Systems and methods for separating objects using vacuum diversion using one or more object handling systems

Abstract

A dispensing system for use in an induction system for use with an object handling system. The dispensing system provides dissimilar objects to one of a plurality of receiving units. The dispensing system includes an air intake system having an opening a fixed distance from a conveyor section, the air intake system assisting in moving objects on the conveyor section from the conveyor section to one of a plurality of adjacent transfer units.

Description

[0001] priority

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 62 / 789,775, filed on January 8, 2019; and this application claims priority to U.S. Patent Application Serial No. 16 / 661,820, filed on October 23, 2019, which claims priority to U.S. Provisional Patent Application Serial No. 62 / 884,351, filed on August 8, 2019, and U.S. Provisional Patent Application Serial No. 62 / 749,509, filed on October 23, 2018; And this application further claims priority to U.S. patent application serial number No. 16 / 543,105 filed on August 16, 2019, which is a continuation of U.S. patent application serial number No. 15 / 956,442 filed on April 18, 2018, which claims priority to U.S. provisional patent application serial number No. 62 / 486,783 filed on April 18, 2017, the disclosures of all of which are hereby incorporated by reference in their entirety. Background Art

[0003] The present invention relates generally to automation (e.g., programmable motion) and other handling systems, and particularly to programmable motion (e.g., robotic) systems intended for use in environments that require various objects (e.g., articles, packages, or packages) to be handled (e.g., sorted and / or otherwise distributed) to a number of output destinations.

[0004] Many object distribution systems receive objects in an ordered or unordered stream, which may be provided as individual objects or in groups (such as in bags), arriving on any of a number of different transport vehicles (usually conveyors, trucks, pallets, Gaylords, or boxes, etc.). Each object must then be distributed to the correct destination container, which is determined by identification information associated with the object, which is usually determined by a label printed on the object. The destination container can take a variety of forms, such as a bag or box or tote.

[0005] The processing of such objects is traditionally completed by workers, who, for example, scan the object using a handheld barcode scanner and then place the object at the assigned location. For example, many order fulfillment operations achieve high efficiency by adopting a process known as wave picking. In wave picking, orders are picked up from warehouse racks and placed at a location (for example, in a cargo box) that accommodates multiple orders for downstream sorting. In the processing stage, individual objects are identified and multi-object orders are merged into, for example, a single cargo box or shelf position so that they can be packaged and then shipped to customers. The processing of these objects (for example, sorting) is traditionally completed by hand. A manual sorter picks up an object from an incoming cargo box, finds a barcode on the object, scans the barcode with a handheld barcode scanner, determines the appropriate cargo box or shelf position for the item from the scanned barcode, and then places the item into the determined cargo box or shelf position, wherein all objects for the order are defined as belonging to the cargo box or shelf position. An automated system for order fulfillment is also proposed. See, for example, U.S. Patent Application Publication No. 2014 / 0244026, which discloses the use of a robotic arm and an arcuate structure that can be moved into the reach of the robotic arm.

[0006] In conventional parcel sorting systems, workers or automated systems typically pick up objects in the order they arrive and sort each object into a collection bin based on a given set of heuristics. For example, all objects of similar types might go to one collection bin, or all objects in a single customer order, or all objects destined for the same shipping destination, etc. Workers or automated systems are required to receive the objects and move each object to their assigned collection bin. If the number of input (received) objects of different types is large, a large number of collection bins may be required.

[0007] Such systems have inherent inefficiencies and inflexibility because the desired goal is to match incoming objects to assigned collection bins. Such systems may require a large number of collection bins (and therefore a large amount of physical space, significant capital costs, and significant operating costs) to the extent that it is not always most efficient to sort all objects to all destinations at once.

[0008] Some partially automated sorting systems involve the use of recirculating conveyors and tilted trays, where the tilted trays receive objects through manual sorting (manual induction), and each tilted tray moves past a scanner. Each object is then scanned and moved to a predefined location assigned to that object. The tray is then tilted to allow the object to fall into that location. In addition, partially automated systems (such as bomb bay recirculating conveyors) involve having the tray open a door on the bottom of each tray when the tray is positioned over a predefined chute, and then the objects fall from the tray into the chute. Again, the objects are scanned while in the tray, assuming that any identification code is visible to the scanner.

[0009] Such partially automated systems are lacking in key areas. As mentioned above, these conveyors have discrete trays that can be loaded with objects; they then pass through a scanning tunnel that scans the object and associates it with the tray it is on. When the tray passes the correct bin, a trigger mechanism causes the tray to dump the object into the bin. However, the disadvantage of such systems is that each turn requires an actuator, which increases mechanical complexity, and the cost of each turn can be very high.

[0010] The alternative is to use human labor to increase the number of turns available in the system or the number of bins collected. This reduces system installation costs but increases operating costs. Multiple units can then work in parallel, effectively increasing throughput linearly while keeping the number of expensive automated turns to a minimum. Such turns do not identify objects or turn them to specific locations, but rather they work with beam breaks or other sensors to try to ensure that an indiscriminate group of objects gets the appropriate turn. The lower cost of such turns combined with the small number of turns keeps the overall system turning cost low.

[0011] Unfortunately, these systems do not address the limitation on the total number of bins in the system. The system simply diverts an equal share of all objects to each parallel manual cell. Each parallel sorting cell must therefore have all of the same collection bin designations; otherwise an object may be delivered to a cell that does not have a bin to which the object is mapped. There remains a need for a more efficient and cost-effective object sorting system that sorts objects of various sizes and weights into appropriate fixed-size collection bins or pallets, yet is efficient at handling such varying sizes and weights of objects.

[0012] Furthermore, such systems require human personnel to oversee the introduction of objects, wherein the processing system may receive objects that it may not be able to manipulate effectively or at all. Summary of the invention

[0013] According to one aspect, the present invention provides a dispensing system for use in an induction system for use with an object handling system. The dispensing system provides dissimilar objects to one of a plurality of receiving units. The dispensing system includes an air intake system having an opening a fixed distance from a conveyor section, the air intake system assisting in moving objects on the conveyor section from the conveyor section to one of a plurality of adjacent transfer units.

[0014] According to another aspect, the present invention provides a dispensing system for use in an induction system for use with an object handling system. The dispensing system provides dissimilar objects to one of a plurality of receiving units. The dispensing system includes an air transport system and an air intake system, the air transport system including a forced air system, the air transport system and the air intake system together assist in moving the objects on the conveyor section from the conveyor section to one of a plurality of adjacent conveyors.

[0015] According to a further aspect, the present invention provides a method of distributing dissimilar objects to one of a plurality of receiving units in a pre-processing system for use with an object handling system. The method includes providing an air transport system opposite an air intake system, and engaging the air transport system with the air intake system to assist in moving the objects on the conveyor section from the conveyor section to one of a plurality of adjacent conveyors. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The following description may be further understood with reference to the accompanying drawings, in which:

[0017] Figure 1 An illustrative diagrammatic view of a processing system and an importing system according to an embodiment of the present invention is shown;

[0018] Figure 2 Shows Figure 1 An illustrative diagrammatic view of an input station of an induction system;

[0019] Figure 3A-3D Shown in Figure 2 illustrative diagrammatic views of the various stages of an object being moved by a perception unit at an input station;

[0020] Figure 4A-4D Shown in Figure 3A-3D illustrative diagrammatic side views of various stages of an object moving in an input station;

[0021] Figure 5 Shows Figure 1 Illustrative diagram bottom view of the perceptual unit of ;

[0022] Figure 6A-6C Shown from Figure 5 The imaging used ( Fig. 6A ), edge detection( Figure 6B ) and volume scan ( Figure 6C )'s perceptual unit's illustrative diagrammatic view of an object;

[0023] Figure 7 shows an illustrative diagrammatic view of a tag including a special treatment word according to an aspect of the system;

[0024] Figure 8 An illustrative diagrammatic view of a labeled object is shown, wherein the label includes a specially processed image(s) according to an aspect of the system;

[0025] Fig. 9 An illustrative diagrammatic view of a processing system and an introduction system according to another embodiment of the present invention is shown, which includes a deformable object introduction restriction system;

[0026] Figure 10A-10C Shown in Fig. 9 An illustrative diagrammatic side view of an object being processed in a deformable object introduction restraint system;

[0027] Fig.11 An illustrative diagrammatic view of a processing system and an import system according to a further embodiment of the present invention is shown, which includes a programmable motion device at an input station;

[0028] Fig.12 Shows Fig.11 An illustrative diagrammatic view of an input station of a system;

[0029] Fig.13 Shows Fig.11 and Fig.12 Illustrative diagrammatic view of a programmable motion device for an input station including an additional optional engaged object sensing unit ( Fig.11 and Fig.12 not shown);

[0030] Fig.14 Shows that there is Fig.13 Additional optional illustrative diagrammatic views of a grasped object engaging an object sensing unit;

[0031] Fig.15 A device with a set of illumination sources and an engaged sensing unit according to one aspect of the present invention is shown. Fig.14 illustrative diagrammatic views of grasped objects;

[0032] Fig.16 Shows Fig.14 An illustrative diagrammatic side view of a system of showing two sets of sensing units;

[0033] Fig.17 Shows Fig.15 An illustrative diagrammatic side view of a system showing Fig.16 The two sets of perceptual units shown in ;

[0034] Fig.18 shows an illustrative diagrammatic view of a 3D scanner system used in accordance with another aspect of the present invention;

[0035] Fig.19 an illustrative diagrammatic view showing a plurality of 3D scanner systems being used in accordance with further aspects of the present invention;

[0036] Fig. 20 an illustrative diagrammatic view showing a 3D scanning process of an end effector grasping an object;

[0037] Fig.21 an illustrative diagrammatic view showing a net 3D scan of an object and a portion of an end effector grasping the object, showing a portion of the 3D scan of the end effector to be removed;

[0038] Figure 22A-22D shows an illustrative diagrammatic view of an object being subjected to a deformability test in accordance with an aspect of the present invention;

[0039] Fig.23 shows an illustrative diagrammatic view of an object processing system for use with a pre-processing system in accordance with an aspect of the present invention;

[0040] Fig.24 Shows Fig.23 An illustrative diagrammatic side view of an object handling system of;

[0041] Fig.25 Shows Fig.23 an illustrative diagrammatic rear view of an object handling system of;

[0042] Fig.26 Shows Fig.23 illustrative diagrammatic views of processing stations in an object processing system;

[0043] Fig. 27 Shows Fig.23 Illustrative front view of the major perceptual systems in the object processing system of

[0044] Figure 28A-28C Shows Fig.23 An illustrative diagrammatic view of a diverting station in an object handling system of FIG. 1 , showing objects on a conveyor ( Fig.28A ), engaged by a steering paddle ( Fig.28B ), and unloading objects into the bracket ( Fig.28C );

[0045] Fig.29 Shows Fig.23 An illustrative diagrammatic view of a destination portion of an object handling system of;

[0046] Fig.30 Shows Fig.29 an illustrative diagrammatic view of a destination portion of a device, wherein the carriage moves along the track and unloads the object into the destination container;

[0047] Fig.31 shows an illustrative diagrammatic layout model view of an import system according to an aspect of the present invention;

[0048] Fig.32 An illustrative diagrammatic layout model view of another import system according to another aspect of the present invention is shown, which shows Fig. 9 A similar layout to the system;

[0049] Fig.33 An illustrative diagrammatic model view of an import system according to another aspect of the present invention is shown, the import system including a classification system;

[0050] Fig.34 An illustrative diagrammatic view of an induction system and a plurality of processing systems according to an embodiment of the present invention is shown;

[0051] Fig.35 An illustrative diagrammatic view of an induction system and a plurality of processing systems according to another embodiment of the present invention is shown;

[0052] Fig.36 An illustrative diagrammatic view showing an induction system and a plurality of processing systems according to a further embodiment of the present invention;

[0053] Fig.37 An illustrative diagrammatic view showing a plurality of induction systems and a plurality of processing systems according to an embodiment of the present invention is shown;

[0054] Fig.38 An illustrative diagrammatic view showing a plurality of different induction systems and a plurality of processing systems according to another embodiment of the present invention;

[0055] Fig.39A and Fig.39B An illustrative diagrammatic view of a weight sensing transmitter portion including a weight scale according to an aspect of the present invention is shown;

[0056] Fig.40A and Fig.40Bshows an illustrative diagrammatic view of a weight sensing transmitter portion including a load cell or force torque sensor in accordance with an aspect of the present invention;

[0057] Figure 41A-41D shows an illustrative diagrammatic view of a weight sensing transmitter portion according to an aspect of the present invention, which further determines the center of mass of an object;

[0058] Fig.42A and Fig.42B An illustrative diagrammatic view of a weight sensing transmitter portion including a plurality of scales according to an aspect of the present invention is shown;

