Methods, systems and apparatus for operating material handling systems

Abstract

This invention discloses a material handling device including a first pop-out belt adjacent to a first cam. The first pop-out belt is configured to facilitate movement of a package between a first conveyor and a second conveyor. A separator wall is adjacent to a second cam. The separator wall is configured to control the movement of the package between the first and second conveyors. In response to rotation of the camshaft in a first direction, the first cam causes the first pop-out belt to extend from the first conveyor. The second cam causes the separator wall to move to a first position. In the first position, the separator wall allows the package to move from the first conveyor to the second conveyor. In response to rotation of the camshaft in a second direction, the first pop-out belt moves to a retracted position, while the separator wall moves to a second position.

Description

[0001] This application is a divisional application of the invention patent application filed on June 5, 2020, with application number 202010509872.6 and entitled "Method, System and Apparatus for Operating a Material Handling System". Technical Field

[0002] This disclosure relates in its entirety to material handling devices in a material handling environment. Background Technology

[0003] Material handling environments, such as but not limited to warehouses, shipping and retail locations, may include various subsystems that combine operations to perform one or more operations (e.g., package transport, storing packages in storage compartments, retrieving packages from storage compartments, etc.). Examples of such subsystems may include, but are not limited to, conveyor systems, robotic arms, single-unit systems, sorting machines, automated storage and retrieval systems (ASRS), etc. In some scenarios, packages may be transferred between various subsystems during the performance of predetermined operations. Summary of the Invention

[0004] Various embodiments shown herein disclose a material handling device. The material handling device includes an actuation unit comprising a motor and a camshaft coupled to the motor. The camshaft includes a first cam and a second cam. Furthermore, the material handling device includes an adjacent first pop-out belt abutting the first cam, wherein the first pop-out belt is configured to facilitate movement of a package between a first conveyor and a second conveyor. Additionally, the material handling device includes a separator wall abutting the second cam, wherein the separator wall is configured to control movement of the package between the first and second conveyors. In response to the motor actuating the camshaft in a first direction, the first cam causes the first pop-out belt to extend above the first conveyor to facilitate movement of the package from the first conveyor to the second conveyor, and the second cam causes the separator wall to move to a first position, wherein in the first position, the separator wall allows the package to move from the first conveyor to the second conveyor. In response to the motor actuating the camshaft in the second direction, the first cam moves the first pop-up belt to a retracted position below the first conveyor, and the second cam moves the separator wall to a second position in which the separator wall prevents the package from moving between the first and second conveyors.

[0005] Various embodiments shown herein disclose a material handling system comprising: a first conveyor; a first subsystem positioned adjacent to the first conveyor; a separator wall positioned between the first conveyor and the first subsystem, wherein the separator wall is configured to control movement of a package between the first conveyor and the first subsystem; a first pop-up belt positioned below the first conveyor, wherein the first pop-up belt is configured to facilitate movement of the package from the first conveyor to the first subsystem; and a camshaft including a first cam and a second cam, wherein the first cam is coupled to the first pop-up belt and the second cam is coupled to the separator wall, and wherein the camshaft is configured to rotate in a first direction and a second direction. In response to rotation of the camshaft in the first direction, the first cam causes the first pop-up belt to extend above the first conveyor to facilitate movement of the package from the first conveyor to the first subsystem, and the second cam causes the separator wall to move to a first position. In the first position, the separator wall allows the package to move from the first conveyor to the first subsystem. In response to the rotation of the camshaft in the second direction, the first cam moves the first pop-up belt to a retracted position below the first conveyor, and the second cam moves the separator wall to a second position in which the separator wall prevents the package from moving between the first conveyor and the first subsystem.

[0006] The various embodiments shown herein disclose a method for operating a material handling system. The method includes a controller determining whether a package to be transferred from a first conveyor to a second conveyor is positioned on the first conveyor. Furthermore, in response to determining that the package is positioned on the first conveyor, the method includes the controller actuating a motor to rotate a camshaft in a first direction, thereby extending a first pop-up belt above the first conveyor and moving a separator wall between the first and second conveyors to a first position, such that the first pop-up belt and the separator wall facilitate movement of the package from the first conveyor to the second conveyor. Additionally, in response to determining that the package has moved from the first conveyor to the second conveyor, the method includes the controller actuating a motor to rotate a camshaft in a second direction, thereby moving the first pop-up belt to a retracted position below the first conveyor and moving the separator wall to a second position, such that the separator wall prevents movement of the package between the first and second conveyors. Attached Figure Description

[0007] The description of the exemplary embodiments can be read in conjunction with the accompanying drawings. It should be understood that, for simplicity and clarity of illustration, the elements shown in the drawings are not necessarily drawn to scale. For example, the dimensions of some elements are exaggerated relative to others. Embodiments incorporating the teachings of this disclosure are shown and described with reference to the accompanying drawings, in which:

[0008] Figure 1 A perspective view of a material handling system according to one or more embodiments is shown;

[0009] Figure 2 A perspective view of a machine according to one or more embodiments is shown;

[0010] Figure 3 An exploded view of a first actuation unit according to one or more embodiments is shown;

[0011] Figure 4 A front view of a first actuation unit according to one or more embodiments is shown;

[0012] Figure 5 A front view of a first cam according to one or more embodiments is shown;

[0013] Figure 6 A cross-sectional view of a machine depicting a first cam according to one or more embodiments is shown;

[0014] Figure 7 Another cross-sectional view of a machine depicting a second cam and a first cam according to one or more embodiments is shown;

[0015] Figure 8 A perspective view of a movable frame according to one or more embodiments is shown;

[0016] Figure 9 A perspective view of a partition wall frame according to one or more embodiments is shown;

[0017] Figure 10 Another perspective view of the machine according to one or more embodiments is shown;

[0018] Figure 11 A perspective view of an example pop-up strip according to one or more embodiments is shown;

[0019] Figure 12 A perspective view of a partition wall according to one or more embodiments is shown;

[0020] Figure 13 A block diagram of a control system according to one or more embodiments is shown;

[0021] Figure 14 A flowchart is shown for a method of operating a material handling system according to one or more embodiments;

[0022] Figure 15 A perspective view of a machine in a first state according to one or more embodiments is shown;

[0023] Figure 16 A perspective view of a machine in a second state according to one or more embodiments is shown;

[0024] Figure 17 A perspective view of a machine in a third state according to one or more embodiments is shown;

[0025] Figure 18 A perspective view of a machine in a fourth state according to one or more embodiments is shown;

[0026] Figure 19 A perspective view of a machine in its fifth state according to one or more embodiments is shown;

[0027] Figure 20 A perspective view of a machine in its sixth state according to one or more embodiments is shown;

[0028] Figure 21 A perspective view of a machine in its seventh state according to one or more embodiments is shown;

[0029] Figure 22 A perspective view of a machine in its eighth state according to one or more embodiments is shown;

[0030] Figure 23 A perspective view of a machine in its ninth state according to one or more embodiments is shown; and

[0031] Figure 24 A flowchart is shown of a method for operating a material handling system according to one or more embodiments. Detailed Implementation

[0032] Some embodiments of this disclosure will be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of this disclosure. In fact, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided to enable this disclosure to meet applicable legal requirements. Throughout this document, similar reference numerals refer to similar elements. The terminology used in this patent is not intended to be restrictive, and the device or portions thereof described herein may be attached or utilized in other orientations.

[0033] The term “comprising” means including but not limited to, and should be interpreted in the manner commonly used in the patent context. It should be understood that the use of broad terms such as “comprising,” “including,” and “having” provides support for narrow terms such as “consisting of,” “substantially composed of,” and “substantially constituted by.”

[0034] The phrases “in one embodiment”, “according to one embodiment”, etc., generally mean that the specific feature, structure or characteristic following the phrase can be included in at least one embodiment of the present disclosure, or can be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0035] The term “exemplary” as used herein means “serving as an example, instance, or illustration.” Any specific implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other specific implementations.

[0036] If the specification states that a component or feature "may," "can," "should," "will," "preferably," "possibly," "usually," "optionally," "for example," "often," or "may" (or other such words) be included or have that characteristic, then that particular component or feature is not necessarily included or has that characteristic. Such components or features may be optionally included in some embodiments or may be excluded.

