material handling vehicle to transfer power between the material handling vehicle and the carousel assembly; and at least one signal contact within the second fork slot of the base and in electrical communication with the carousel assembly, the at least one signal contact adapted to engage with a corresponding signal contact on the clamp assembly to transmit a communication signal between the material handling vehicle and the carousel assembly, Wherein the clamp assembly is positioned between the forks on the material handling vehicle.

8. The material sorting system according to claim 7, wherein: The at least one power contact and / or the at least one signal contact are spring loaded.

9. The material sorting system according to claim 7, wherein: The at least one power contact and / or the at least one signal contact protrudes into a cavity formed by the pair of prongs.

10. The material sorting system according to claim 9, wherein: The at least one power contact and / or the at least one signal contact protrudes from the bottom wall or the top wall of the base.

11. The material sorting system according to claim 9, wherein: The at least one power contact and / or the at least one signal contact protrudes from the central wall of the base.

12. The material sorting system according to claim 7, wherein: The at least one power contact is a first power contact extending from the top wall toward the bottom wall of the base.

13. The material sorting system according to claim 12, wherein: The base further includes a second power contact extending from the bottom wall and opposite the first power contact.

14. The material sorting system according to claim 13, wherein: The base further comprises: a first signal contact extending from the top wall toward the bottom wall of the base; and A second signal contact extends from the bottom wall and is opposite to the first signal contact.

15. The material sorting system according to claim 14, wherein: The first power contact and the first signal contact are disposed in one of the pair of fork grooves; and The second power contact and the second signal contact are arranged in the other fork groove of the pair of fork grooves.

16. The material sorting system according to claim 7, wherein: The carousel assembly also includes an actuation mechanism configured to move the plurality of storage units relative to the base.

17. The material sorting system according to claim 16, wherein: The actuation mechanism is configured to move the plurality of storage units in an upward and downward direction relative to the base.

18. The material sorting system according to claim 16, wherein: The actuation mechanism is configured to rotate the plurality of storage units relative to the base.

19. The material sorting system according to claim 7, wherein: The plurality of storage units include a plurality of powered rollers along a base of each of the plurality of storage units.

20. The material sorting system according to claim 19, wherein: The carousel assembly includes a conveyor actuation mechanism configured to rotate the plurality of powered rollers to load or unload merchandise onto a storage unit among the plurality of storage units.

21. A material sorting system, comprising: A rotary conveyor belt assembly, the rotary conveyor belt assembly comprising: a plurality of storage units; and an actuation mechanism configured to move the plurality of storage units relative to the base; a power contact in electrical communication with the actuation mechanism, the power contact adapted to engage a corresponding power contact on a clamp assembly of a material handling vehicle to transfer power between the material handling vehicle and the carousel assembly; and a signal contact in electrical communication with the actuation mechanism, the signal contact being adapted to engage a corresponding signal contact on the clamp assembly to transmit a communication signal between the material handling vehicle and the carousel assembly, wherein the base defines a first fork slot and a second fork slot, the first fork slot and the second fork slot being adapted to receive a pair of forks from the material handling vehicle; wherein the power contact is arranged in the first fork groove and the signal contact is arranged in the second fork groove; and Wherein the clamp assembly is positioned between the forks on the material handling vehicle.

22. The material sorting system of claim 21, further comprising a drive system coupled to the base.

23. The material sorting system according to claim 21, wherein: The carousel assembly further comprises: a set of posts extending from the base; and A movable track on each post, the plurality of storage units being coupled along the movable track, wherein the actuation mechanism is configured to move the plurality of storage units along the movable track between stop positions.

24. The material sorting system of claim 23, wherein: The set of columns includes an indicator light adjacent to the stop position of the plurality of storage units and configured to indicate a placement location of the picked merchandise.

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