[0059] Figure 43A-43C An illustrative diagrammatic view of a weight sensing conveyor portion including a plurality of rollers having either a load cell or a force torque sensor according to an aspect of the present invention is shown;

[0060] Fig.44 An illustrative diagrammatic view of an end effector used in accordance with an aspect of the present invention is shown, the end effector including any of a load cell or a force torque sensor;

[0061] Fig.45 shows an illustrative diagrammatic view of an end effector used in accordance with an aspect of the present invention, the end effector including a magnetic sensor;

[0062] Fig.46 shows an illustrative diagrammatic view of an end effector used in accordance with an aspect of the present invention, the end effector including a vacuum flow and / or pressure sensor;

[0063] Fig.47 shows an illustrative diagrammatic view of a weight sensing bracket used in accordance with an aspect of the present invention;

[0064] Fig.48 Shows Fig.47 An illustrative diagrammatic side view of a weight sensing bracket;

[0065] Fig.49 An illustrative diagrammatic view of an induction system according to an aspect of the present invention is shown, the induction system including an inclined conveyor having a conveyor portion including a bomb bay lift door;

[0066] Fig.50A and Fig.50B A diagram showing a horizontal conveyor according to one aspect of the present invention. Fig.49 illustrative diagrammatic view of a conveyor portion of;

[0067] Fig.51A and Fig.51B Shows Fig.50A and Fig.50B an illustrative diagrammatic end view of a conveyor portion of;

[0068] Fig.52A and Fig.52B shows an illustrative diagrammatic view of a conveyor section used in accordance with an aspect of the present invention, the conveyor section including a bomb bay door above a further inclined conveyor;

[0069] Fig.53 shows an illustrative diagrammatic view of a gas permeable conveyor portion having a vacuum roller used in accordance with an aspect of the present invention;

[0070] Fig.54 shows an illustrative diagrammatic view of an induction system according to an aspect of the present invention, the induction system including a gas permeable conveyor portion and a vacuum roll;

[0071] Figure 55A-Figure 55D The system for providing sorting by weight is shown in FIG. Fig.54 an illustrative diagrammatic side view of a gas permeable conveyor portion and a vacuum roll of;

[0072] Fig.56 An illustrative diagrammatic view of an induction system according to an aspect of the present invention is shown, the induction system including a conveyor to conveyor transport station;

[0073] Fig.57 shows an illustrative diagrammatic view of a gas permeable conveyor portion having a blower and a vacuum source used in accordance with an aspect of the present invention;

[0074] Fig.58 Shows Fig.57 illustrative diagrammatic side view of a gas permeable conveyor portion, a blower and a vacuum;

[0075] Figure 59A-Figure 59C shows the Fig.57 illustrative diagrammatic side view of a gas permeable conveyor portion, a blower and a vacuum;

[0076] Fig.60 shows an illustrative diagrammatic view of a gas permeable conveyor portion having a side blower and a side vacuum source used in accordance with an aspect of the present invention;

[0077] Fig.61 shows an illustrative diagrammatic view of a gas permeable conveyor portion having a side blower and side vacuum source and a bottom side blower source used in accordance with an aspect of the present invention;

[0078] Fig.62shows an illustrative diagrammatic view of a conveyor portion having a side blower and a side vacuum source used in accordance with an aspect of the present invention;

[0079] Fig.63 A diagram showing a device with relative chutes used in accordance with one aspect of the present invention Fig.62 illustrative diagrammatic views of a conveyor portion, a side blower, and a side vacuum source;

[0080] Fig.64 Shows Fig.63 illustrative diagrammatic views of a conveyor portion, a side blower, a side vacuum source, and opposing chutes;

[0081] Fig.65 An illustrative diagrammatic view of a conveyor section used in accordance with one aspect of the present invention is shown, the conveyor section including bi-directional rollers and a pair of opposing chutes;

[0082] Fig.66A and Fig.66B An illustrative diagrammatic view of a conveyor section used in accordance with an aspect of the present invention is shown, the conveyor section including bi-directional rollers and a pair of opposing chutes having bomb bay doors;

[0083] Fig.67 An illustrative diagrammatic view of a conveyor section used in accordance with an aspect of the present invention is shown, the conveyor section including a side blower and a side vacuum source and a pair of opposing chutes having bomb bay doors;

[0084] Fig.68A and Fig.68B shows an illustrative diagrammatic view of a conveyor portion having side paddles and a pair of opposing chutes used in accordance with an aspect of the present invention;

[0085] Fig.69 shows an illustrative diagrammatic view of a conveyor portion having side paddles and opposing chutes, one of the side paddles and opposing chutes including a bomb bay door, used in accordance with an aspect of the present invention;

[0086] Fig.70 As shown in reference Figure 1 , Fig. 9 , Fig.11 , Figure 34-Figure 38 , Fig.49 , Fig.54 , Fig.56 and Figure 63-Figure 69 Illustrative diagrammatic views of a plurality of processing systems for use with the disclosed induction systems employing manual and automated processing stations;

[0087] Fig.71 shows the same as the reference Figure 63-Figure 69An illustrative diagrammatic view of an object handling system for use with the disclosed automated carrier and an induction system for an automated processing station;

[0088] Fig.72 shows the same as the reference Figure 63-Figure 69 an illustrative diagrammatic view of an object handling system for use with the disclosed automated carrier and induction system for a manual handling station; and

[0089] Fig.73 shows the same as the reference Figure 63-Figure 69 an illustrative diagrammatic view of an object handling system for use with the disclosed automated carrier induction system, the induction system including both manual and automated handling stations;

[0090] The drawings shown are for illustrative purposes only. DETAILED DESCRIPTION

[0091] According to one embodiment, the present invention provides an import filter system in which objects (e.g., packages) are shielded and restricted from entering an object processing system. According to certain aspects of the present invention, only objects that meet defined criteria can be processed by the object processing system. The import filter system includes at least one evaluation system and a plurality of processing paths, at least one of the plurality of processing paths leading to an object processing system according to certain aspects of the present invention.

[0092] Automated package sorting systems need to be able to singulate and sort individual packages so that they can be routed to specific destinations. Some package sorting systems use robotic picking systems to manipulate packages. The robot obtains a grip on the package, separates the package from a pile of other packages to a position where the package can then be scanned and sends the package to a sorting location. Such automated package handling systems inevitably encounter packages that cannot be handled, for example, the package exceeds the system's packaging specifications. For example, a robot or gripper can only pick up goods within a weight specification. Therefore, the goods that it cannot manipulate may include goods that are too light or too heavy, too large or too small, or otherwise cannot be manipulated by the system.

[0093] These incompatible packages can potentially jam the system. If they are too large, they may get stuck on the conveyor system as they pass through the robotic package sorting system, preventing other packages from flowing through. Incompatible packages may also reduce the effective throughput of the sorting system. If they do make it through and are presented to the robotic picking system in a pile, the robot may attempt to pick up the incompatible package. If the package is outside the system's specifications, the resulting grip on the object may not be sufficient to safely transport the item, and the robot may drop the package and potentially damage it. Alternatively, if it is able to successfully pick and transport the package, in the process of doing so it may somehow damage the robotic picking system in the force required to move the out-of-spec package.

[0094] Compatible package specifications may include: a valid package weight range, a compatible package size range, a set of valid label types (e.g., printed labels vs. adhesive labels), exclusion of items marked as fragile, exclusion of items marked as insured high value and therefore preferably more carefully sorted manually, exclusion of items marked as containing hazardous materials (such as lithium ion batteries), and exclusion of packages that may be marked in the database as requiring exceptions or manual handling for any other reason. It is desirable to provide a system that filters out incompatible packages before they reach the package handling system, and / or improves the ability of the package handling system to specifically identify incompatible packages so that robotic picking is not attempted on objects that require manual manipulation.

[0095] According to an embodiment, the present invention provides an induction system for limiting and managing the induction of objects into an object handling system. In certain aspects, the system provides methods to automatically reroute incompatible packages before they reach a package sorting system consisting of one or more robotic pickers, or to minimize their impact if they reach a robotic pick area.

[0096] For example, Figure 1 An induction system 10 is shown filtering (eg, limiting or managing) objects being fed to an object handling system 12. The induction system 10 includes an input station 14 to which objects are presented, for example, in a single stream on a conveyor 22. Figure 1 , Fig. 9 , Fig.11 , Fig.23 , Figure 34-Figure 38 , Fig.49 , Fig.56 and Fig.70Any of the conveyors of the system may be cleated or uncleated conveyors, and the system may monitor the movement of the conveyors (and thus the objects thereon) via a plurality of sensors and / or a conveyor speed control system. The response evaluation portion 16 of the conveyor 22 includes one or more transport roller sets 30, and one or more disturbance rollers 32, such as Figure 2 Further references Figure 3A-3D , the perception unit (eg, camera or scanner) 18 is oriented horizontally toward the conveyor portion 16 , and the perception unit (eg, camera or scanner) 20 is oriented downward toward the conveyor portion 16 .

[0097] refer to Figure 4A-4D As the object travels along the transport roller 30, the object will contact the disturbance roller 32 (eg Figure 4B (as shown). The (multiple) disturbance rollers 32 can be any of the larger diameter rollers, or can be elevated relative to the transport rollers 30, and can rotate at a faster rotational speed than the transport rollers 30. In this way, and using the sensing units 18, 20, the system can (in conjunction with the computer processing system 100) determine a variety of characteristics of the object 34. For example, the rollers 32 can be mounted on force torque sensors (as described below with reference to Fig.40A - Figure 42C further discussed), and when it is determined (using the sensing unit 18) that the object 34 is balanced on the roller 32, the system can determine an estimated weight. Thus the roller(s) 32 on the force torque sensor can be used to determine the weight of the object as it passes over the roller(s).

[0098] Additionally, if the roller(s) 32 rotate at a faster rotational speed, the system can determine the inertia value of the object 34 as the roller(s) engage the object and as the object is removed from the roller(s). A variety of further characteristics may also be determined or estimated, such as, for example, determining or estimating the center of mass (COM) using the roller(s) in conjunction with the sensing unit as discussed further herein and below. The system may further use the sensing unit and roller(s) 32 (together with the computer processing system 100) to determine whether the object is a foldable bag by observing whether the object separates and / or whether the shape of the object changes as it moves over the roller(s) 32, and / or again use the sensing unit(s) and roller(s) 32 to determine whether the assumed object 34 is actually a multi-pick (comprising multiple objects). According to a further aspect of the invention, the transport roller 30 may be replaced by a conveyor portion located below the height of the disturbance roller 32.

[0099] The induction system 10 may further include a multi-purpose sensing unit 24 located above the conveyor 22 (higher than the unit 20) for use in Figure 1The sensor unit 24 includes a light 74 and one or more sensor units 76 (eg, scanners or cameras) for detecting any identification marks (eg, barcodes, QR codes, RFID, tags, etc.) on the objects on the conveyor 22.

[0100] The perception unit 24 also includes scanning and receiving units 80 , 82 , and an edge detection unit 84 for capturing various characteristics of selected objects on the conveyor 22 . Fig. 6A The view from the capture system is shown, and knowing the recorded volume of the view of the empty conveyor 22, the volume V of the object 27 can be estimated. 27 In particular, Figure 6C As shown, a volume scan is performed on the object 27. This volume is compared with the recorded data or the recorded object data provided by the sensing unit 18, 20 about the item identified by the identification mark.

[0101] According to a further aspect of the invention, the system may additionally employ an edge detection sensor 84 which (again in conjunction with the processing system 100) is used to detect the edges of any object in the container, for example using data regarding any of intensity, shadow detection, or echo detection, and may be used, for example, to determine any of size, shape, and / or contour, such as Figure 6B shown.

[0102] The scanning unit 80 and the receiving unit 82 (with Figure 1 The scanning unit 80 and the receiving unit 82 send and receive signals (eg, infrared signals). Figure 6C The volumetric data may be acquired, for example, using any of a light detection and ranging (LIDAR) scanner, a pulsed time-of-flight camera, a continuous wave time-of-flight camera, a structured light camera, or a passive stereo camera.

[0103] As referenced below Figure 39A-Figure 43C As discussed in more detail, the weight sensing transmitter portion may also be used to determine the weight of an object. For example, Figure 1 The weight sensing conveyor portion 55 can be used to determine the weight of the object 8 (again, as discussed below). As the object is fed through the input station, the object will pass through the response evaluation portion 16 and the multi-purpose sensing unit 24 (e.g., object 28) and can then be evaluated by the weight sensing conveyor portion.

[0104] Reference again Figure 1, the import system 10 can provide unidentified objects (and objects identified as unsuitable for processing) 36 through the conveyor 35 to the abnormal cargo box 50. If the object (e.g., 40, 42) is identified as suitable for processing, the object is diverted by the multi-directional conveyor 33 toward the conveyor 38. The conveyor 38 can direct the (multiple) objects toward the feed conveyor 46 via the multi-directional conveyor 44, or the system can determine that the object (e.g., object 49) should be directed along the conveyor 48 toward any of the additional processing stations (e.g., similar to the processing station 12 but capable of handling different types of objects). For example, as discussed in more detail below, the system can employ multiple processing stations, each of which is capable of handling different objects (such as objects of different sizes or weight ranges).