[0037] As used herein, the term "package" can refer to a physical item, parcel, object, component, device, etc. For example, a warehouse or retail point (e.g., a scene) may be configured to store packages, such as parcels, envelopes, cartons, shipping containers, handbags, etc., for transport. In some examples, a package can refer to a two-dimensional (2D) package and / or a three-dimensional (3D) package. In an exemplary embodiment, a 3D package can refer to a package having three dimensions (e.g., height, width, and length). In one example embodiment, a 2D package can refer to a 3D package in which one of the dimensions is negligible (e.g., height). Some examples of 2D packages may include, but are not limited to, paper, envelopes, etc.

[0038] As used herein, the term "subsystem" corresponds to a machine configured to perform a task, or an area in a material handling environment where a task is to be performed. Some examples of subsystems may include, but are not limited to, conveyor systems, ASRS systems, sorting systems, pallet systems, accumulator areas, etc.

[0039] As used herein, the term "conveyor" refers to a material handling device that can be configured to transfer packages or objects in a conveying direction above a conveying plane. Some examples of conveyors may include, but are not limited to, belt-based conveyors or roller-based conveyors.

[0040] The term "transfer plane" may correspond to the plane defined by the surface of a conveying device on which a package is placed. In some examples, the package may slide on the plane when the conveying device is operated.

[0041] The term "transfer axis" can be used to describe the axis along which a package is transferred when the transfer device is in operation.

[0042] Material handling environments, such as warehouses and retail outlets, comprise one or more subsystems, such as conveyors, robotic arms, single-unit systems, sorting machines, etc. These subsystems can be combined to perform predetermined operations within the material handling environment. In some implementations, packages may be transferred from one subsystem to another during the performance of predetermined operations. Typically, robotic arms are used to transfer packages between various subsystems. However, the count of packages transferred between the various subsystems may be limited by the capacity of the robotic arm. In one example implementation, the capacity of the robotic arm may be determined based on the count of packages that the robotic arm can pick up and place per minute. Therefore, the overall productivity of the material handling environment may depend on the capacity of the robotic arm.

[0043] The apparatus, systems, and methods described herein disclose a machine capable of transferring packages between one or more subsystems in a material handling environment. For example, the machine is capable of transferring packages between a first conveyor and a second conveyor. In one example embodiment, the machine may include a main frame positioned below the first and second conveyors. Furthermore, the machine may include an actuation unit positioned on the frame. The actuation unit may include a motor and a camshaft. In some examples, the camshaft is coupled to the motor such that the motor facilitates rotation of the camshaft in a first direction or a second direction. In one example embodiment, the first direction may correspond to clockwise rotation of the camshaft, and the second direction may correspond to counterclockwise rotation of the camshaft. In one example embodiment, the camshaft may include a first cam, a second cam, and a third cam. In some examples, the first cam, the second cam, and the third cam may have profiles. In one example embodiment, the shape of the cam may correspond to the profile of the cam. In some examples, the shape of the cam may allow the radius of the cam to be different at each point on the cam.

[0044] In some examples, a first cam, a second cam, and a third cam are positioned on a camshaft such that the first and third cams can have the same orientation (hereinafter referred to as the first orientation), while the second cam can have a second orientation relative to the first or third cam. In one example embodiment, the orientation of the cams can be defined as the angle of an arc formed by a point on one cam and the same point on another cam, wherein the cam and the other cam are coupled to the same camshaft. In one example embodiment, when the two cams have the same orientation, the angle of the arc is zero. Therefore, the angle of the arc formed by the same point on the first and third cams is zero. In some examples, the angle of the arc formed by the same point on the first and second cams is 270 degrees.

[0045] In some examples, the scope of this disclosure is not limited to first, second, and third cams having the same shape. In an alternative embodiment, the first and third cams may have a first shape, and the second cam may have a second shape. In one example embodiment, the first shape may differ from the second shape.

[0046] In one example embodiment, the machine further includes a first pop-out belt, a second pop-out belt, and a separator wall coupled to the main frame. The first and second pop-out belts may abut a first cam and a third cam, respectively. Furthermore, the first and second pop-out belts may be movably positioned below the first and second conveyors, respectively. For example, the first and second pop-out belts may be configured to move between a retracted position and an extended position. In one example embodiment, in the retracted position, the first and second pop-out belts are positioned below the first and second conveyors, respectively. In one example embodiment, in the extended position, the first and second pop-out belts extend above the first and second conveyors, respectively, such that the first and second pop-out belts are positioned above the first and second conveyors, respectively. In some examples, the movement of the first and second pop-out belts between the retracted and extended positions may be controlled based on the movement of the first and third cams.

[0047] In one example embodiment, the divider wall may abut against the second cam and may be positioned between the first and second conveyors. In some examples, a first end of the divider wall may abut against the second cam. In one example embodiment, the divider wall may be configured to control movement of the package between the first and second conveyors. For example, the divider wall may be configured to prevent movement of the package between the first and second conveyors when the divider wall is in a first position. In one example embodiment, in the first position, a second end of the divider wall extends above the first and second conveyors. Alternatively, the divider wall may be configured to allow movement of the package between the first and second conveyors when the divider wall is in a second position. In one example embodiment, in the second position, a second end of the divider wall retracts below the first and second conveyors. Similar to the first and second pop-up conveyors, the movement of the divider wall between the first and second positions is controlled based on the movement of the second cam on the camshaft.

[0048] In one example implementation, the motor can rotate the camshaft in a first direction or a second direction. Because the second cam is out of phase with the first and third cams, the separator wall can move in a direction opposite to the direction of the first and second pop-up belts.

[0049] For example, when the motor rotates the camshaft in a first direction, the first and second pop-up belts can move to an extended position, while the separator wall can move to a first position (i.e., the second end of the separator wall retracts below the first and second conveyors). In the extended position, the first and second pop-up belts are positioned above the first and second conveyors. Furthermore, the first pop-up belt can engage with a package on the first conveyor and can move that package onto the second conveyor. In some examples, the second pop-up belt (which is positioned above the second conveyor) can be configured to receive a package from the first conveyor.

[0050] Similarly, when the motor rotates the camshaft in the second direction, the first and second pop-out belts can move to the retracted position, while the separator wall can move to the second position (i.e., the second end of the separator wall extends above the first and second conveyors). Therefore, the separator wall prevents the package from moving between the first and second conveyors.

[0051] Therefore, this machine enables packages to be transferred / moved between various subsystems without the need for a robotic arm. Consequently, the overall productivity of the material handling environment is improved.

[0052] Figure 1 A material handling system 100 according to one or more embodiments described herein is illustrated. The material handling system 100 includes a first subsystem 102, a second subsystem 104, a machine 106, and a control system 107.

[0053] In one example embodiment, the first subsystem 102 may correspond to a package turning assembly, which may further include a first conveying device 110, a pusher assembly 112, and a platform 114. In some examples, the platform 114 may be further coupled to another subsystem (not shown) configured to transfer packages on the platform 114. For example, the platform 114 may be coupled to another conveying device (not shown) configured to transfer packages on the platform 114. In some examples, without departing from the scope of this disclosure, the platform 114 itself may be part of another conveying device. In one example embodiment, the other conveying device may have a first conveying plane 116 and may be configured to transfer packages along a first conveying axis 118. Since the platform 114 is part of another conveying device, the platform 114 may also have the first conveying plane 116. Furthermore, the platform 114 may be configured to receive packages transferred by the other conveying device along the first conveying axis 118. In one example embodiment, the platform 114 may further have a first edge 120 and a second edge 122 along a second conveying axis 124. In one example implementation, the first transmission axis 118 may be orthogonal to the second transmission axis 124.

[0054] A first conveying device 110 may be positioned along a second conveying axis 124 at a first edge 120 of a platform 114. In some examples, the first conveying device 110 may be configured to transfer / transfer packages along the second conveying axis 124. In some examples, the first conveying device 110 may further have a second conveying plane 126. In one example embodiment, the first conveying device 110 may be positioned on a machine 106. Furthermore, the first conveying device 110 may include a plurality of rollers 128 spaced apart from each other to define one or more gaps 130.

[0055] In some examples, the scope of this disclosure is not limited to the first conveying device 110 comprising a plurality of rollers 128. In an alternative embodiment, the first conveying device 110 may be a belt-based conveying device. In such a scenario, the belt of the conveying device may define one or more gaps 130.