[0105] According to yet a further aspect of the invention, the system can employ optical character recognition (OCR) to read the label and detect, for example, trigger words such as "paint" or "hazard" or "Is it hazardous?: yes" or "fragile", such as Figure 7 In a further aspect, the system may identify an image such as Figure 8 The trigger image shown at 112 in the figure indicates that the contents are flammable, require to be kept upright, or are otherwise dangerous or require special handling, making these contents unsuitable for processing by the object handling system 12. The use of such a process allows the detection of objects that are incompatible with the processing system due to their contents indicated by the trigger mark on the external label. This may involve reading the label as described above, and not picking up the object or moving the object to an exception processing area, or it may involve simply identifying the object. For example, if the system includes an object database, the system can recognize a mark (such as a bar code) and then look up information about the scanned code (such as the object contains hazardous materials or otherwise requires special handling). In this case, the system routes the object towards the exception area.

[0106] Fig. 9 An inlet system 11 is shown that can provide selected objects to an object processing system 12. The inlet system 11 includes a Figure 1-Figure 8 The input station 14 discussed includes a conveyor 22 (having a response evaluation section 16 including a transport roller 30, a disturbance roller 32 and sensing units 18, 20), and a multi-purpose sensing unit 24, and a weighing conveyor 55 for evaluating objects 34, 27, 28 and 29 as discussed above. Again, the system can determine which of the feed objects is provided as a bag, for example, by observing the object as it passes over the disturbance roller(s) using the sensing unit(s), and in particular, observing the rate or amount of change in the speed and / or shape of the object as it is processed.

[0107] exist Fig. 9 In the induction system of FIG. 1 , as each object arrives at the infeed multi-directional routing conveyor 132, the object is either routed to the off-spec conveyor 134 (e.g., object 136), routed to the on-spec conveyor 138 (e.g., objects 140, 142), or routed to the bag handling conveyor 144 (e.g., objects 146, 151, 153). When the objects are provided as bags (e.g., shipping bags made of polyethylene), it may be more difficult to determine the size or other handling parameters of the objects. If the objects are identified as bags (or other flexible, malleable objects), such objects (again, e.g., 146, 148, 151, 153) are diverted to the bag handling system.

[0108] In particular, the conveyor 144 leads to a deformable object introduction restraint system 194, which includes a programmable motion device, such as an articulated arm 192 having an end effector 193 having a load cell or force torque sensor 195 (e.g., Figure 10A-10C ). In particular, the system will move the end effector 193 so that the object 191 contacts the opening formed by the inclined wall 133. If the load cell or force torque sensor 195 detects excessive force (above the sensor threshold) when the object contacts the inclined wall 133, the system can reject the object for processing. The object will then be placed on a conveyor 196 connected to the conveyor 134, leading to an area for objects not processed by the system 12, such as, for example, a collection bin or a manual processing station. Thus, the system can limit the acceptance of objects that are deformable but still too rigid for processing by the system 12. The load cell or force torque sensor 135 can also be set on the inclined wall as shown at 133 (instead of using the load cell or force torque sensor 195 or in conjunction with the use of the load cell or force torque sensor 195) or at the base of the inclined wall as shown at 135. On the other hand, if the object 191 is moved into the opening provided by the angled wall 133 without triggering any load cells or force torque sensors above a threshold, the system can move the object 191 to a conveyor 198 leading to the processing system 12.

[0109] If object 191 is determined to be insufficiently flexible for processing by object handling system 12 (again, see Fig. 9), the object may be placed by articulated arm 192 onto an out-of-gauge conveyor 196 (which may be coupled to conveyor 134). If object 191 is determined to be sufficiently flexible for handling by an object handling system (or another system coupled thereto as discussed in more detail below), object 191 is placed by articulated arm 192 onto conveyor 198 leading to bidirectional conveyor 45. If the object is to be handled by object handling system 12, the object is directed toward conveyor 19, and if the object is to be handled by a further object handling system (as discussed below, for example, with reference to Fig.36 ), the object (eg 43) is directed towards a further conveyor 47. Again, the operation is controlled by one or more computer processing systems 200.

[0110] For example, Fig.11 A further induction system 13 is shown according to an embodiment of the present invention that constrains or manages packages fed into the object handling system 12. The induction system 13 includes an input station 114 that includes an induction input programmable motion device designed to be able to grasp and move a variety of objects, such as an articulated arm 116 and an end effector 118 (e.g., Fig.12 and Fig.13 120). In particular, the articulated arm 116 can be designed to grasp and move, for example, objects that are too large or too heavy to be manipulated by the handling system 12, as well as objects that are designed to be manipulated by the handling system 12. Objects (individually or in a container 120) are provided to the articulated arm 116 on an infeed conveyor 122. Any of the various detection units 117 can also be positioned about and oriented toward the end effector 118 of the articulated arm 116, as discussed further below.

[0111] For example, the input system may determine which of the feed objects are provided as bags by observing the objects while they are held by the end effector 118, as described below with reference to Figure 22A-22D Further discussion. Fig.11 In the induction system of FIG. 1 , as each object (e.g., object 128 on conveyor 130 or object 129 on weight sensing conveyor section 155) arrives at the infeed multi-directional routing conveyor 132, the object is either routed to the out-of-spec conveyor 134 (e.g., object 136), routed to the on-spec conveyor 138 (e.g., objects 140, 142), or routed to the bag handling conveyor 144 (e.g., objects 146, 151, 153), as described above with reference to FIG. Fig. 9When the object is provided as a bag (e.g., a shipping bag made of polyethylene), it may be more difficult to determine the size or other handling parameters of the object. If the object is identified as a bag (or other flexible, malleable object), such object (again, e.g., 146, 148, 151, 153) is diverted to the bag handling system.

[0112] Again, the conveyor 144 leads to a deformable object introduction restraint system 194, which includes a programmable motion device, such as an articulated arm 192 with an end effector having a load cell or force torque sensor (as described above with reference to Figure 10A-10C As discussed). The system will move the end effector so that the object is brought into contact with the opening formed by the inclined wall. If the load cell or force torque sensor detects excessive force (above the sensor threshold) when the object contacts the inclined wall, the system can reject the object for processing. The object will then be placed on a conveyor 196 connected to the conveyor 134, leading to an area of ​​objects that are not processed by the system 12. Again, the conveyor 134 can, for example, lead to a collection bin or manual processing station. Thus, the system can limit the acceptance of objects that are deformable but still too rigid to be processed by the system 12. The load cell or force torque sensor can also be set on the inclined wall (without using the load cell or force torque sensor 195 or in conjunction with the use of the load cell or force torque sensor 195) or at the base of the inclined wall. On the other hand, if the object moves into the opening provided by the inclined wall without triggering any load cell or force torque sensor above the threshold, the system can move the object to the conveyor 198 leading to the processing system 12.

[0113] If the object is determined to be insufficiently flexible for processing by the object handling system 12, the object may be placed by the articulated arm 192 onto an out-of-spec conveyor 196 (which, again, may be coupled to the conveyor 134). If the object is determined to be sufficiently flexible for processing by the object handling system (or another system coupled thereto as discussed in more detail below), the object may be placed by the articulated arm 192 onto a conveyor 198 leading to the bi-directional conveyor 59. If the object is to be processed by the object handling system 12, the object is directed toward the conveyor 51, and if the object is to be processed by a further object handling system (as discussed below, for example, with reference to Fig.37 ), the object (eg 53) is directed towards a further conveyor 57. Again, the operation is controlled by one or more computer processing systems 200.

[0114] refer to Fig.12 and Fig.13, the perception system 124 captures perception data about objects beneath the perception system 124 (whether or not in the container 120). Object 128 is identified by the perception system 124 and then grabbed and placed on the routing conveyor 130. The empty container 120 is routed along the empty container conveyor 126. Note the placement of the object on the conveyor 130 (and again each of the conveyors may also be a cleated conveyor). Fig.11 As each object reaches the feed diverter 132, the object is either routed to the out-of-spec conveyor 134 (e.g., object 136), routed to the on-spec conveyor 138 (e.g., objects 140, 142), or routed to the bag handling conveyor 144 (e.g., objects 146, 148, 151, 153). The conveyor 130 may also include a weight sensing conveyor portion 155 for determining the weight of the object 129, as described below with reference to Figure 39A-Figure 43C The end effector 118 may further include a force torque sensor 154 and / or as further referenced below. Fig.46 As discussed above, the internal air pressure and / or air flow sensors, force torque sensor 154 is used to determine the weight of the object held by end effector 118, as described below with reference to Fig.44 and Fig.45 Further discussion.

[0115] Again, when the object is provided as a bag (e.g., a shipping bag made of, for example, polyethylene), determining the size and manipulation parameters of the object may be more difficult. If the object is identified as a bag (or other flexible, malleable object), such object (again, e.g., 146, 148, 151, 153) is diverted to a bag handling system, as discussed further above. The end effector 118 may also include a load cell or force torque sensor 154 for determining the weight of the object being grasped (as described below with reference to Fig.44 and Fig.45 ), and in a further aspect, the conveyor 30 may include a weighing portion 155 (again, as described below with reference to Figure 39A-Figure 43C As discussed), each object can be weighed at the weighing portion 155.

[0116] According to a further aspect, the system can estimate the volume of the object while it is held by the end effector. In particular, the system can estimate the volume of the picked item while it is held by the gripper and compare the estimated volume to the known volume. One approach is to estimate the volume of one or more items while the gripper is holding the object 197 (or multiple objects). Fig.14 and Fig.15In such a system 150, one or more sensing units 152, 154, 156, 158 (e.g., cameras or 3D scanners) are placed around the scanning volume. Fig.16 and Fig.17 Opposite each sensing unit is an illumination source 162, 164, 166, 168 and in front of each illumination source is a diffusing screen 172, 174, 176, 178.

[0117] like Fig.17 As shown, sensory data about an object 197 illuminated by an illumination source (e.g., 168) and a diffuser (e.g., 178) backlight will be captured by each sensory unit (e.g., 158). According to various aspects, three sensory units spaced one hundred and twenty degrees apart can be used, and according to further aspects, fewer sensory units (e.g., one or two) can be used, and the object can be rotated between data collection captures.

[0118] The scan volume can be the volume above the area from which the item is picked up; or the scan volume can be strategically placed between the pick-up location and the drop location to minimize travel time. Within the scan volume, the system takes a snapshot of the volume of the item held by the gripper. As discussed above, the volume can be estimated in a variety of ways depending on the sensor type.

[0119] For example, if the sensors are cameras, two or more cameras may be placed in a ring around the volume and oriented slightly upward toward a backlit screen (as discussed above), which may be in the shape of a cross-section of a torus, with the held volume held between all the cameras and a brightly lit white screen. The brightly lit screen backlights one or more held objects, leaving the interior volume black. Each sensing unit and associated illumination source may be activated in sequence, such that no two illumination sources are on at the same time. This allows easy segmentation of the held volume in the image.

[0120] The illumination can be provided as a specific wavelength that is not present in the room, or the illumination can be modulated and the detector can demodulate the received sensory data so that only the illumination from the associated source is provided. The black area, once back-projected into space, becomes a frustum, and the object is known to be located within the three-dimensional frustum. Each camera generates a separate frustum with the property that the volume of the item is a subset of all frustums. The intersection of all frustums yields an upper limit on the volume of (multiple) objects. The addition of cameras improves the accuracy of the volume estimate. The gripper can be visible within the camera, and since the position of the gripper is known, the volume of the gripper can be subtracted from the frustum or volume estimate.

[0121] According to other aspects, a 3D scanner that acquires a 3D image of the scanned volume can be used, and then a volume estimate can be obtained in a similar manner by fusing the point clouds received from each sensor together, but without the need to segment the image from the background using backlighting. Each 3D scanner returns a 3D image, returns a depth for each pixel in the image, and again any of a light detection and ranging (LIDAR) scanner, a pulsed time-of-flight camera, a continuous wave time-of-flight camera, a structured light camera, or a passive stereo camera can be used.

[0122] For example, Fig.18 3D scanner 182 is shown projecting a grid 188 onto the field of view. 3D scanner 182 can be used in conjunction with one, two, or three other 3D scanners (two more are shown at 184, 186) to Fig.19 180 is used in the system 180 shown. The 3D scanners are oriented toward a common volume in which the object 197 is positioned while being attached to the end effector 118. Again, with three such 3D scanners, the scanners can be positioned one hundred and twenty degrees apart (ninety degrees apart if four are used; opposite to each other if only two are used). Fig. 20 and Fig.21 , each 3D scanner (e.g., 182) captures 3D data about object 197. Again, the volume of the end effector can be removed from the captured data.

[0123] According to a further aspect, the system can detect changes in the shape of an object when it is being pushed. This can be done when the object is first lifted (e.g. Fig.11 At the input station 114 and / or at Fig. 9 and Fig.11 The deformable object is introduced into the restriction system 194 in the reference. Figure 22A-22D When an object (e.g., 145) is lifted from a container or conveyor by end effector 118, object 145 may be Fig. 22B is maintained, and then Fig. 22C and Fig.22D The object is subjected to rapid jerking motion as shown. If the shape of the object changes (more than, for example, 2%, 5%, or 10%), the object may be classified as a deformable object, such as a polyethylene shipping bag. The scanning may be performed by any of the volume scanning, edge detection, LIDAR, and camera image analysis systems discussed above. If the object is determined to be a deformable object, the object is routed to the conveyor 44 as discussed above.

[0124] Again, the conveyor 144 leads to a deformable object introduction and restraint system 194. The deformable object introduction and restraint system 194 includes a programmable motion device, such as an articulated arm 192 having an end effector 193, which has a load cell or force torque sensor 195 (such as Figure 10A-10C 133). In particular, the system will move the end effector 193 so that the object is brought into contact with the opening formed by the inclined wall 133. If the load cell or force torque sensor 195 detects excessive force (above the sensor threshold) when the object contacts the inclined wall 133, the system can reject the object for processing. The object will then be placed on a conveyor 196 connected to the conveyor 134, leading to an area of ​​objects that are not processed by the system 12. Thus, the system can limit the acceptance of objects that are deformable but still too rigid to be processed by the system 12. The load cell or force torque sensor can also be set on the inclined wall as shown at 133 (without using the load cell or force torque sensor 195 or in conjunction with the use of the load cell or force torque sensor 195) or at the base of the inclined wall as shown at 135. On the other hand, if the object 145 is moved into the opening provided by the inclined wall 133 without triggering any load cell or force torque sensor above the threshold, the system can move the object 145 to the conveyor 198 leading to the processing system 12.

[0125] For example, the processing system 12 may include a feed area 201 into which objects may be provided by a processing feed conveyor (e.g., 46, 19, 51). The feed conveyor 202 conveys the objects from the feed area 201 to an intermediate conveyor 204 at a processing station 206. The feed conveyor 202 may include a wedge to assist in lifting the objects from the input area 200 to the intermediate conveyor 204.

[0126] The processing station 206 also includes a grasping perception system 208 that observes the objects on the intermediate conveyor 204 and, as shown in FIG. Fig.23206. The processing station 206 also includes a programmable motion device 210 (such as an articulated arm) and a primary sensing system 212 (such as a drop sensing unit). The grasping sensing system 212 examines the object to identify the object when possible and determines a good grasping point. The object is then grasped by the device 210 and falls into the drop sensing system 212 to ensure that the object is accurately identified. The object then falls onto a primary transport system 214 (e.g., a conveyor) through the primary sensing system 212. The primary transport system 214 carries the object through one or more diverters 216, 218, which can be engaged to divert the object from the primary transport system 214 to any one of the brackets 220, 222, 224 (when the corresponding bracket is aligned with the diverter) or to the input area 200. Each of the carriages 220, 222, 224 can reciprocate along tracks that run between rows of destination stations 226 of the shuttle section 228 (as discussed in more detail below).

[0127] The flow of objects Fig.24 2, which shows an object moving from a feed area 201 to an intermediate conveyor 204. A programmable motion device 210 causes the object to drop into a drop sensing unit 212, and the object then lands on a primary transport system 214. The object is then transferred by the primary transport system 214 to a diverter, which selectively diverts the object to a carriage (e.g., 220, 222, 224). The carriage takes the object to one of a plurality of destination stations 226 (e.g., a processing box or a processing bin), and drops the object into the appropriate destination station. When a destination station is full or otherwise completed, the destination station is moved to an output conveyor.

[0128] Fig.25 Shows Fig.23 A rear view of the system more clearly showing the programmable motion device and drop sensing system. The primary transport system 214 may be a cleated conveyor and objects may be dropped onto the cleated conveyor such that each cleated section provides one object. The speed of the conveyors 202 and 214 may also be controlled to assist in providing a single stream of objects to the diverters 216, 218. The system may be operated using a computer processing control system 200 that communicates with the conveyor control system, sensing unit, programmable motion device, diverter, box or bin removal system, and any and all sensors that may be provided in the system.

[0129] refer to Fig.26, the processing station 206 includes a grasping perception system 208 mounted above the intermediate conveyor 204, which provides the objects to be processed. For example, the grasping perception system 20 may include (on its bottom side) a camera, a depth sensor, and a light. A combination of 2D and 3D (depth) data is acquired. The depth sensor 74 can provide depth information, which can be used together with the camera image data to determine depth information about various objects in the view. The lights can be used to remove shadows and facilitate identification of object edges, and can be turned on all during use, or can be illuminated in a desired sequence to assist in object identification. The system uses these imaging and various algorithms to generate a set of candidate grasping locations for objects in the cargo box, as discussed in more detail below.

[0130] The programmable motion device 210 may include a robotic arm equipped with sensors and computations that, when assumed to be incorporated herein, exhibit the following capabilities: (a) it is able to pick up objects from a single stream of objects using, for example, an end effector; (b) it is able to move objects to arbitrary locations within its workspace; and (c) it is able to generate a map of objects that can be picked up, represented as a candidate set of grip points in a workcell, and a list of polyhedrons in space that enclose the objects. The allowable objects are determined by the capabilities of the robotic system. Their size, weight, and geometry are assumed to enable the robotic system to pick up, move, and place them. These can be any kind of ordered cargo, packages, parcels, or other items that benefit from automated handling.

[0131] The correct processing destination is determined by a symbol (e.g., a bar code) on the object. It is assumed that the objects should be marked with a visually unique mark (such as a bar code or radio frequency identification (RFID) tag) at one or more locations on their exterior so that they can be identified using a scanner. The type of marking depends on the type of scanning system used, but can include 1D or 2D bar code symbology. Multiple symbologies or marking methods can be used. The type of scanner used is assumed to be compatible with the marking method. The marking by the bar code, RFID tag or other means encodes a symbol string, which is usually a string of letters and numbers that identifies the object.

[0132] Once grasped, the object can be moved by the programmable motion device 210 to a primary perception system 212 (such as a drop scanner). The object can even fall into the perception system 212. In a further aspect, if a sufficient single stream of objects is provided on the intermediate conveyor 204, the programmable motion device can be provided as a diverter (e.g., a push-pull rod) that diverts the objects from the intermediate conveyor to the drop scanner. Additionally, the movement speed and direction of the intermediate conveyor 204 (as well as the movement and speed of the feed conveyor 202) can be controlled to further facilitate providing a single stream of objects on the intermediate conveyor 204 adjacent to the drop scanner.

[0133] like Fig. 27 As further shown in , the primary perception system 212 may include a structure 234 having a top opening 236 and a bottom opening 238, and may be covered by an encapsulation material 240. The structure 234 includes a plurality of sources (e.g., illumination sources such as LEDs) 242 and a plurality of image perception units (e.g., cameras) 244. The sources 242 may be provided in various arrangements, and each may be oriented toward the center of the opening. The perception units 244 are also generally oriented toward the opening, although some cameras are oriented horizontally, others are oriented upward, and some are oriented downward. The system 212 also includes an entry source (e.g., an infrared source) 246 and an entry detector (e.g., an infrared detector) 247 for detecting when an object enters the perception system 212. Thus, the LEDs and cameras surround the interior of the structure 234, and the cameras are positioned to view the interior via a window that may include a glass or plastic covering (e.g., 248).

[0134] According to certain aspects, the present invention provides the ability to identify objects via bar codes or other visual indicia by employing a sensing system into which the object may be dropped. Automated scanning systems will not be able to see bar codes on objects that are not presented in an exposed or visible manner. Thus, the system 212 is designed to view an object from a large number of different views very quickly, thereby reducing or eliminating the possibility that the system 212 will not be able to view the identification indicia on the object.

[0135] After detection by the perception unit 212, the object is now positively identified and falls onto the primary transport system 214 (eg, a conveyor). Fig.23 and Fig.25, the primary transport system 214 moves the identified object toward a diverter 216, 218, or (if the object cannot be identified), the object can be returned to the input area 200 or can be dropped from the end of the conveyor 214 into a manual handling container, the diverter 216, 218 being selectively engageable to divert the object from the conveyor to any one of the carriages 220, 222, 224. Each carriage 220, 224, 226 can be reciprocated between destination containers 230 in one of a plurality of destination sections 228. According to certain aspects, space efficiency can be provided by first moving the object from the input area 201 along the feed conveyor 202 in a direction having a horizontal component and a vertical component. The object then drops through the drop scanner 212 (vertically) and lands on the primary transport conveyor 214, which also moves the object in a direction having a horizontal component (opposite to the direction of the feed conveyor 202) and a vertical component. The object is then moved horizontally by the carriages 220, 222, 224 and dropped (vertically) over a target destination station 230 (such as a destination container).

[0136] refer to Figure 28A-28C , a diverter unit (e.g., 216) can be actuated to push an object (e.g., 250) from the conveyor 214 into a selected carriage (e.g., 220) running along a track 221 between destination locations (stations) 230. The diverter unit can include a pair of paddles 223 suspended by a frame 225 that provides linearly actuatable paddles to move the object 250 out of the conveyor in either direction transverse to the conveyor. Again, referring to Fig.18 One direction of diversion for the diverter 216 is to return the objects to the feed area 201.

[0137] Due to the inherent dynamic flexibility, the systems of various embodiments provide many advantages. The flexible correspondence between sorter outputs and destinations provides that the sorter output can be less than the destination, so the entire system can require less space. The flexible correspondence between sorter outputs and destinations also provides that the system can select the most efficient order for manipulating objects in a manner that varies with the specific mix of objects and downstream needs. By adding sorters, the system can also be easily scalable and more robust because the failure of a single sorter can be dynamically handled without even stopping the system. It should be possible for the sorter to prioritize objects that need to be manipulated quickly, or prioritize objects for which a given sorter may have a dedicated gripper, based on the order of the objects.

[0138] Fig.29A destination portion (e.g., such as any of the portions 228 of the system 12) is shown, which includes a movable carriage (e.g., 220) that can receive an object 252 from an end effector of a programmable motion device. The movable carriage 220 is reciprocally movable along a guide rail 221 between two rows of destination containers 230. Fig.29 As shown, each destination container 230 includes a guide chute that guides the object dropped therein to the destination container 230 below. The carriage 220 moves along the track 221, and the carriage can be actuated to cause the object 252 to drop into the desired destination container 230 via the guide chute (e.g., Fig.30 shown).

[0139] Thus, the movable carriage can be reciprocated between destination containers, and the carriage / each carriage moves along the track and can be actuated to drop an object (e.g., 252) into a desired destination container. In some aspects, the carriage (e.g., 220) can include a sensor (e.g., transmitter and receiver pair 260 and / or 262) that can be used to confirm that the carriage has received an object or to confirm that the carriage has unloaded an object. In a further aspect, the carriage can be mounted to the track base via a load cell 264 so that the weight within the carriage can be determined based on the load cell output sensor data, as described below with reference to Fig.47 and Fig.48 As further discussed. Knowledge of the weight within the cradle can be used to confirm that the cradle has received an object, and that the cradle has unloaded an object. Knowledge of the weight can also confirm that the object in the cradle is indeed the object that the system expects to be in the cradle (where the system includes previously recorded data about the weight of each object).

[0140] According to one aspect, the present invention provides an automated material handling system that is tasked in part to route objects carried in bins to stations where the objects are transported from one bin to another at an automated station using one or more programmable motion devices, such as articulated arms, and the automated material handling system may further include a manual station. The objects may be provided in bins, which may be containers, totes, boxes, etc. The overall goal of the system may be to sort and ship goods, perform order fulfillment, replenish storage inventory, or provide any general system that requires transporting individual objects from a bin to a processing system.

[0141] The objects may be packages, boxes, flats or plastic bags in a shipping center, or consumer products in an e-commerce fulfillment center, or product and warehouse packaging in a retail distribution center (DC). The delivery of objects or boxes of objects may take many forms, including belt or roller conveyors, chutes, mobile robots, or human workers. The pickup station for transporting goods may be an automated system, including a robotic system, or a station operated by a human.