[0056] In one example embodiment, the pusher assembly 112 may be positioned at a second edge 122 of the platform 114 along a second conveyor axis 124. In one example embodiment, the pusher assembly 112 may include a pusher 132 configured to translate along the second conveyor axis 124. In some examples, the pusher 132 may be actuated using a servo motor (not shown) or via a hydraulic system (not shown). In one example embodiment, the pusher 132 may be configured to push packages on the platform 114 onto a first conveyor 110. In some examples, the scope of this disclosure is not limited to using the pusher assembly 112 to return packages to the first conveyor 110. In an alternative embodiment, the subsystem 102 may not include the pusher assembly 132. In such embodiments, the platform 114 may include a vertical belt 109 configured to move packages onto the first conveyor 110 along the second conveyor axis 124.

[0057] In some examples, the scope of this disclosure is not limited to the first subsystem 102 as a package return component 108. In one example embodiment, the first subsystem 102 may correspond to any other machine without departing from the scope of this disclosure. For example, the first subsystem 102 may consist only of the first conveying device 110.

[0058] In one example implementation, the second subsystem 104 may be positioned adjacent to the first subsystem 102. For example, the second subsystem 104 may be positioned adjacent to the first conveying device 110 along a first conveying axis 118. In some examples, the second subsystem 104 may correspond to a second conveying device 134 configured to transfer packages along a second conveying axis 124. Furthermore, the second conveying device 134 may be positioned on top of the machine 106. In one example implementation, the second conveying device 134 may include a plurality of trays 136. Each of the plurality of trays 136 may have a top surface 138 and a bottom surface 140. The top surface 138 of each of the plurality of trays 136 may define one or more slots 142 extending from the top surface 138 to the bottom surface 140.

[0059] In some examples, the scope of this disclosure is not limited to the second subsystem 104 being the second conveying device 134. In one example embodiment, without departing from the scope of this disclosure, the second subsystem may correspond to any other machine or area / zone within the material handling system 100. For example, the second subsystem 104 may correspond to an accumulation area in the material handling system 100. In another example, the second subsystem may correspond to an automated storage and retrieval system (ASRS) system.

[0060] In one example implementation, machine 106 may be configured to facilitate the movement of packages between the first subsystem 102 and the second subsystem 104. Figures 2 to 24 The structure and operation of machine 106 are described.

[0061] Figure 2 A perspective view of a machine 106 according to one or more embodiments described herein is shown. The machine 106 includes a main frame 202, a movable frame 204, a partition wall frame 206, a first actuation unit 208, and a second actuation unit 210.

[0062] In one example embodiment, the main frame 202 may be positioned on the base plate of the material handling system 100. In some examples, the main frame 202 has a rectangular shape and a plurality of first corners 212a, 212b, 212c, and 212d. Furthermore, the main frame 202 may have a plurality of edges 214a, 214b, 214c, and 214d. In some examples, edges 214a and 214c are positioned along a second axis 216, while edges 214b and 214d are positioned along a second axis 218. Those skilled in the art will understand that the scope of this disclosure is not limited to a main frame 202 having a rectangular shape. In one example embodiment, the shape of the main frame 202 may correspond to any other polygon.

[0063] Additionally, the main frame 202 may also include a plurality of first support rods 220a, 220b, 220c, 220d, and 220e. In one example embodiment, the plurality of first support rods 220a, 220b, 220c, 220d, and 220e are positioned along a second axis 218 such that a first end 222 of each of the plurality of first support rods 220a, 220b, 220c, 220d, and 220e is connected to an edge 214a, and a second end 224 of each of the plurality of first support rods 220a, 220b, 220c, 220d, and 220e is connected to an edge 214c. In some examples, the plurality of first support rods 220a, 220b, 220c, 220d, and 220e may be equidistant from each other. In an alternative embodiment, the plurality of first support rods 220a, 220b, 220c, 220d, and 220e may be unequally spaced from each other. In such an embodiment, first support rod 220a may be positioned proximal to edge 214b. Furthermore, first support rods 220b, 220c, and 220d may be located near the central portion of the main frame 202. In an example embodiment, the central portion of the main frame 202 may correspond to a predetermined region surrounding half the length of edge 214a. Furthermore, first support rod 220e may be positioned proximal to edge 214d.

[0064] In one example implementation, the first actuation unit 208 may be mounted on the edge 214d of the main frame 202 and on a plurality of first support rods 220a, 220b, 220c, 220d, and 220e. Figure 3 and Figure 4 The first actuation unit 208 is further described.

[0065] Figure 3 An exploded view of a first actuation unit 208 according to one or more embodiments described herein is shown. The first actuation unit 208 includes a motor 302, a first camshaft 304, a second camshaft 306, a serpentine belt, and a pulley mechanism 308. The motor 302 is coupled to the serpentine belt and pulley mechanism 308. Furthermore, the first camshaft 304 and the second camshaft 306 are coupled to the serpentine belt and pulley mechanism 308. Figure 4 The structure of the serpentine belt and pulley mechanism 308 is further described.

[0066] Figure 4 A front view of a first actuation unit 208 according to one or more embodiments described herein is shown. The front view of the first actuation unit 208 depicts a serpentine belt and pulley mechanism 308. The serpentine belt and pulley mechanism 308 includes a first belt 402, a motor pulley 404, a tension pulley 406, a first drive pulley 408, a second drive pulley 410, and a belt and pulley frame 412. In one example embodiment, the motor pulley 404, tension pulley 406, first drive pulley 408, and second drive pulley 410 are mounted on a first side 414 of the belt and pulley frame 412. Furthermore, the motor 302 is mounted on a second side 416 of the belt and pulley frame 412 (see [link to documentation]). Figure 3 In some examples, motor 302 may be coupled to motor pulley 404. Furthermore, in some examples, motor pulley 404 may be further coupled through the first belt 402 to tension pulley 406, first drive pulley 408, and second drive pulley 410. Therefore, when motor 302 rotates motor pulley 404, motor pulley 404 causes first drive pulley 408, second drive pulley 410, and tension pulley 406 to rotate. In some examples, tension pulley 406, first drive pulley 408, second drive pulley 410, and motor pulley 404 are configured such that first drive pulley 408, second drive pulley 410, and motor pulley 404 rotate in the same direction while tension pulley 406 rotates in the opposite direction to the rotation of motor pulley 404. For example, if motor pulley 404 rotates clockwise, first drive pulley 408 and second drive pulley 410 also rotate clockwise. Therefore, the tension pulley 406 rotates counterclockwise.

[0067] Re-reference Figure 3The first camshaft 304 can be coupled to the first drive pulley 408, and the second camshaft 306 can be coupled to the second drive pulley 410. In one example embodiment, the structure of the first camshaft 304 is similar to that of the second camshaft 306. For the purposes of description, the structure of the first camshaft 304 has been described. However, those skilled in the art will recognize that the structural details of the first camshaft 304 described herein also apply to the second camshaft 306.

[0068] In one example embodiment, the first camshaft 304 may include a first cam 310, a second cam 312, a third cam 314, a plurality of bearings 316a, 316b, 316c, and 316d, and a shaft 318. In one example embodiment, the plurality of bearings 316a, 316b, 316c, and 316d are configured to be fixedly mounted on a plurality of first support rods 220a, 220b, 220c, 220d, and 220e. For example, bearing 316a is fixedly mounted on first support rod 220a. Similarly, bearings 316b, 316c, and 316d are fixedly mounted on first support rods 220b, 220d, and 220e, respectively. In some examples, the shaft 318 may pass through each of the plurality of bearings 316a, 316b, 316c, and 316d. In one example embodiment, the shaft 318 may have a first end 320 and a second end 322. The first end 320 of the shaft 318 is connected to the bearing 316a, and the second end 322 of the shaft 318 is connected to the first drive pulley 408. In some examples, the shaft 318 can rotate relative to a plurality of bearings 316a, 316b, 316c and 316d.

[0069] In one example embodiment, the first cam 310, the second cam 312, and the third cam 314 can be positioned on the shaft 318 at predetermined locations. For example, the first cam 310 can be positioned near the bearing 316a, and the third cam 314 can be positioned near the bearing 316d. Furthermore, the second cam 312 can be positioned between the first cam 310 and the third cam 314. Additionally, when the first actuation unit 208 is mounted on the main frame 202, the second cam 312 can be positioned near the first support rod 220c. In one example embodiment, the first cam 310, the second cam 312, and the third cam 314 also rotate when the shaft 318 rotates. In one example embodiment, the first cam 310, the second cam 312, and the third cam 314 have identical structures. For descriptive purposes, the structure of the first cam 310 has been described. However, those skilled in the art will recognize that the structural details of the first cam 310 also apply to the second cam 312 and the third cam 314. Figure 5 The structure of the first cam 310 is described.