[0142] Fig.31 A diagrammatic view of an import restriction system 300 is shown, which includes an infeed conveyor 302 leading to a sorting system 304. Once sorted by the sorting system 304, the objects are directed toward a routing system 306, which routes the objects to one of a plurality of directions as shown at 308, 310, 312. For example, similar to Fig.11 The model of the system shown in Fig.32 Shown in. Fig.32 The system 320 includes an infeed conveyor 322 that directs objects to a sorting system 324. The sorting system 324, in conjunction with one or more computer processing systems 100, 200 and databases therein or coupled thereto, directs objects toward a routing system 330 (via conveyor 328) and directs empty cartons along a carton outbound conveyor 326. The routing system 330 directs objects to one of three different directions. Objects accepted for processing are directed along conveyor 332 to be processed by an object processing system 334. Objects outside of the system specifications for processing are directed along a non-processable object conveyor 344 to be processed by a system or method other than the processing system 334. Certain objects that do not fall directly into either classification (e.g., objects provided in polyethylene bags) are provided to a bag processor 338 via a bag processing conveyor 336. At the bag processor 338, the objects undergo testing and, depending on the results, are directed toward the object processor 334 via a processor 340 or toward a non-processable object station via a conveyor 342.

[0143] The system of the present invention can be used in a variety of routing system applications. For example, the import restriction system of the present invention can be used with multiple routing and processing systems. For example, Fig.33A system 350 is shown that includes an infeed conveyor 352 that provides objects to a sorting system 354. The sorting system 354 determines to which of a plurality of processing systems (e.g., A, B, or C as shown at 362, 370, 374) the object is to be sent. In particular, the object first leaves the sorting system 354 and travels along a conveyor 356 toward a first routing system 358. Certain objects (determined by the sorting system 354) to be directed toward processing system (A) 362 are directed along conveyor 360 toward processing system (A) 362. All other objects are directed along conveyor 364 toward a second routing system 366. Further objects (determined by the sorting system 354) to be directed toward processing system (B) 370 are directed along conveyor 368 toward processing system (B) 370. All other objects are directed along conveyor 372 toward routing system 374. For example, any of the handling systems A, B, or C can be an automated handling station (e.g., designed for large or small / heavy or light objects) or a manual handling station (e.g., where a person can make decisions regarding object handling or physically move an object to a destination location). In a further aspect, station C can be a pass-through exception bin into which objects to be manually handled are placed.

[0144] As an example, Fig.34 As shown in the above reference Figure 1-Figure 8 The induction system 10 and object handling system 12 discussed, and the additional object handling systems 25 and 26 in series. In particular, the induction system 10 includes an input station 14 having a response evaluation portion 16 of a conveyor 22, a multi-purpose sensing unit 24 and a weight sensing conveyor portion 55 for evaluating objects (e.g., 28), and as described above with reference to Figure 1-Figure 8 The use of multi-directional conveyor 53 discussed herein provides objects to an abnormal container 50 (eg, object 35) via conveyor 35 or provides objects to conveyor 41 (eg, objects 40, 42).

[0145] The objects to be processed (e.g., objects 40, 42) are each assigned an object processing station (e.g., 12, 25, 26) toward which they are routed. In particular, the objects to be processed (again, e.g., 40, 42) may be routed to the appropriate processing station based on any of a variety of parameters, such as size, weight, packaging material (box, bag, odd-shaped object, etc.), and even shipping location, and each object processing station may, for example, include components specifically adapted for a certain size, weight, packaging material, etc. Certain objects may be routed by multi-directional conveyor 44 along conveyor 46 to object processing station 12, while other objects (e.g., objects 49, 52, 54) are directed along conveyor 48 toward further processing stations. Some of those objects may be routed by multi-directional conveyor 56 along conveyor 58 toward object processing station 25, while other objects (e.g., objects 61, 62, 63) are directed along conveyor 60 toward further processing stations. Some of these objects may be routed by multi-directional conveyor 64 along conveyor 65 toward object processing station 26, while other objects (e.g., 67) are directed toward further processing stations along conveyor 66. The operation of the system may be controlled by one or more computer processing systems (e.g., 100, 68, and 69).

[0146] As an example, Fig.35 As shown in the above reference Fig. 9 10, and the additional object handling systems 25 and 26 in series. In particular, the induction system 11 includes an input station 14 having a response evaluation portion 16 of a conveyor 22, a multi-purpose sensing unit 24, and a weight sensing conveyor portion 55 for evaluating objects, and as described above with reference to Fig. 9 10 using a multi-directional conveyor 132 to provide objects to either an abnormal container via conveyor 134 or to conveyor 138 or to bag handling conveyor 144. Any object detected as being packed in a bag is directed to conveyor 144 toward deformable object introduction system 194 including articulated arm 192, where deformable object introduction system 194 is described above with reference to Fig. 9 The object is tested as discussed in FIG. 10 and as described above with reference to Fig. 9 Objects are directed along the non-processable object conveyor 196 or along the processable object conveyor 198 as discussed in connection with FIG. 10 .

[0147] Again, the objects to be processed are each assigned an object processing station (e.g., 12, 25, 26) toward which they are routed. In particular, the objects to be processed (e.g., 43, 52, 54) can be routed to the appropriate processing station based on any of a variety of parameters (such as size, weight, packaging material (boxes, bags, oddly shaped objects, etc.), and even shipping location), and each object processing station can, for example, include components that are particularly suitable for a particular size, weight, packaging material, etc. Certain objects can be routed by multi-directional conveyor 45 along conveyor 19 to object processing station 12, while other objects (e.g., objects 43, 52, 54) are directed toward further processing stations along conveyor 47. As described above with reference to Fig.34 As discussed, some of those objects may be routed by multi-directional conveyor 56 along conveyor 58 toward object processing station 25, while other objects (e.g., objects 61, 62, 63) are directed toward further processing stations along conveyor 60. Some of those objects may be routed by multi-directional conveyor 64 along conveyor 65 toward object processing station 26, while other objects (e.g., 67) are directed toward further processing stations along conveyor 66. The operation of the system may be controlled by one or more computer processing systems (e.g., 200, 68, and 69).

[0148] Fig.36 As shown in the above reference Figure 11-22D The system discussed includes an induction system 13 and an object handling system 12, and additional object handling systems 25 and 26 in series. In particular, the induction system 13 includes an input station 114, which includes a container infeed conveyor 122, a container outfeed conveyor 126, an articulated arm 132, and an object infeed conveyor 13, and as described above with reference to Figure 11-22D The use of the multi-directional conveyor 132 discussed above provides objects to either an abnormal container via conveyor 134 or to convey objects to conveyor 138 or to convey objects to bag handling conveyor 144. Any object detected as being packed in a bag is directed to conveyor 144 toward a deformable object introduction system 194 including an articulated arm 192, as described above with reference to Figure 11-22D As discussed, the object is tested at the deformable object introduction system 194 and as described in reference Figure 11-22D The object in question is guided along the non-processable object conveyor 196 or along the processable object conveyor 198.

[0149] Again, the objects to be processed are each assigned an object processing station (e.g., 12, 25, 26) toward which they are routed. In particular, the objects to be processed can be routed to the appropriate processing station based on any of a variety of parameters (such as size, weight, packaging material (boxes, bags, oddly shaped objects, etc.), and even shipping location), and each object processing station can, for example, include components that are particularly suitable for a particular size, weight, packaging material, etc. Certain objects can be routed to object processing station 12 along conveyor 51 by multi-directional conveyor 59, while other objects (e.g., objects 52, 53, 54) are directed toward further processing stations along conveyor 47. As described above with reference to Fig.35 As discussed, some of those objects may be routed by multi-directional conveyor 56 along conveyor 55 toward object processing station 25, while other objects (e.g., objects 61, 62, 63) are directed toward further processing stations along conveyor 60. Some of those objects may be routed by multi-directional conveyor 64 along conveyor 65 toward object processing station 26, while other objects (e.g., 67) are directed toward further processing stations along conveyor 66. The operation of the system may be controlled by one or more computer processing systems (e.g., 200, 68, and 69).

[0150] Fig.37 The induction system 15 and the parallel object handling systems 12, 17, 21, 23 are shown. The induction system 15 includes not only Figure 1-Figure 8 The input station 14 discussed, the input station 14 includes the response evaluation portion of the conveyor 22, the multi-purpose sensing unit 24, the weight sensing conveyor portion 55 and the multi-directional conveyor 53, and the induction system 15 further includes multiple sets of multi-purpose sensing units, weight sensing conveyor portions and multi-directional conveyors for evaluating objects (e.g., 28). The multi-directional conveyor 53 leads to the conveyor 41 and the multi-directional conveyor 44 for providing the objects (e.g., 40, 42) to the object handling system 12 via the conveyor 46 and providing the objects to any additional object handling systems connected in series with the object handling system 12 (e.g., the object 49 on the conveyor 48), as described above with reference to Fig.34 discussed.

[0151] In particular, conveyor 22 also includes an additional inspection station 86 having a multi-purpose sensing unit 85, a weight sensing conveyor portion 87, and a multi-directional conveyor 88 for evaluating objects (e.g., 81) and for optionally directing objects (e.g., 83, 89) along conveyor 31 toward multi-directional conveyor 90. Multi-directional conveyor 90 leads to conveyor 91 for providing objects to object handling system 17 and providing objects (e.g., object 93) along conveyor 92 to any additional object handling systems connected in series with object handling system 17.

[0152] The conveyor 22 further includes an additional inspection station 96 having a multi-purpose sensing unit 95, a weight sensing conveyor portion 97, and a multi-directional conveyor 99 for evaluating objects (e.g., 98) and for optionally directing objects (e.g., 111, 113) along a conveyor 151 toward a multi-directional conveyor 115. The multi-directional conveyor 115 leads to a conveyor 117 for providing objects to the object handling system 21 and providing objects (e.g., object 121) along a conveyor 119 to any additional object handling systems connected in series with the object handling system 21.

[0153] Conveyor 22 further includes an additional inspection station 127 having a multi-purpose sensing unit 125, a weight sensing conveyor portion 129, and a multi-directional conveyor 131 for evaluating objects (e.g., 137) and for optionally directing objects (e.g., 139, 141) along conveyor 153 toward multi-directional conveyor 145. Multi-directional conveyor 145 leads to conveyor 147 for providing objects to object handling system 23 and providing objects (e.g., object 155) along conveyor 149 to any additional object handling systems in series with object handling system 21. Thus, objects (e.g., 28, 36, 81, 94, 98, 123, 137) can be routed along conveyor 22 to any of a plurality of processing stations and then directed along lateral conveyors (e.g., 41, 31, 151, 153) to any of a plurality of processing stations in series along the lateral conveyors. Unprocessable objects (e.g., object 157) may be provided to an abnormal container 159 at the end of the conveyor 22. The operation of the system may be controlled by one or more computer processing systems 100, 161, 163, 165. Again, objects to be processed may be routed to appropriate processing stations based on any of a variety of parameters such as size, weight, packaging material (box, bag, oddly shaped object, etc.), and even shipping location, and each object processing station may, for example, include components specifically adapted for a particular size, weight, packaging material, etc.

[0154] Fig.38 A number of different types of inlet systems are shown for use with a number of object handling systems. The inlet system 114 includes the Figure 11-Figure 22, the input container conveyor 122, the output container conveyor 126 and the articulated arm 116, the weight-sensing side conveyor 155, the multi-directional conveyor 132, the deformable object introduction restriction system 194 and the articulated arm 192, and the conveyors 57, 130, 138, 144, 196, 134 and 198 discussed above. The conveyors 138 and 198 lead to the multi-directional conveyor 59, where the objects are directed to the object handling system 12 via the conveyor 51, or are directed along the conveyor 57 toward one of a plurality of further object handling systems (e.g., the object 53), as described above with reference to Fig.36 However, the multidirectional conveyor 132 does not lead to a non-processable object collection bin, but rather leads via conveyor 181 to a further induction system.

[0155] In particular, conveyor 181 leads to induction system 14, as described above with reference to Fig. 9 10, the introduction system 14 includes the response evaluation portion 16, the multi-purpose sensing unit 24, the weight sensing conveyor portion, the multi-directional conveyor 132 and the deformable object introduction restriction system 194 and the articulated arm 192, and conveyors 19, 22, 138, 144, 196 and 198. Conveyors 138 and 198 lead to the multi-directional conveyor 45, where the object is guided to the object handling system 177 via the conveyor 19, or along the conveyor 47 (e.g., the object 43) is guided toward one of a plurality of further object handling systems, as described above with reference to Fig.35 Again, the multidirectional conveyor 132 does not lead to a non-processable object collection bin, but leads via conveyor 183 to a further induction system.

[0156] The conveyor 183 leads to a further induction system 14, as described above with reference to Figure 1-Figure 8 As discussed, the further introduction system 14 includes the response evaluation portion 16, the multi-purpose sensing unit 24, the weight sensing conveyor portion, the multi-directional conveyor 132 and the deformable object introduction restriction system 194 and the articulated arm 192, as well as the conveyors 22, 40, 46, 48, 35 and 198. The conveyor 41 leads to the multi-directional conveyor 44, where the object is directed to the object handling system 179 via the conveyor 46, or is directed along the conveyor 48 toward one of a plurality of further object handling systems (e.g., the object 49), as described above with reference to Fig.34 The objects not to be processed (eg, the objects 36 ) are provided to the unprocessable object exception container 50 via the conveyor 35 .