[0070] Figure 5 A front view of a first cam 310 according to one or more embodiments described herein is shown. In one example embodiment, the first cam 310 includes a base wheel 502 and a cam wheel 504. In some examples, the base wheel 502 has a first surface 506 on which the cam wheel 504 can be coupled. In one example embodiment, the cam wheel 504 has an edge 508 defining a profile 510 of the cam wheel 504. In some examples, the profile 510 of the cam wheel 504 causes the radius of the cam wheel 504 to vary at each point on the edge 508. For example, the radius of the cam wheel 504 is minimum at point A (shown by 512) and maximum at point B (shown by 514).

[0071] Re-reference Figure 3 The second cam 312 and the third cam 314 may have the same structure as the first cam 310. However, in some examples, the orientations of the first cam 310, the second cam 312, and the third cam 314 on the shaft 318 may be different. For example, the first cam 310 and the third cam 314 may have a first orientation relative to each other, while the second cam 312 may have a second orientation relative to either the first cam 310 or the third cam 314. In one example embodiment, the orientation of a cam relative to other cams may be defined as the angle of the arc formed by a point on the cam (e.g., point A (shown by 512)) and the same point on other cams (e.g., point A (shown by 512)). For example, the first cam 310 and the third cam 316 may have the same orientation (i.e., the angle of the arc formed by point A512 on the first cam 310 and point A512 on the third cam 314 is 0 degrees). Furthermore, the orientation of the second cam 312 may be different from the orientations of the first cam 310 and the third cam 314. For example, the angle of the arc formed by point A 512 on the first cam 310 and point A 512 on the second cam 312 is approximately 270 degrees. Therefore, when point A (depicted by 512) on the first cam 310 points upwards, point B (depicted by 514) on the second cam 312 also points upwards. Such illustrations are shown in... Figure 6 and Figure 7 Described in the text.

[0072] Figure 6 A cross-sectional view of a machine 106 depicting a second cam 312 according to one or more embodiments described herein is shown. Figure 7 Another cross-sectional view of a machine 106 depicting a third cam 314 and a second cam 312 according to one or more embodiments described herein is shown. Reference Figure 6 and Figure 7It can be observed that point B (described by 514) on the second cam 312 points upward, while point A (described by 512) on the third cam 314 points upward (see...). Figure 7 In addition, it can be found from Figure 7 It is observed that the angle (described by 702) of the arc formed by point B on the third cam 314 (described by 514) and point B on the second cam 312 (described by 514) is approximately 270 degrees. In other words, the second cam 312 is in a flipped orientation relative to the first cam 310 and the third cam 314.

[0073] Re-reference Figure 2 A first linear guide 226 may be mounted at each of the plurality of first corners 212a, 212b, 212c, and 212d of the main frame 202. The first linear guide 226 includes a vertical shaft 228 and a stop 230. A first end 231 of the vertical shaft 228 is fixedly coupled to a first corner of the plurality of first corners 212a, 212b, 212c, and 212d (e.g., 212a). Furthermore, a second end 232 of the vertical shaft 228 is coupled to the stop 230. In one example embodiment, the first linear guide 226 is coupled to each of the plurality of first corners 212a, 212b, 212c, and 212d along a third axis 234.

[0074] In one example implementation, the movable frame 204 is movably mounted on the main frame 202 through a first linear guide 226 at each of a plurality of first corners 212a, 212b, 212c, and 212d. In some examples, the first linear guide 226 may define a lateral path for the movable frame 204. The movable frame 204 can be configured to move along the third axis 234 when the first linear guide 226 extends from the main frame 202 along a third axis 234 and the first linear guide 226 defines a lateral path for the movable frame 204. In one example implementation, combined with Figure 8 The structure of the movable frame 204 is further described.

[0075] Figure 8 A perspective view of a movable frame 204 according to one or more embodiments is shown.

[0076] The movable frame 204 includes a first beam 802, a second beam 804, and a plurality of second support rods 806a, 806b, 806c, and 806d. In one example embodiment, the first beam 802 can be positioned parallel to the second beam 804 along a first axis 216. The first beam 802 has a first end 808, a second end 810, a first top surface 812, and a first bottom surface 814. In one example embodiment, the first top surface 812 of the first beam 802 defines a first through-hole 816 at the first end 808 of the first beam 802. Furthermore, the first top surface 812 defines a second through-hole 818 at the second end 810 of the first beam 802. Similar to the first beam 802, the second beam 804 has a third end 820, a fourth end 822, a second top surface 824, and a second bottom surface 826. Furthermore, similar to the first beam 802, the second top surface 824 defines a third through hole 828 at a third end 820 and a fourth through hole 830 at a fourth end 822. In one example embodiment, when the movable frame 204 is mounted on the main frame 202, the first through hole 816, the second through hole 818, the third through hole 828, and the fourth through hole 830 are configured to receive a first linear guide 226 (located at each of the plurality of first corners 212a, 212b, 212c, and 212d).

[0077] In one example embodiment, a plurality of second support rods 806a, 806b, 806c, and 806d are connected to the first beam 802 and the second beam 804 along a second axis 218. In some examples, the plurality of second support rods 806a, 806b, 806c, and 806d may be connected to the first beam 802 and the second beam 804 such that the distance between second support rods 806a and 806b (described by 832) may be equal to the distance between second support rods 806c and 806d (described by 834). Furthermore, the distance between second support rods 806c and 806b (described by 836) may be greater than the distance between second support rods 806b and 806a. In some examples, the second support rod 806a may be positioned proximal to a first end 808 of the first beam 802 and a third end 820 of the second beam 804. In addition, the second support rod 806d can be positioned near the second end 810 of the first beam 802 and the fourth end 822 of the second beam 804.

[0078] In one example embodiment, the movable frame 204 may further include a first leg 838, a second leg 840, a third leg 842, and a fourth leg 844. In some examples, the first leg 838 and the second leg 840 may be coupled to a second support rod 806a. Furthermore, the first leg 838 may be proximal to the first beam 802, and the second leg 840 may be proximal to the second beam 804. In some examples, the third leg 842 and the fourth leg 844 may be coupled to a second support rod 806d. The third leg 842 may be proximal to the first beam 802, and the fourth leg 844 may be proximal to the second beam 804. In one example embodiment, when the movable frame 204 is mounted on the main frame 202, the first leg 838, the second leg 840, the third leg 842, and the fourth leg 844 may be configured to extend from the movable frame 204 toward the main frame 202 along a third axis. When the movable frame 204 is mounted on the main frame 202, the third leg 842 and the fourth leg 844 are respectively adjacent to the first cam 310 on the first camshaft 304 and the first cam 310 on the second camshaft 306. Similarly, the first leg 838 and the second leg 840 are respectively adjacent to the third cam 314 on the first camshaft 304 and the third cam 314 on the second camshaft 306.

[0079] Re-reference Figure 2 The machine 106 may also include one or more second linear guides 236a and 236b that can be mounted along the third axis 234 on the first support rod 220c. In one example embodiment, the one or more second linear guides 236a and 236b may have a structure similar to the first linear guide 226.

[0080] In some examples, the divider wall frame 206 can be movably mounted on the main frame 202 via one or more second linear guides 236a and 236b. Similar to the movable frame 204, the divider wall frame 206 is movable along a third axis 234. Figure 9 The structure of the separator wall frame 206 is further described.

[0081] Figure 9A perspective view of a divider wall frame 206 according to one or more embodiments described herein is shown. In one example embodiment, the divider wall frame 206 includes a wall frame beam 902, a first vertical support beam 904, a second vertical support beam 906, a wall socket 908, a first channel 910, a second channel 912, a fifth leg 914, and a sixth leg 916. The wall frame beam 902 is positioned along a second axis 218 and has a first end 918 and a second end 920 along the second axis 218. Furthermore, the wall frame beam 902 includes a third end 922 and a fourth end 924 along a third axis 234. Additionally, the wall frame beam 902 has a first surface 926 and a second surface 928.

[0082] In some examples, the first channel 910 and the second channel 912 may be coupled to the wall frame beam 902 on the first surface 926 of the wall frame beam 902. In some examples, when the divider wall frame 206 is mounted on the main frame 202, the first channel 910 and the second channel 912 may be configured to receive one or more second linear guides 236a and 236b. Additionally, on the first surface 926 of the wall frame beam 902, a fifth leg 914 and a sixth leg 916 may be mounted at the first end 918 and the second end 920 of the wall frame beam 902, respectively. In one example embodiment, the fifth leg 914 and the sixth leg 916 may extend along the third axis 234 beyond the third end 922 of the wall frame beam 902. In some examples, when the divider wall frame 206 is mounted on one or more second linear guides 236a and 236b on the main frame 202, the fifth leg 914 and the sixth leg 916 may respectively abut the second cam 312 on the first camshaft 304 and the second camshaft 306.