[0157] Again, the objects to be processed are each assigned an object processing station (e.g., 12, 177, 179) toward which they are routed. In particular, the objects to be processed may be routed to the appropriate processing station based on any of a variety of parameters such as size, weight, packaging material (boxes, bags, oddly shaped objects, etc.), and even shipping location, and each object processing station may, for example, include components specifically adapted for a particular size, weight, packaging material, etc. The operation of the system may be controlled by one or more computer processing systems 100, 200, 301.

[0158] Any of a variety of detection systems may also be used in the above disclosed and further aspects of the invention. For example, as discussed above with respect to the weight sensing transmitter discussed above, such a weight sensing transmitter may be provided in a variety of systems. For example, with reference to Fig.39A and Fig.39B , the weight sensing transmitter system 380 can be Figure 1 , Fig. 9 , Fig.11 , Figure 34-Figure 38 , Fig.49 , Fig.56 and Fig.70 For use in any of the induction systems of FIG. 3 , the weight sensing conveyor system 380 includes a weight scale 382 including a base 384 and a scale 386 disposed between an upper 388 and a lower 390 portion of a conveyor portion 392. Thus, objects on the conveyor can be weighed while they are on the conveyor.

[0159] Fig.40A and Fig.40B A weight sensing transmitter system 400 is shown, which can be used in Figure 1 , Fig. 9 , Fig.11 , Figure 34-Figure 38 , Fig.49 , Fig.56 and Fig.70 The weight sensing conveyor system 400 is used in any of the inlet systems of FIG. 1 and includes a conveyor portion 402 mounted on rollers 404, 406, each of which is mounted at both ends of a pair of load cells 408, 410 (only one of the pair of load cells 408, 410 is shown at one end of each roller 404, 406). Damaged packages can also be identified by the sensing system, for example, if the package appears wet or leaking. By having the load cells 408, 410 include moisture sensors, it can be Figure 1 , Fig. 9 , Fig.11 , Figure 34-Figure 38 , Fig.49 , Fig.56and Fig.70 A moisture sensor is used in conjunction with the transmitter 382 in any of the pre-processing systems in the embodiment. In other embodiments, a camera capable of detecting moisture (e.g., a 1000 fps camera capable of tracking photons) may also be used in such an import system. Any moisture detected indicates that the object may be damaged and requires exception handling.

[0160] refer to Figure 41A-41D According to further aspects of the present invention, system 400 may further provide for determining not only the weight of object 412 on conveyor portion 402, but may further use the difference between the length end and the width end and the weight sensed by each load cell 408, 410 to determine the center of mass area of ​​object 412. For example, system 400 may be configured to: Figure 1 , Fig. 9 , Fig.11 , Figure 34-Figure 38 , Fig.49 , Fig.56 and Fig.70 Used in any of the inlet gas systems.

[0161] refer to Fig.42A and Fig.42B , weight scales (such as Figure 39A-Figure 39B As shown) can be provided as multiple scales. For example, Fig.42A and Fig.42B Scale system 420 is shown, which includes four scale parts 422, 424, 426, 428 on a scale base 430. Scale system 420 can be Figure 1 , Fig. 9 and Fig.11 Used in any of the pre-processing systems of. Using such a scale system, multiple scales can also be used to locate the center of mass of the object on the scale system 420.

[0162] Fig.43A -43C shows a scale system 440, which includes a plurality of rollers 442 mounted within a frame 444 on a base 446, wherein each roller 442 is mounted to the frame 444 via a load cell or force torque sensor 446 on either end of each roller 442. The system 440 may be Figure 1 , Fig. 9 and Fig.11 By monitoring the output of each of the load cells or force torque sensors 446, the center of mass of the object on the roller can be determined.

[0163] Thus, such a system providing weight sensing in a presentation conveyor may include one or more load cells or weight-sensitive mechanisms embedded in a surface on which objects are presented to a programmable motion device, such as an articulated arm. The weight and / or observed density (weight / volume) of each object may be estimated using a camera of the programmable motion system or a distance sensor that can sense volume. When these values ​​exceed specifications, the object may be diverted or otherwise bypassed from the processing system. In order to better locate incompatible objects (e.g., packages), there may be a grid of such weight-sensitive mechanisms that can sense which area in the pick-up zone contains one or more incompatible objects, and then allow picking from any area except where (multiple) incompatible objects are detected. In addition, the system can detect flow readings when gripping an object. If the air flow (F1) is too high (compared to the expected flow (F2) for a particular object), the system may allow the object to be diverted from or passed through the object handling system.

[0164] Thus, in a further aspect, the end effector of the programmable motion device (and as referred to herein Figure 9-22D , Fig.35 , Fig.36 , Fig.38 , Fig.54 , Fig.70 and Fig.71 The discussion may include Fig.44 The end effector 450 shown includes a load cell or force torque sensor 454 that separates the lower part 458 and the upper part 452 coupled to the programmable motion device. The system can use a load-sensitive device at the gripper to estimate the weight of the object. If the object exceeds the acceptable weight specification, the object is released into a flow directed toward the abnormal area. Moreover, any movement of the lower part relative to the upper part will be detected by the load cell. Therefore, the weight of any object grasped by the flexible bellows 456 under vacuum can be determined. Although the object can move relative to the lower part 458 (for example, by using a flexible bellows), any movement of the object grasped by the movement of the lower part 458 relative to the upper part 452 will be detected by the load cell or force torque sensor 454. Therefore, not only the weight, but also the balance / imbalance of the grasping and any torque applied to the lower part 458 will be detected. Again, if the sensed (estimated) weight of the grasped object exceeds the expected weight (exceeds a threshold), the system can release the object to be simply diverted from the handling station, or directed to an exception area.

[0165] According to a further aspect, the system can limit the initial gripping force. For example, the system can use a partially open gripper valve to limit the maximum gripping force (V1) in the vacuum gripper 450 until the object is lifted. Once the object is lifted, the gripper valve can be fully closed, allowing the vacuum force to reach a greater vacuum (V2) to perform safe and secure transportation of the object. Such processing ensures that the object will not fall during transportation and limits the introduction of objects into the handling system where there is a risk of the object falling or being mishandled.

[0166] Fig.45 An end effector 460 for use in a system according to another aspect of the present invention is shown, the end effector 460 comprising a rigid portion 462 coupled to a programmable motion device and a flexible bellows 464 that can move relative to the rigid portion. Attached to the lower portion of the flexible bellows 464 is a rigid bracket 466, which includes a belt portion surrounding the flexible bellows and a vertical portion 465 that is orthogonal to the belt portion. The top of the vertical portion includes a magnet or sensor, and mounted on the end effector is another of the magnet or sensor pairs 468, 469. The magnet and sensor pair provide a sensor system that will detect any movement of the bottom of the end effector relative to the rigid portion 462 of the end effector. In this way, the weight of an object or a characteristic description of the grasp of any object (e.g., balance / imbalance or torque applied to the end effector) can also be determined. The end effector 460 can be used with reference to this article. Figure 9-22D , Fig.35 , Fig.36 , Fig.38 , Fig.54 , Fig.70 and Fig.71 Used with any of the end effector systems discussed.

[0167] refer to Fig.46 , the system may use an end effector 455 (such as any of the end effectors discussed herein) that includes a sensor 457 (such as a flow sensor or a pressure sensor). The system may calculate from observations of the flow and / or pressure while holding the item whether the gripper 459 has an adequate grasp of the object. In particular, the system may measure the flow reading while gripping the object and determine whether the measured value is within a range of values ​​for a pickable object. If the object is not pickable, the object may be passed to an exception area without being processed. The end effector 455 may be used in conjunction with the above referenced Figure 10A-Figure 13 and Fig.54 Any of the systems discussed can be used together.

[0168] Fig.47 and Fig.48 The invention according to one aspect of the present invention is shown Fig.23 , Fig.25 and Figure 28A-Figure 30 A similar carriage 470 is shown for use in the system, the carriage 470 having a body 472 including a higher rear wall 474 against which an object can be redirected into the generally V-shaped body 472 of the carriage. The carriage 470 is mounted on a frame 480 via a load cell or force torque sensor 476, 478, and the movement of the carriage 470 along the track and tilting is controlled by an actuation system 482. Communications and electronic control are provided by an electronic processing and communication system 488 (as shown in FIG. 43). Again, the load cell or force torque sensor 476, 478 can be used to determine the weight of the contents of the carriage. For example, once the beam interruption transmitter and receiver pair 484, 486 detect an object, the system according to an embodiment will average the weight values ​​of the two load cells (W1, W2), double the result, and subtract the weight of the body 472. According to other embodiments, the load cell itself can register a change indicating that the carriage has received or discharged an object.

[0169] Many further filtering systems, diverter systems, testing systems, routing systems, and processing systems may be used in the above aspects of the invention and in further following aspects. For example, certain embodiments may relate to methods for filtering packages that are too heavy, and doing so before they reach one of the robotic pickers. Such systems may include a passive bomb bay drop system. Such systems may involve routing incoming packages on a chute with one or more bomb bay doors. The bomb bay doors are held closed by springs whose stiffness is adjusted so that packages that are too heavy are dropped by the bomb bay doors. Packages whose weight is less than the limit cannot exert enough force to open the passive bomb bay door(s). The passive bomb bay doors are mounted on the chute so that the packages naturally fall or slide through the bomb bay without falling.

[0170] Thus according to a further aspect, the filtration system of the invention may include an actuatable bomb bay drop system (e.g. motor actuated or spring loaded). According to one aspect of the invention, as the package travels over the bomb bay door(s), a sensor measures the weight of the package and a controller opens the bomb bay door(s) by either turning on the bomb bay motor or a mechanism to unlock the bomb bay door, which then closes the bomb bay door again.

[0171] Fig.49 An induction system 487 having an object handling system 12 is shown. The induction system 487 includes an input portion 14 and an abnormal container 21 for receiving a body of non-processable objects (e.g., 36) via a conveyor 35, as described above with reference to Figure 1-Figure 8As discussed, the input portion 14 includes the response evaluation portion 16 of the conveyor 22, the side sensing unit 18, the overhead sensing unit 20, the multi-purpose sensing unit 24, the weight sensing conveyor portion 53, and the multi-directional conveyor 33. The induction system 487 also includes an inclined conveyor 492, which includes portions 495, 496 and 497 and travels above the second lower conveyor 489. Further reference Fig.50A and Fig.50B As object 499 travels from conveyor section 495 onto conveyor section 496, a weight sensor (e.g., a force torque sensor) 485 detects the weight of the object. If the object is above or below a specified weight, the object falls onto lower conveyor 489 and is routed toward object handling system 12 via conveyor 491 via multi-directional conveyor 493. As discussed above, the system can select whether an object that is too heavy or too light to be handled by a processing station coupled to conveyor section 497 is dropped through bomb bay door 498. The door can be actuated by motor 483. Alternatively, the bomb bay conveyor can be designed to operate via a spring mechanism that opens when the weight is above a threshold and conveyor 497 can be directed to the appropriate object handling system.

[0172] Fig.51A and Fig.51B An end view of a bomb bay door 498 is shown above a conveyor 494, wherein the door is closed, such as by a spring or motor actuator, in response to input from a force torque sensor ( Fig.51A ) and open ( Fig.51B ) to allow the object 499 to fall from the upper conveyor 496 to the lower conveyor 489. According to a further aspect, the door may include weight-triggered flexible interlocking fingers or tines, such as Fig.66A and 66B shown.

[0173] For example, Fig.52A and Fig.52B A system 491 is shown that includes an upper inclined conveyor system 492 running above a lower inclined conveyor system 494. The system 491 can be used with Figure 1 , Fig. 9 and Fig.11 Use any of the import systems in , replacing Figure 1 , Fig. 9 and with Fig.11 One or more of the transmitters shown in the use, for example, as Fig.49The lower conveyor 494 of such a system may alternatively lead to an abnormal cargo box. The upper conveyor 492 includes active conveyor sections 495, 497 and a set of bomb bay doors. The upper conveyor 492 (as well as the lower conveyor 494) may be inclined (extending in the X and Y directions) so that if an object 499 above the top of the door 498 does not fall, the object 499 can slide over the door to the next conveyor section 497. Reference Fig.52B If door 498 is a passive bomb bay door, and if object 499 is too heavy (e.g., to overcome a spring mechanism), door 498 will open, causing object 499 to fall to lower conveyor 494. If door 498 is a motor-actuated bomb bay door, and if object 499 is determined to be too heavy (e.g., by a different weighing system disclosed above, such as if conveyor portion 495 is a weighing conveyor as discussed above), door 498 will be opened by the motor, causing object 499 to fall to lower conveyor 494.

[0174] Fig.53 A breathable conveyor 500 is shown including a conveyor material 506 having openings 508 therein to allow air to flow through the material 506. The breathable conveyor 500 may be formed of a perforated, mesh, or woven material and driven on rollers 502, 504, with one roller (e.g., 502) including openings 503 and a vacuum being provided into the roller 502 through the openings 503. Fig.54 As shown, such a system can be used in an import system 489 having an object handling system 12.

[0175] Fig.54 The introduction system 489 includes an input portion 14 and an additional conveyor 509 leading to a gas permeable conveyor 500, as described above with reference to Figure 1-Figure 8 As discussed, the input portion 14 includes the response evaluation portion 16 of the conveyor 22, the side sensing unit 18, the overhead sensing unit 20, the multi-purpose sensing unit 24, the weight sensing conveyor portion 53, and the multi-directional conveyor 33. The free end of the air permeable conveyor is positioned on two or more receiving stations, which may be conveyors, chutes, or automated carriers. Fig.54 3. The objects to be processed can be routed by multi-directional conveyor 33 to conveyor 511, which runs between a pair of articulated arms 521, 523 and a pair of conveyors 525, 527, which lead to object handling conveyors 531 (leading to object handling system 12) and 535 via further multi-directional conveyors 529, 533.

[0176] Further references Fig.55A, objects can be provided on conveyor 500 with a vacuum applied, and as the objects pass around the outside of the rollers, heavier objects (e.g., object 503) can fall directly from the conveyor into bin 513, as shown. Fig.55B Slightly lighter objects (e.g., 505) can travel further under roller 502 into cargo box 515, as shown. Fig.55C As shown, very light objects (e.g., 507) can only be dropped from the now inverted conveyor 506 into the cargo box 517 when the conveyor leaves the vacuum provided by the rollers 502, as shown. Fig.55D As shown. With such a system, objects also do not need to be separated on the conveyor, as objects adjacent to each other will fall according to their own response to the vacuum. Additionally, one or more sensing systems 692 can monitor the movement of objects falling from the conveyor and can communicate with one or more control systems 694 to adjust either the vacuum pressure 696 at the conveyor (via a vacuum controller) or the conveyor speed 498 (via a rotational speed controller). Fig.53 and Figure 55A-Figure 5 The system of D can be used, for example, in further systems disclosed herein.

[0177] Again, the receiving station can be any of an automated carrier, chute, or conveyor. Fig.56 An inlet system 647 is shown including an input portion 14 and an additional conveyor 509 leading to a gas permeable conveyor 500, as described above with reference to Figure 1-Figure 8 As discussed, the input portion 14 includes the response evaluation portion 16 of the conveyor 22, the side sensing unit 18, the overhead sensing unit 20, the multi-purpose sensing unit 24, the weight sensing conveyor portion 53, and the multi-directional conveyor 33. In this example, the air permeable conveyor is positioned on the automated carrier 513', the chute 515' leading to the automated carrier 649, and the carrier 517'. The objects to be processed can be routed by the multi-directional conveyor 33 to the conveyor 537, which runs between a pair of conveyors 541, 545, which lead to object processing conveyors 553 (leading to the object handling system 12) and 557 via further multi-directional conveyors 551, 555. The conveyors 537, 541 and 545 also pass through the object transport station 547, as described below with reference to Figure 57-Figure 69 As further discussed, and in some examples, conveyors 541 and 545 are lower than conveyor 537, while in other examples, each is at the same height. At the object transport station, the object is transported from the conveyor to any of a variety of further units, such as to other conveyors, chutes, or mobile units.

[0178] For example, according to a further aspect of the invention, an induction system can be used that can distinguish between objects by passing objects with a blower that pushes lighter packages out of the package stream, leaving behind heavier packages. The greater inertia of the heavier packages overcomes the air resistance created by the blown gas. For lighter packages, the air resistance exceeds the lower inertia of the lighter packages. The airflow is adjusted so that for common package types, the blown-away stream contains packages that meet weight specifications to the greatest extent possible.

[0179] For example, Fig.57 Shown with the above reference Fig.53 A similar air permeable conveyor 501 as discussed above is designed to allow large amounts of air to blow through openings 508 in a web 506 that moves along rollers (providing a conveying surface). Fig.57 As shown, such a gas permeable conveyor 501 can be used in a system 510, where an object moves along an approach conveyor 512 and moves on the gas permeable conveyor 501. Below the gas permeable conveyor 501 is a blower source 514 that blows air through the gas permeable conveyor 500, and above the gas permeable conveyor 501 is a vacuum source 516 that draws air through the gas permeable conveyor 501. Both the blower 514 and the vacuum source 516 can include a screen or an array of openings (partially as shown in FIG. Fig.60 501). The combination of blower 514 and vacuum source 516 will cause some objects to be lifted off conveyor 501. Objects that are too heavy to be lifted off conveyor 501 will travel along conveyor 501 and be transported to follower conveyor 518. System 510 can replace Figure 1 , Fig. 9 and Fig.11 Any of the conveyors in the system is used, wherein the lighter objects are then routed to the light object handling station, as shown in reference Figure 59A-Figure 59C Further discussed.

[0180] Additionally, if Fig.58 As shown, the system can further include one or more sensing systems 521 that communicate with a vacuum control processor 523 coupled to a vacuum controller 525, and communicate with a blower control processor 527 coupled to a blower controller 529. In this way, the operation of the system can be monitored and the air flow of the blower and vacuum can be adjusted as needed.

[0181] refer to Fig.59AAs the object 520 is lifted toward the vacuum source 516, it is initially pushed by the air from the blower source 514 and lifted by the vacuum source 516. Once the object contacts the screen on the vacuum source 516, the vacuum force will be strong enough that the air from the blower is no longer necessary to hold the object against the vacuum source 516. The vacuum source 516 can be movably mounted on a track 522 so that the vacuum source 518 can be moved to be positioned above the conveyor 501 or any of the adjacent conveyors 524, 526, see reference 524. Fig.59B For example, vacuum source 516 may be moved over conveyor 524 while holding object 520, and then the vacuum may be stopped, allowing the object to fall onto conveyor 524, as shown. Fig.59C The vacuum source 516 is then returned to a position above the conveyor 501. In this manner, the vacuum source and / or the blower source can be used to distinguish and separate objects having different characteristics, such as weight or mass.

[0182] According to a further aspect, the system can further provide mass picking through such a vacuum system. Objects can pass through an area where a large vacuum surface is suspended upside down above the objects. The system can grip a large number of objects - many objects at a time - but only light objects can be lifted, and heavy objects cannot be lifted out of the stream of objects. The balance of the vacuum lifting force to the weight and packaging material can be adjusted so that all objects remaining have a minimum weight, or all objects lifted are below a maximum weight.

[0183] An introduction system according to a further embodiment of the present invention may include a system 530 including a blower source 532 and a vacuum source 534 positioned on either side of a gas permeable conveyor 536, such as Fig.60 532 by allowing greater airflow to draw certain objects toward vacuum source 532. Conveyor 536 is fed objects by infeed conveyor 538 and provides objects (objects not removed from conveyor 536 by blower source 532 and vacuum source 534) to outfeed conveyor 539. Objects removed from conveyor 536 fall onto either of another conveyor below and to the side of conveyor 536, or onto a chute or other moving carrier, as discussed in more detail below. Fig.58 Similar monitoring and control systems can also be used with Fig.60 system.

[0184] refer to Fig.61, a system 540 according to a further embodiment of the present invention may include a blower source 542 and a vacuum source 544 positioned on either side of an air permeable conveyor 546, and another blower source 543. The conveyor 546 is fed objects by an infeed conveyor 548 and provides objects (objects not removed from the conveyor 546 by the blower sources 542, 543 and the vacuum source 544) to an outfeed conveyor 549. The blower source 543 may further facilitate the use of the blower source 542 and the vacuum source 544 to move objects. Again, objects removed from the conveyor 546 fall onto either of another conveyor below and to the side of the conveyor 536, or onto a chute or other moving carrier, as discussed in more detail below. With Fig.58 Similar monitoring and control systems can also be used with Fig.61 system.

[0185] In applications where the object is light enough to be removed from a non-perforated conveyor (and / or a blower and vacuum source is high), a system 550 may be provided that includes a blower source 552 and a vacuum source 554 positioned on either side of a conveyor 556, such as Fig.62 As shown. Conveyor 556 is fed objects by infeed conveyor 558 and provides objects (objects not removed from conveyor 556 by blower source 552 and vacuum source 554) to outfeed conveyor 559. Again, objects removed from conveyor 556 fall onto either of another conveyor below and to the side of conveyor 556, or onto a chute or other moving carrier, as discussed in more detail below. Fig.58 Similar monitoring and control systems can also be used with Fig.62 system.

[0186] As mentioned above, objects may be routed to any of a chute, a conveyor, a mobile carrier, etc. For example, Fig.63 A system 560 is shown, which includes a central transmitter as described above with reference to Figure 39A-Figure 43C The system discussed has an in-feed conveyor section 562, an out-feed conveyor section 564, and a weight sensing conveyor 566. The system 560 also includes a pair of sources 568, 570 on either side of the weight sensing conveyor 566, and each source 568, 570 can provide forced air via a blower or vacuum so that objects can be moved out of the conveyor 566 in either direction by the blower-vacuum pair.

[0187] Further references Fig.64In the side view shown, objects can be blown onto chute 572 leading to conveyor 574 (e.g., by engaging source 570 as a blower and source 568 as a vacuum source), or can be blown onto chute 576 leading to mobile carrier 578 (e.g., by engaging source 568 as a blower and source 570 as a vacuum source). The selection of whether to move the object to conveyor 574 or mobile carrier 578 can be the result of airflow between sources 568, 570, or in other aspects, can be triggered by the detected weight of the object on conveyor 566. In further aspects, weight sensing conveyor 566 can be used to confirm the weight of the object and further provide feedback to the control system (e.g., 100) so that the sources can be adjusted (together or independently) to more finely adjust their object removal capabilities.

[0188] Fig.65 A system 600 is shown that includes a central conveyor having an infeed conveyor portion 602, an outfeed conveyor portion 604, and a weight sensing multi-directional conveyor 606. The weight sensing multi-directional conveyor 606 may include a plurality of weight sensing multi-directional conveyors as described above with reference to FIG. Figure 39A-Figure 43C The weight sensing rollers 442 discussed, and a series of orthogonally arranged narrow conveyor belts 608. Either the rollers 442 or the belts 608 can be lowered / raised relative to the other to provide that the object can remain on the conveyor 606 and be provided to the outfeed conveyor 604, or can be routed by the belts 608 to the chute 610 leading to the conveyor 612 or to the chute 614 leading to the mobile carrier 616. The selection of whether the object is moved to the conveyor 612 or the mobile carrier 616, or remains on the conveyor 606 can be triggered by the detected weight of the object on the conveyor 606. The mobile carrier 616 can include a bin or box into which the received object is dropped, and the mobile carrier 616 can be moved around the track system, as discussed in more detail below.

[0189] According to a further aspect of the present invention, Fig.66A and Fig.66B A system 620 is shown that includes a central conveyor having an infeed conveyor portion 622, an outfeed conveyor portion 624, and a weight sensing multi-directional conveyor 626. Again, the weight sensing multi-directional conveyor 626 may include the weight sensing multi-directional conveyor 626 as described above with reference to FIG. Figure 39A-Figure 43CThe weight sensing roller 442 discussed, and a series of orthogonally arranged narrow conveyor belts 628. Either the roller 442 or the belt 628 can be lowered / raised relative to the other to provide that the object can be left on the conveyor 626 or provided to the outfeed conveyor 624, or can be routed by the belt 628 to the chute 630 leading to the conveyor 632 or to the chute 634 leading to the mobile carrier 636. Additionally, the chute 630 includes a bomb bay door 638 that opens above a further conveyor 639. The bomb bay door 638 can be motor actuated, or designed to be released by a spring at a certain weight threshold, as described above with reference to Figure 49-52B The detected weight of an object on conveyor 606 may trigger a selection of whether the object is moved to conveyor 612, conveyor 639, or mobile carrier 616, or remains on conveyor 626. Again, mobile carrier 616 may include a bin or box into which the received object is dropped, and mobile carrier 616 may be moved around a track system, as discussed in more detail below.

[0190] Fig.67 Shows something like Fig.63 The system 560 includes a central transmitter having a central transmitter as described above with reference to Figure 39A-Figure 43C The infeed conveyor section 562, outfeed conveyor section 564 and weight sensing conveyor 566 are discussed. The system 560 also includes a pair of sources 568, 570 located on either side of the weight sensing conveyor 566, and each source 568, 570 can provide forced air via a blower or vacuum so that objects can be moved out of the conveyor 566 in either direction by the blower-vacuum pair. In addition to the chute 576 leading to the automated carrier 578, Fig.67 The system also includes a chute 573 having a pair of bomb bay doors 577 (as described above with reference to Figure 49-51B As discussed), for selectively providing objects to conveyor 574 or causing objects to drop onto conveyor 575 adjacent to conveyor 574.