[0083] In one example embodiment, a first vertical support beam 904 and a second vertical support beam 906 are fixedly connected to a fourth end 822 of a wall frame beam 902. Furthermore, the first vertical support beam 904 and the second vertical support beam 906 extend along a third axis 234. Additionally, a wall socket 908 is fixedly mounted on the first vertical support beam 904 and the second vertical support beam 906, such that the long edge 930 of the wall socket 908 extends along a second axis 218.

[0084] Re-reference Figure 2In one example embodiment, the movable frame 204 and the separator wall frame 206 can be used to mount the first package translation component and the second package translation component onto the machine 106, respectively. In one example embodiment, the first package translation component and the second package translation component may correspond to components that facilitate the movement of packages between various subsystems of the material handling system 100. Some examples of the first package translation component and the second package translation component may include, but are not limited to, pop-up belts and separator walls. Figure 10 The image further shows machine 106 assembled with pop-up belts and divider walls.

[0085] Figure 10 Another perspective view of machine 106 according to one or more embodiments is shown. (Reference) Figure 10 The machine 106 also includes a first pop-out belt 1002, a second pop-out belt 1004, and a separator wall 1006. The first pop-out belt 1002 and the second pop-out belt 1004 are connectable to a movable frame 204. In some examples, the first pop-out belt 1002 is connectable to second support rods 806c and 806d on the movable frame 204. Furthermore, the second pop-out belt 1004 is connectable to second support rods 806a and 806b. In some examples, the first pop-out belt 1002 and the second pop-out belt 1004 are further connectable to a second actuation unit 210.

[0086] Additionally, the second actuation unit 210 may be mounted on the movable frame 204. In some examples, the second actuation unit 210 may be configured to actuate the first pop-out belt 1002 and the second pop-out belt 1004. Figure 11 The structure of the first pop-out strip 1002 and the second pop-out strip 1004 is further described.

[0087] In one example implementation, the partition wall 1006 may be coupled to the partition wall frame 206. For example, the partition wall 1006 may be coupled to a wall socket 908 of the partition wall frame 206. Figure 12 The structure of the separator wall 1006 is further described.

[0088] Figure 11 A perspective view of an example pop-out belt 1100 according to one or more embodiments described herein is shown. The example pop-out belt 1100 includes a bracket 1102, a plurality of pulleys 1104, and a second belt 1106. The bracket 1102 may include a seventh leg 1108 and an eighth leg 1110. In some examples, the seventh leg 1108 and the eighth leg 1110 of the bracket 1102 enable the example pop-out belt 1100 to be coupled to a plurality of second support rods 1006a, 1006b, 1006c, and 1006d.

[0089] Furthermore, the bracket includes an extendable arm 1112. In some examples, a plurality of pulleys 1104 are coupled to the extendable arm 1112. Additionally, a second belt 1106 is wound around the plurality of pulleys 1104. Furthermore, an example pop-up belt 1100 may be coupled to a movable frame 204 such that the extendable arm 1112 of the example pop-up belt 1100 extends along a first conveyor axis 118. Therefore, the second belt 1106 also extends along the first conveyor axis 118.

[0090] Those skilled in the art will recognize that the first pop-up strip 1002 and the second pop-up strip 1004 may have a structure similar to that of the example pop-up strip 1100.

[0091] Figure 12 A perspective view of a separator wall 1006 according to one or more embodiments is shown. In one example embodiment, the separator wall 1006 may include a first end 1202, a second end 1204, and a set of passive rollers 1206. The first end 1202 may be configured to be coupled to a separator wall frame 206. The second end 1204 may be configured to receive the set of passive rollers 1206. In one example embodiment, the set of passive rollers 1206 is configured to facilitate movement of the package along a first conveying axis 118, such as in combination with... Figure 14 and Figures 18 to 20 Further details are provided.

[0092] Return to reference Figure 1 The control system 107 can be configured to control the operation of the material handling system 100. For example, the control system 107 can be configured to control the operation of the first conveyor 110, the second conveyor 134, and the machine 106. Figure 13 The structure of the control system 107 is described.

[0093] Figure 13 A block diagram of a control system 107 according to one or more embodiments described herein is shown. The control system 107 includes a processor 1302, a memory device 1304, an input / output (I / O) device interface unit 1306, and one or more package detection sensors 1308a, 1308b, and 1308c. In one example embodiment, the processor 1302 is communicatively coupled to the memory device 1304, the I / O device interface unit 1306, and the one or more package detection sensors 1308a, 1308b, and 1308c.

[0094] Processor 1302 can be implemented as a device including one or more microprocessors having one or more accompanying digital signal processors, one or more processors without accompanying digital signal processors, one or more coprocessors, one or more multi-core processors, one or more controllers, processing circuitry, one or more computers, various other processing elements (including integrated circuits, such as application-specific integrated circuits (ASICs) or field-programmable gate arrays (FPGAs)), or some combination thereof. Therefore, although in Figure 13 While illustrated as a single processor, in embodiments, processor 1302 may include multiple processors and signal processing modules. The multiple processors may be implemented on a single electronic device or distributed across multiple electronic devices that are collectively configured to serve as circuitry for the material handling system 100. The multiple processors may operatively communicate with each other and may be collectively configured to perform one or more functions of the circuitry for the material handling system 100 as described herein. In one example embodiment, processor 1302 may be configured to execute instructions stored in memory device 1304 or otherwise accessible to processor 1302. As described herein, when these instructions are executed by processor 1302, they may cause the circuitry for the material handling system 100 to perform one or more of these functions.

[0095] Regardless of whether processor 1302 is configured by a hardware method, a firmware / software method, or a combination thereof, the processor may include an entity capable of performing operations and making corresponding configurations according to embodiments of this disclosure. Thus, for example, when processor 1302 is implemented as an ASIC, FPGA, etc., processor 1302 may include hardware specifically configured to perform one or more of the operations described herein. Alternatively, for example, when processor 1302 is implemented as an executor of instructions (such as those that can be stored in memory device 1304), instructions may specifically configure processor 1302 to perform one or more algorithms and operations described herein.

[0096] Therefore, the processor 1302 used herein may refer to a programmable microprocessor, microcomputer, or one or more multiprocessor chips that can be configured by software instructions (application programs) to perform functions including those described in the various embodiments above. In some devices, multiple processors may be provided dedicated to wireless communication functions and one processor dedicated to running other applications. The software application may be stored in internal memory before being accessed and loaded into the processor. The processor may include sufficient internal memory to store the application software instructions. In many devices, the internal memory may be volatile or non-volatile memory such as flash memory or a combination of both. The memory may also be located within another computing resource (e.g., enabling computer-readable instructions to be downloaded via the Internet or another wired or wireless connection).

[0097] Memory device 1304 may include suitable logic, circuitry, and / or interfaces adapted to store a set of instructions executable by processor 1302 to perform predetermined operations. Some specific implementations of the memory include, but are not limited to, hard disks, random access memory, cache memory, read-only memory (ROM), erasable programmable read-only memory (EPROM) and electrically erasable programmable read-only memory (EEPROM), flash memory, magnetic tape cassettes, magnetic tape, disk storage devices or other magnetic storage devices, optical disc read-only memory (CD-ROM), digital versatile optical disc read-only memory (DVD-ROM), optical discs, circuitry configured to store information, or some combination thereof. In one embodiment, without departing from the scope of this disclosure, memory device 1304 may be integrated with processor 1302 on a single chip. In one example embodiment, memory device 1304 is configured to store a first set of pre-stored features and a second set of pre-stored features. In some examples, the first set of pre-stored features corresponds to unique features of a first type of package. Additionally, the second set of pre-stored features corresponds to unique features of a second type of package. In one example implementation, the first set of pre-stored features and the second set of pre-stored features may correspond to scale-invariant feature transform (SIFT) descriptors used to uniquely identify objects (e.g., first type of packaging or second type of packaging).