[0191] Fig.68A and Fig.68B A system 580 is shown, which includes a central transmitter having a central transmitter as described above with reference to Figure 39A-Figure 43C The infeed conveyor section 582, outfeed conveyor section 584 and weight sensing conveyor 586 are discussed. The system 580 also includes a pair of paddles 588, 590 located on either side of the weight sensing conveyor 586, and each paddle 588, 590 can be used to push objects on the weight sensing conveyor 586 out of the conveyor 586 in either direction, or the objects can remain on the conveyor 586 and be moved to the outfeed conveyor section 584. Further reference Fig.68B, the object may be pushed onto chute 592 leading to conveyor 594, or may be pushed onto chute 596 leading to mobile carrier 598. The selection of whether the object is moved to conveyor 574 or mobile carrier 578, or remains on conveyor 586, may be triggered by the detected weight of the object on conveyor 586. Mobile carrier 598 may include a bin or box into which the received object is dropped, and mobile carrier 598 may be moved around a track system, as discussed in more detail below.

[0192] Fig.69 Shows something like Fig.68A and Fig.68B A system comprising a central transmitter having a Figure 39A-Figure 43C The in-feed conveyor section 582, out-feed conveyor section 584 and weight sensing conveyor 586 are discussed. The system 580 also includes a pair of paddles 588, 590 located on either side of the weight sensing conveyor 586, and each paddle 588, 590 can be used to push objects on the weight sensing conveyor 586 out of the conveyor 586 in either direction, or the objects can remain on the conveyor 586 and be moved to the out-feed conveyor section 584. In addition to the chute 596 leading to the automated carrier 598, Fig.69 The system also includes a chute 593 having a pair of bomb bay doors 597 (as described above with reference to Figure 49-51B As discussed), for selectively providing objects to conveyor 594 or causing objects to drop onto conveyor 595 adjacent to conveyor 594.

[0193] The object handling system may include multiple stations as discussed above, and the import filtering may direct different objects to different stations based on various object characteristics and end effector characteristics (e.g., knowing which end effector is better suited to manipulate which object). The ability to provide objects from a feed conveyor to a variety of handling systems provides great flexibility, and the ability to provide objects to an automated carrier provides further flexibility in object handling. For example, Fig.70 An object handling system 650 is shown that includes a plurality of workstations 652, 654, 656 that receive objects via diverters 660, 662, 670, 672, 680, 682 under the control of one or more handling systems 690. For example, workstation 652 may be well suited to move bags for a destination location 666 using an articulated arm 664, and, for example, workstation 654 may be more suited to move cylinders to a destination location 676 using an articulated arm. Another workstation 656 may, for example, include a worker 684 for moving objects to a destination location 686 that is not easily handled by any articulated arm.

[0194] The object handling system used with the inlet filtering system and method of various embodiments of the present invention can be any of a variety of object handling systems (such as sorting systems, automated storage and retrieval systems, and distribution and redistribution systems). For example, according to further embodiments, the present invention provides a system that can automate outbound processing of a processing system. The system can include one or more automated picking stations 700 (such as Fig.71 ) and a manual pick-up station 800 (as shown Fig.72 ), the automated pick station 700 and the manual pick station 800 are provided with containers by a fleet of mobile carriers traversing the intelligent floor structure formed by the track segments as discussed above. The carriers can carry cargo boxes, which can store objects. The system can provide a novel goods-to-picker system that uses a fleet of small mobile carriers to carry individual inventory totes and outbound containers to or from the pick station.

[0195] Embodiments of the system according to the present invention include an automated picking station that picks each from an inventory tote and loads each into an outbound container. The system involves a combination of machine vision, task and motion planning, control, error detection and recovery, and sensor-enabled artificial intelligence, hardware platforms to achieve a real-time and robust solution for singulating items from a cluttered container.

[0196] refer to Fig.71 The automated picking system 700 uses a multimodal sensing unit to sense the contents of the container and picks each one from the homogeneous inventory tote and places them into the heterogeneous outbound container using a robotic arm equipped with an automated programmable motion gripper and integrated software in the handling system 720. These elements are co-located in a work cell that meets industry standard safety requirements and cooperates with a track system to keep the automated picking system fed with a continuous supply of inventory totes and outbound containers.

[0197] In particular, the system 700 includes an array 702 of track elements 704 as discussed above, and an automated carrier 706 advancing on the track elements 704 as discussed above. One or more overhead perception units 708 (e.g., cameras or scanners) acquire perception data about objects in a cargo box or tote 710, and perception data about the location of a destination box 712. A programmable motion device (such as a robotic system 714) picks up an object from the cargo box or tote 710 and places the object in an adjacent box 712. Then, one or both of the units 710, 712 are automatically moved back into the grid, and one or two new such units are moved into a position adjacent to the robotic system. At the same time, the robotic system is used to process another pair of adjacent units (again, cargo box or tote 710 and box 712) on the other side of the robotic system 714. Thus, the robotic system processes a pair of processing units on one side, and then switches the two sides when the first side is replenished. In this way, the system 700 does not need to wait for a new pair of object processing units to be presented to the robotic system. The array 702 of track elements 704 may also include shelf stations 716 where the mobile unit 706 may park or pick up a tote 710 or box 712. The system operates under the control of a computer processor 720, for example.

[0198] The manual pick station system is a goods-to-person pick station supplied by a mobile automated movement carrier on a rail system as discussed above. The system has the same form and function as the automated pick station in that both are supplied by the same carrier, both are connected to the same rail system grid, and both transport each from an inventory tote to an outbound container. The manual system 800 (e.g. Fig.72 shown) rely on manual team members to perform the picking operations.

[0199] In addition, the manual system raises the carrier to an ergonomic height (e.g., via a ramp), ensures safe access to the containers on the carrier, and includes a monitoring interface (HMI) to guide the team member's activities. The identity of the SKU and the number of items to be picked are displayed on the HMI. The team member must scan the UPC of each unit using a presentation scanner or a handheld barcode scanner to verify that the pick is complete. Once all picks between a pair of containers are completed, the team member presses a button to mark it complete.

[0200] According to this embodiment (and / or in combination with a system including an automated picking system as discussed above), Fig.72The system 800 may include an array 802 of track elements 804 disposed on a plane 806 and an inclined surface 808 leading to another plane. The system 800 may also include a visual data screen 809 that provides visual data to a human sorter, thereby informing the human sorter what goods are to be moved from a tote or case 810 to a destination box 812. The system operates under the control of, for example, a computer processor 820.

[0201] While a significant amount of the picking throughput of the entire system is expected to be handled by the automated picking system, the manual picking system provides the carrier and track systems with (a) the ability to scale quickly to meet unplanned demand growth; (b) the ability to handle cargo that is not yet available for automation; and (c) the ability to serve as a QA, problem solving, or inventory consolidation station throughout the distribution system. Thus, the system provides significant scalability and troubleshooting capabilities because manual picking can be easily added to an otherwise fully automated system. Once the manual picking system is enabled (occupied by a sorter), the system will begin sending totes or cartons 810 and boxes 812 to the manual picking stations. The automated picking stations and manual picking stations are designed to occupy the same footprint, so that a manual station can be replaced by an automated picking station later with minimal modifications to the rest of the system.

[0202] Third, carriers are small mobile robots that can interchangeably carry inventory totes, outbound containers, or vendor boxes. These carriers can remove or replace containers from storage fixtures using simple linkages. Since a carrier can only carry one container at a time, it can be smaller, lighter, and consume less energy than larger robots while being much faster. Since carriers travel on smart tile floors, they have reduced sensing, computing, and precision requirements compared to mobile robots operating on bare floors. These features improve cost performance metrics.

[0203] All carriers operate as independent container delivery agents on the same shared roadway of the track section. The carriers can move forward, backward, left, or right to travel around each other and to any location in the system. This flexibility allows the carriers to play multiple roles in the system by: (a) transferring inventory totes to a pickup station; (b) transferring outbound containers to a pickup station; (c) transferring inventory totes to and from bulk storage; (d) transferring full outbound containers to a discharge lane; (e) transferring empty outbound containers to the system. Additionally, carriers can be added incrementally as needed to scale as the facility grows.

[0204] Track floor modules are standard-sized, modular and connectable floor sections. These tiles provide navigation and a standard driving surface for carriers and can serve as storage areas for containers. Modules connect to robotic pick-up units, induction stations from bulk storage and unloading stations near loading docks. Modules eliminate the need for other forms of automation (e.g., conveyors) for transporting containers within the system.

[0205] like Fig.73 As shown at 900 in the diagram, the system can be expanded to include a much larger array of track modules 902 and a number of processing stations 904, and the number of processing stations 904, for example, can be any of the inventory infeed stations, empty outbound container infeed stations, automated and manual processing stations, and outbound stations as discussed above. The system operates under the control of, for example, a computer processor 906.

[0206] Those skilled in the art will appreciate that various modifications and variations can be made to the embodiments disclosed above without departing from the spirit and scope of the present invention.

[0207] What is sought to be protected is:

Claims

1. A dispensing system for use in an induction system for use with an object handling system, the dispensing system for providing dissimilar objects to one of a plurality of receiving units, the dispensing system comprising: a breathable transmitter portion; an air inlet system including a vacuum source having a screen-like opening facing the conveyor portion at a fixed distance above the conveyor portion; as well as a forced air system including a blower having an opening facing toward the air intake system from below the air permeable conveyor portion; Wherein the air intake system and the forced air system cooperate to draw objects from the air permeable conveyor portion into contact with the screen-like opening of the vacuum source.

2. The distribution system according to claim 1, characterized in that The conveyor portion includes a conveyor having a plurality of openings therein.

3. The distribution system according to claim 1 or claim 2, characterized in that: The conveyor portion is formed from a mesh material.

4. The distribution system according to claim 1, wherein: The vacuum source of the air intake system may be dynamically adjusted to accommodate various objects presented to the conveyor portion.

5. The distribution system according to claim 1, characterized in that The dispensing system further comprises a sensing unit oriented towards the object on the conveyor portion.

6. The distribution system according to claim 1, characterized in that The distribution system includes an adjustable vacuum control system for adjusting the vacuum of the intake system.

7. The distribution system according to claim 1, wherein: The intake system is movably mounted on a track to carry the object drawn into the intake system toward one of a plurality of adjacent conveyors.

8. A dispensing system for use in an induction system for use with an object handling system, the dispensing system for providing dissimilar objects to one of a plurality of receiving units, the dispensing system comprising: a breathable transmitter portion; Forced air systems and air intake systems, The air intake system includes a vacuum source and a screen, and the air intake system is movably mounted on a track at a fixed distance above the air permeable conveyor portion, The forced air system includes a blower source, the blower source opposing the air intake system from below the air permeable conveyor portion, wherein the vacuum source of the air intake system draws air through the air permeable conveyor portion and the blower source of the forced air system blows air through the air permeable conveyor portion to lift objects from the air permeable conveyor portion into contact with the screen of the vacuum source, and The air intake system moves along the track to carry the object to one of a plurality of adjacent conveyors.

9. The distribution system according to claim 8, characterized in that The air permeable conveyor portion includes a conveyor having a plurality of openings therein.

10. The distribution system according to claim 8 or claim 9, characterized in that: The air permeable conveyor portion is formed from a mesh material.

11. The dispensing system of claim 8, further comprising an adjustable vacuum control system that can dynamically adjust the air flow rate provided by the vacuum source to accommodate various objects presented to the air permeable conveyor portion.

12. The distribution system according to claim 11, characterized in that The dispensing system further includes a sensing unit oriented toward the object on the air permeable conveyor portion.

13. The distribution system according to claim 11, characterized in that The distribution system includes an adjustable vacuum control system for adjusting the vacuum of the intake system.

14. A method of distributing dissimilar objects to one of a plurality of receiving units in a pre-processing system for use with an object processing system using the distributing system of any preceding claim, the method comprising: providing the forced air system opposite the intake air system, and The forced air system and the air intake system are coupled to assist in moving an object on the conveyor section from the conveyor section to one of a plurality of adjacent conveyors.

15. The method of claim 14, further comprising dynamically adjusting the vacuum source of the air intake system to accommodate various objects presented to the conveyor portion.

16. The method according to claim 14, characterized in that The air intake system opens above the conveyor portion.

17. The method according to claim 14, characterized in that An opening of the air intake system is horizontally adjacent to the conveyor portion.

18. The method of claim 14, wherein: The forced air system opens below the conveyor portion.

19. The method of claim 14, wherein: An opening of the forced air system is horizontally adjacent to the conveyor portion.

20. The method of claim 14, wherein: The intake system is movably mounted on a track to carry objects drawn into the intake system toward one of the adjacent conveyors.

21. The method of claim 14, wherein: The object processing system includes a plurality of object processing stations.

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