[0098] I / O device interface unit 1306 may include suitable logic, circuitry, and / or interfaces adapted to transmit and receive information from one or more components of material handling system 100. For example, I / O device interface unit 1306 may be configured to send messages to / receive messages from one or more package detection sensors 1308a, 1308b, and 1308c, first actuation unit 208, and second actuation unit 210. In one example embodiment, I / O device interface unit 1306 may be configured to communicate with one or more components according to one or more device communication protocols, such as, but not limited to, I2C communication protocol, Serial Peripheral Interface (SPI) communication protocol, serial communication protocol, Controller Area Network (CAN) communication protocol, and... Communication protocol. Some examples of the input / output interface unit 306 may include, but are not limited to, data acquisition (DAQ) cards, electric drive driver circuits, etc.

[0099] One or more package detection sensors 1308a, 1308b, and 1308c may include suitable logic / circuit enabling them to detect the presence of a package at one or more predetermined locations, such as on a first conveyor 110, platform 114, and / or a second conveyor 134. For example, package detection sensor 1308a may be positioned on platform 114 to determine the presence of a package on platform 114. Similarly, package detection sensor 1308b may be positioned proximal to the first conveyor 110 to determine whether a package is located on the first conveyor 110. As another example, package detection sensor 1308c may be located proximal to the second conveyor 134 to determine the presence of a package on the second conveyor 134. Some examples of the one or more package detection sensors 1308a, 1308b, and 1308c may include, but are not limited to, infrared (IR) sensors, image capture devices, proximity sensors, etc.

[0100] Combination Figure 14 The operation of the control system 107 is further described.

[0101] Figure 14 and Figure 24 An example embodiment of the invention is shown, consisting of, such as Figure 1 An example flowchart of the operations performed by the apparatus of the control system 107 is provided. It should be understood that each block in the flowchart, and combinations of blocks in the flowchart, can be implemented by various means, such as hardware, firmware, one or more processors, circuitry, and / or other devices associated with the execution of software including one or more computer program instructions. For example, one or more of the processes described above can be embodied by computer program instructions. In this regard, the computer program instructions embodying the processes described above can be stored in the memory of an apparatus employing an embodiment of the present invention and executed by a processor in the apparatus. It is understood that any such computer program instructions can be loaded onto a computer or other programmable apparatus (e.g., hardware) to produce a machine such that the resulting computer or other programmable apparatus provides an implementation of the functions specified in one or more flowchart blocks. These computer program instructions can also be stored in a non-transitory computer-readable storage memory that can instruct the computer or other programmable apparatus to operate in a particular manner, such that the instructions stored in the computer-readable storage memory produce an article of writing whose execution can implement the functions specified in one or more flowchart blocks. Computer program instructions can also be loaded onto a computer or other programmable device to cause a series of operations to be performed on the computer or other programmable device, thereby producing a computer-implemented method, such that the instructions, which execute on the computer or other programmable device, provide operations for implementing the functions specified in one or more flowchart blocks. Therefore, when Figure 14 and Figure 24 When the operation is performed, the computer or processing circuitry is transformed into a specific machine configured to execute the example embodiments of the present invention. Therefore, Figure 14 and Figure 24 The operation is limited to configuring one or more computers or processors to execute algorithms from various example implementations. In some cases, execution can be provided for general-purpose computers. Figure 14 and Figure 24 The algorithm is an instance of a processor to transform a general-purpose computer into a specific machine configured to execute the example implementation.

[0102] Therefore, the boxes in a flowchart support combinations of devices for performing a specified function and combinations of operations for performing the specified function. It will also be understood that one or more boxes in a flowchart, as well as combinations of boxes in a flowchart, can be implemented by a hardware-based dedicated computer system or a combination of dedicated hardware and computer instructions to perform the specified function.

[0103] Figure 14 A flowchart 1400 illustrates a method for operating a material handling system 100 according to one or more embodiments. (In conjunction with...) Figures 1 to 13 Flowchart 1400 is described.

[0104] At step 1402, the material handling system 100 includes means for determining whether a package is present on the platform 114, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc. In one example embodiment, the I / O device interface unit 1306 may use a package detection sensor 1308a positioned proximal to the platform 114 to determine whether a package is present on the platform 114. For example, when a package is present on the platform 114, the I / O device interface unit 1306 may receive a first package presence signal from the package detection sensor 1308a.

[0105] As discussed, the package detection sensor 1308a may correspond to an IR sensor. In such a specific embodiment, the IR sensor may be configured to generate a first package presence signal. In one example embodiment, the IR sensor may include an IR transmitter and an IR receiver. The IR transmitter may be configured to generate an IR signal. When no package is present on platform 114, the IR receiver may not receive the IR signal generated by the IR transmitter. However, when a package is present on platform 114, the IR signal from the IR transmitter may be reflected from the surface of the package back to the IR receiver. In response to receiving the reflected IR signal, the IR receiver may generate a first package presence signal.

[0106] In one example implementation, if the I / O device interface unit 1306 determines that the package exists on the platform 114, the processor 1302 may be configured to execute step 1404. However, if the I / O device interface unit 1306 determines that the package does not exist on the platform 114, the processor 1302 may be configured to repeat step 1402.

[0107] In response to receiving a signal indicating the presence of a first package, at step 1404, the material handling system 100 includes means for transmitting a first instruction to the pusher assembly 112 to push the package onto the first conveyor 110, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc. In one example embodiment, the pusher assembly 112 may be configured to actuate the pusher 132 to push the package onto the first conveyor 110 based on the receipt of the first instruction. As discussed, the pusher 132 may be actuated using a servo motor or a hydraulic system. Therefore, the pusher assembly 112 may be configured to actuate a servo motor or a hydraulic system to push the package onto the first conveyor 110.

[0108] In an alternative embodiment, where the first subsystem 102 does not include the pusher assembly 112, the I / O device interface unit 1106 may be configured to actuate the vertical belt 109 on the platform 114. Actuating the vertical belt 109 moves the package along the second conveyor axis 124 onto the first conveyor 110.

[0109] At step 1406, the material handling system 100 includes means for determining whether a package is on the first conveying device 110, such as the control system 107, processor 1302, I / O device interface unit 1306, etc. In one example embodiment, the I / O device interface unit 1306 may be configured to use a package detection sensor 1308b to determine whether a package is on the first conveying device 110. For example, the I / O device interface unit 1306 may receive a second package presence signal from the package detection sensor 1308b indicating the presence of a package. Therefore, the I / O device interface unit 1306 may determine that the package is present on the first conveying device 110. Subsequently, the processor 1302 may execute step 1408. However, if the I / O device interface unit 1306 determines that the package is not present on the first conveying device 110, the processor 1302 may be configured to repeat step 1402.

[0110] At step 1408, the material handling system 100 includes means for transmitting a second command to the first actuation unit 208, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc. In one example embodiment, in response to receiving the second command, the first actuation unit 208 may cause the motor 302 to rotate the first camshaft 304 and the second camshaft 306 in a first direction. As discussed, the first direction corresponds to clockwise rotation of the first camshaft 304 and the second camshaft 306. The rotation of the first camshaft 304 and the second camshaft 306 causes the first cam 310, the second cam 312, and the third cam 314 to rotate, which further causes the movable frame 204 and the separator wall frame 206 to translate along the third axis 234.

[0111] In some examples, because the movable frame 204 and the divider wall frame 206 are connected to different cams on the first camshaft 304 and the second camshaft 306, their translational directions are different. For example, as discussed above, the movable frame 204 is adjacent to the first cam 310 and the third cam 314 on the first camshaft 304 and the second camshaft 306, while the divider wall frame 206 is connected to the second cam 312. Furthermore, as discussed, the orientation of the second cam 312 is different from that of the first cam 310 and the third cam 314. For example, when point A (described by 512) of the first cam 310 and the third cam 314 is adjacent to the movable frame 204, point B (described by 514) is adjacent to the divider wall frame 206. Therefore, when the first camshaft 304 and the second camshaft 306 rotate in the first direction, the first cam 310 and the third cam 314 rotate from point A (depicted in 512) to point B (depicted in 512), while the second cam rotates from point B (depicted in 514) to point A (depicted in 512). Since the radius of the cam wheel 504 at point A (depicted in 512) is smaller than the radius of the cam wheel 504 at point B (depicted in 514), when the first camshaft 304 and the second camshaft 306 rotate in the first direction, the movable frame 204 translates upward along the third axis 234, while the separator wall frame 206 translates downward along the third axis 234.

[0112] Since the first pop-out belt 1002 and the second pop-out belt 1004 are connected to the movable frame 204, the first pop-out belt 1002 and the second pop-out belt 1004 can extend from the first conveyor 110 and the second conveyor 134, respectively, when the movable frame 204 translates in the upward direction. In some examples, the first pop-out belt 1002 and the second pop-out belt 1004 can extend upward through the gap 130 and one or more slots 142 in the first conveyor 110 and the second conveyor 134, respectively. Furthermore, since the separator wall 1006 is connected to the separator wall frame 206, the separator wall 1006 also translates in the downward direction when the separator wall frame 206 translates in the downward direction (when the first camshaft 304 and the second camshaft 306 rotate in the first direction). In some examples, the first pop-out belt 1002, the second pop-out belt 1004, and the separator wall 1006 may translate in their respective directions until the second belt 1106 on the first pop-out belt 1002 and the second pop-out belt 1004, along with the set of driven rollers 1206, are in the same plane. For example, the first camshaft 304 and the second camshaft 306 rotate by a predetermined angular displacement. In one example embodiment, the predetermined angular displacement may correspond to the amount of rotation (in a first direction) of the first camshaft 304 and the second camshaft 306 so that the second belt 1106 on the first pop-out belt 1002 and the second pop-out belt 1004, along with the set of driven rollers 1206, are in the same plane. In one example embodiment, after the first camshaft 304 and the second camshaft 306 have rotated by a predetermined angular displacement, the first pop-out belt 1002 and the second pop-out belt 1004 are in an extended position. Furthermore, the separator wall 1006 is in a first position. The translation of the first pop-out belt 1002, the second pop-out belt 1004, and the separator wall 1006 is as follows: Figures 15 to 17 Further details are shown below.

[0113] refer to Figure 15 It can be observed that the first pop-up belt 1002 and the second pop-up belt 1004 are respectively located at their retracted positions 1502 below the first conveyor 110 and the second conveyor 134. Furthermore, referring to... Figure 15 The separator wall 1006 is located at a second position 1504, which is above the positions of the first conveyor 110 and the second conveyor 134. Therefore, it can be observed that the separator wall 1006 prevents the package 1506 from moving between the first conveyor 110 and the second conveyor 134.

[0114] refer to Figure 16It can be observed that the first pop-out belt 1002 and the second pop-out belt 1004 are respectively located at a third position 1602 below the first conveyor 110 and the second conveyor 134. Furthermore, the third position 1602 is higher than the retracted position 1502. Additionally, the separator wall 1006 can be observed at a fourth position 1604, which is below the second position 1504.

[0115] refer to Figure 17 It can be observed that the first pop-out belt 1002 and the second pop-out belt 1004 are in the extended position 1702. Furthermore, the separator wall 1006 is in the first position 1704, which is below the fourth position 1604. Furthermore, it can be observed that the second belt 1106 of the first pop-out belt 1002 and the second pop-out belt 1004 is in the same plane as the plane of the set of passive rollers 1206 (described by 1706). Furthermore, it can be observed that the first pop-out belt 1002 and the second pop-out belt 1004 engage with the package 1506 positioned on the first conveyor 110. In some examples, the first pop-out belt 1002 may be configured to lift the package 1506 above the first conveyor 110 (e.g., from...). Figure 17 (Observed).

[0116] Re-reference Figure 14 At step 1410, the material handling system 100 includes means for transmitting a third instruction to the second actuation unit 210, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc. In one example embodiment, in response to receiving the third instruction, the second actuation unit 210 can move the first pop-up belt 1002 and the second belt 1106 on the second pop-up belt along the first conveyor axis 118. For example, the second actuation unit 210 can rotate a plurality of pulleys 1104, thereby moving the second belt 1106 along the first conveyor axis 118. Since the package engages with the first pop-up belt 1002, the movement of the second belt 1106 on the first pop-up belt 1002 causes the package to move along the first conveyor axis 118. Because the second belt 1106 on the first pop-up conveyor 1002 and the second pop-up conveyor 1004 is in the same plane as the set of passive rollers 1206 on the separator wall 1006, the package 1506 moves over the set of passive rollers 1206 onto the second pop-up conveyor 1004 (extending from the second conveyor 134). Since the second belt 1106 on the second pop-up conveyor 1004 also moves along the first conveyor axis 118, the second pop-up conveyor 1004 facilitates the movement of the package 1506 over the second conveyor 134.

[0117] The movement of the package from the first conveyor 110 to the second conveyor 134 via Figures 18 to 20 As shown. Reference Figure 18It can be observed that the package 1506 translates along the first conveyor axis 118. Furthermore, it can be observed that the package 1506 is positioned on the first pop-up conveyor 1002 and the set of driven rollers 1206. In some examples, the set of driven rollers 1206 rotates based on the frictional force between the set of driven rollers 1206 and the surface of the package 1506. (Reference) Figure 19 It can be observed that the package 1506 has moved to a position where it engages with both the first pop-up belt 1002 and the second pop-up belt 1004. Furthermore, it can be observed that the package 1506 moves past the set of passive rollers 1206. (Reference) Figure 20 It can be observed that package 1506 has been received by the second pop-up belt 1004 and positioned over the second conveyor 134.

[0118] Re-reference Figure 14 At step 1412, the material handling system 100 includes means for determining whether a package is positioned on the second conveyor 134, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc. In one example embodiment, the I / O device interface unit 1306 may use a package detection sensor 1308c (located proximal to the second conveyor 134) to determine whether a package is positioned on the second conveyor 134. In some examples, the I / O device interface unit 1306 may determine that a package is positioned on the second conveyor 134 based on receiving a third package presence signal from the package detection sensor 1308c. If the I / O device interface unit 1306 receives a third package presence signal from the package detection sensor 1308c, the processor 1302 may be configured to perform step 1414. However, if the I / O device interface unit 1306 does not receive a third package presence signal, the processor 1302 may be configured to repeat step 1412.

[0119] At step 1414, the material handling system 100 includes means, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc., for transmitting a fourth command to the first actuation unit 208 to rotate the first camshaft 304 and the second camshaft 306 in a second direction. In one example embodiment, the second direction (i.e., counterclockwise) is opposite to the first direction (i.e., clockwise). In response to receiving the fourth command, the first actuation unit 208 can rotate the first camshaft 304 and the second camshaft 306 in the second direction. Rotating the first camshaft 304 and the second camshaft 306 in the second direction causes the first cam 310 and the third cam 314 to rotate from point B (depicted by 514) to point A (depicted by 512). Furthermore, the third cam rotates from point A (depicted by 512) to point B (depicted by 514). Therefore, the separator wall 1006 moves upward to a second position, in which it extends from the first conveyor 110 and the second conveyor 134 to prevent the package from moving between the first conveyor 110 and the second conveyor 134. Simultaneously, the first pop-out conveyor belt 1002 and the second pop-out conveyor belt 1004 retract to their retracted positions below the first conveyor 110 and the second conveyor 134, respectively.

[0120] Figures 21 to 23 The movement of the first pop-out belt 1002, the second pop-out belt 1004, and the separator wall 1006 is shown when the first camshaft 304 and the second camshaft 306 rotate in the second direction.

[0121] refer to Figure 21 It can be observed that the first pop-up belt 1002 and the second pop-up belt 1004 are respectively located at extension positions 1702 above the first conveyor 110 and the second conveyor 134. Furthermore, referring to... Figure 21 The separator wall 1006 is located at the first position 1704.

[0122] refer to Figure 22 It can be observed that the first pop-out belt 1002 and the second pop-out belt 1004 are respectively located at a third position 1602 below the first conveyor 110 and the second conveyor 134. Furthermore, the third position 1602 is lower than the extended position 1702. Additionally, the separator wall 1006 can be observed at a fourth position 1604, which is above the first position 1704.

[0123] refer to Figure 23It can be observed that the first pop-out belt 1002 and the second pop-out belt 1004 are in the retracted position 1502. Furthermore, the separator wall 1006 is in the first position 1704, which is above the fourth position 1604. Therefore, the separator wall 1006 prevents the package from moving between the first conveyor 110 and the second conveyor 134.

[0124] In some examples, when the first actuation unit 208 is de-energized, the weight of the movable frame 204 can cause it to move downwards. When the partition wall frame 206 and the movable frame 204 are coupled to the same camshaft (i.e., the second camshaft 306 and the first camshaft 304), such downward movement of the movable frame 204 can cause the partition wall frame 206 to move upwards. To avoid such movement due to the weight difference between the movable frame 204 and the partition wall frame 206, in some examples, the partition wall frame 206 can be mounted on the main frame 202 by a counterweight member 602 (see [link to relevant documentation]). Figure 6 Such a counterweight 602 can be configured to balance the weight difference between the divider wall frame 206 and the movable frame 204. Some examples of the counterweight 602 may include, but are not limited to, springs.

[0125] Figure 24 Another flowchart 2400 is shown according to one or more embodiments described herein, illustrating a method for operating the physical handling system 100.

[0126] At step 2402, the material handling system 100 includes means for determining whether a package to be transferred from the first conveyor 110 to the second conveyor 134 is positioned on the first conveyor 110, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc.

[0127] At step 2404, the material handling system 100 includes means for rotating the first camshaft 304 in a first direction by actuating the motor 302 via a controller, thereby extending the first pop-up conveyor 1002 above the first conveyor 110, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc. Furthermore, the rotation of the motor 302 moves a separator wall 1006 positioned between the first and second conveyors to a first position, such that the first pop-up conveyor 1002 and the separator wall 1006 facilitate the movement of packages from the first conveyor 110 to the second conveyor 134.

[0128] At step 2406, the material handling system 100 includes means for the controller to actuate the motor 302 to rotate the first camshaft 304 in a second direction, thereby moving the first pop-up belt 1002 to a retracted position below the first conveyor 110 and moving the separator wall 1006 to a second position such that the separator wall 1006 prevents the package from moving between the first conveyor 110 and the second conveyor 134, such as a control system 107, a processor 1302, an I / O device interface unit 1306, etc.

Claims

1. A material handling device, comprising: A first pop-out conveyor belt is configured to facilitate the movement of the package between a first conveyor and a second conveyor. A separator wall, configured to control the movement of the package between the first conveying device and the second conveying device. In the first operating mode, the first pop-up conveyor extends from the first conveyor to facilitate the movement of the package from the first conveyor to the second conveyor, and the divider wall moves to a first position, wherein in the first position, the divider wall allows the package to move from the first conveyor to the second conveyor. In the second operating mode, the first pop-up belt moves to a retracted position below the first conveyor and the separator wall moves to a second position to prevent the package from moving between the first conveyor and the second conveyor. Including the motor's actuation unit; and A camshaft coupled to the motor, wherein the camshaft includes a first cam and a second cam, wherein the first cam is coupled to the first pop-up belt and the second cam is coupled to the separator wall, wherein the second cam is out of phase with the first cam such that the separator wall moves in a direction opposite to the direction of the first pop-up belt, wherein when the camshaft rotates in a first direction in the first operating mode, the first cam causes the first pop-up belt to extend from the first conveyor, and the second cam causes the separator wall to move to a first position such that the separator wall retracts below the first and second conveyors to allow the package to move from the first conveyor to the second conveyor; wherein when the camshaft rotates in a second direction in the second operating mode, the first cam causes the first pop-up belt to move to a retracted position below the first conveyor, and the second cam causes the separator wall to move to a second position such that the separator wall extends above the first and second conveyors to prevent the package from moving between the first and second conveyors.

2. The material handling device according to claim 1, wherein the camshaft further includes a third cam, wherein the second orientation of the second cam is the same as the third orientation of the third cam.

3. The material handling device according to claim 2, further comprising a second pop-out belt adjacent to the third cam, wherein the second pop-out belt is configured to facilitate movement of the package between the first conveyor and the second conveyor.

4. The material handling device according to claim 3, wherein the second cam facilitates movement of the second pop-up belt between an extended position and a retracted position, wherein in the retracted position the second pop-up belt is positioned below the second conveyor, and wherein in the extended position the second pop-up belt extends above the second conveyor.

5. The material handling device according to claim 1, wherein the first cam facilitates movement of the first pop-up belt between an extended position and a retracted position, and wherein in the extended position, the first pop-up belt extends above the first conveyor.

6. The material handling device according to claim 1, wherein the separator wall further includes a first end and a second end, wherein the first end of the separator wall is adjacent to the second cam, and wherein a roller is mounted on the second end.

7. The material handling device according to claim 3, wherein the second pop-out belt and the first pop-out belt are positioned in the same plane.

8. The material handling device according to claim 6, wherein in the first position, the roller and the first pop-out belt are in the same plane.

9. The material handling apparatus of claim 6, wherein the roller is a passive roller configured to rotate according to the movement of the package from the first conveying device to the second conveying device, wherein the roller rotates based on the frictional force between the package and the roller.

10. A material handling system, comprising: First transmission device; The first subsystem is located adjacent to the first transmission device; A separator wall, positioned between the first conveying device and the first subsystem, wherein the separator wall is configured to control the movement of the package between the first conveying device and the first subsystem; A first pop-out belt is positioned below the first conveyor, wherein the first pop-out belt is configured to facilitate the movement of the package from the first conveyor to the first subsystem. In the first operating mode, the first pop-up conveyor extends above the first conveyor to facilitate the movement of the package from the first conveyor to the first subsystem, and the divider wall moves to a first position, wherein in the first position, the divider wall allows the package to move from the first conveyor to the first subsystem. In the second operating mode, the first pop-up belt moves to a retracted position below the first conveyor, and the separator wall moves to a second position to prevent the package from moving between the first conveyor and the first subsystem. Including the motor's actuation unit; and A camshaft coupled to the motor, wherein the camshaft includes a first cam and a second cam, wherein the first cam is coupled to the first pop-up belt and the second cam is coupled to the separator wall, wherein the second cam is out of phase with the first cam such that the separator wall moves in a direction opposite to the direction of the first pop-up belt, wherein when the camshaft rotates in a first direction in the first operating mode, the first cam causes the first pop-up belt to extend from the first conveyor, and the second cam causes the separator wall to move to a first position such that the separator wall retracts below the first and second conveyors to allow the package to move from the first conveyor to the second conveyor; wherein when the camshaft rotates in a second direction in the second operating mode, the first cam causes the first pop-up belt to move to a retracted position below the first conveyor, and the second cam causes the separator wall to move to a second position such that the separator wall extends above the first and second conveyors to prevent the package from moving between the first and second conveyors.

11. The material handling system of claim 10, wherein the camshaft further comprises a third cam, wherein the second orientation of the second cam is the same as the third orientation of the third cam.

12. The material handling system of claim 11, wherein the first subsystem corresponds to the second conveyor positioned adjacent to the first conveyor, wherein the material handling system further includes a second pop-out belt adjacent to the third cam, wherein the second pop-out belt is configured to facilitate movement of the package between the first conveyor and the first subsystem.

13. The material handling system of claim 12, wherein the third cam facilitates movement of the second pop-up belt between an extended position and a retracted position, wherein in the retracted position the second pop-up belt is positioned below the first subsystem, and wherein in the extended position the second pop-up belt extends above the first subsystem.

14. The material handling system of claim 10, wherein the separator wall further comprises a first end and a second end, wherein the first end of the separator wall is adjacent to the second cam, and wherein a roller is mounted on the second end of the separator wall.

15. The material handling system of claim 14, wherein in the first position, the roller and the first pop-up belt are in the same plane.

16. A method for operating a material handling system, the method comprising: The controller determines whether the package to be transferred from the first conveying device to the second conveying device is located on the first conveying device; In response to determining that the package is located on the first conveyor, the controller actuates the first pop-out belt to extend above the first conveyor and moves the separator wall between the first and second conveyors to a first position, such that the first conveyor and the separator wall facilitate the movement of the package from the first conveyor to the second conveyor. and In response to determining that the package has moved from the first conveyor to the second conveyor, the controller actuates the first pop-up conveyor to a retracted position below the first conveyor and moves the separator wall to a second position, such that the separator wall prevents the package from moving between the first and second conveyors. The material handling system includes a camshaft coupled to a motor, wherein the camshaft includes a first cam and a second cam, wherein the first cam is coupled to the first pop-up conveyor and the second cam is coupled to the separator wall, wherein the second cam is out of phase with the first cam, causing the separator wall to move in a direction opposite to that of the first pop-up conveyor. The controller actuates the motor to move the camshaft... Rotation in a first direction causes the first pop-up belt to extend above the first conveyor and causes the separator wall to move to a first position, wherein in the first position, the separator wall retracts below the first and second conveyors to allow the package to move from the first conveyor to the second conveyor, wherein the controller actuates the motor to rotate the camshaft in a second direction, causing the first pop-up belt to move to a retracted position below the first conveyor and causing the separator wall to move to a second position, wherein in the second position, the separator wall extends above the first and second conveyors to prevent the package from moving between the first and second conveyors.

17. The method of claim 16, further comprising: The controller actuates the first pop-up conveyor to move in a first direction so that the package moves from the first conveyor to the second conveyor.

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