System and method for automated picking and handling of parts

Abstract

An automated part handling system (100) includes a conveyor (22), a robotic arm (120) configured to pick parts from a part receptacle and place the picked parts on the conveyor (22), a vision device (160, 164) disposed above or adjacent to the conveyor and configured to determine a quantity of parts picked by the robotic arm from the part receptacle and placed on the conveyor, a memory, and a processor communicatively coupled to the conveyor, the robotic arm, and the vision device. The memory includes program instructions executable by the processor to implement a picking process configured to receive information from the vision device (160, 164) regarding a quantity of parts picked by the robotic arm (120) and placed on the conveyor, selectively control the robotic arm to retrieve a plurality of picked parts from the conveyor based on the received information regarding the quantity of picked parts, and selectively control the robotic arm to place one or more retrieved parts back into the part receptacle when the quantity of parts picked by the robotic arm differs from a predetermined quantity of parts specified in the program instructions.

Description

TECHNICAL FIELD

[0001] The present invention relates to a system and method for automatically picking and processing parts, and more particularly, to a system and method for automatically picking, inspecting, and packaging parts for distribution to customers. BACKGROUND

[0002] Manufacturers of parts, such as machine parts for heavy equipment, ground engaging tools for use on earth moving machinery, and other products manufactured using various subtractive and / or other manufacturing methods, can use electronic markets, such as those accessible via the Internet, that include catalogs of items or products that can be purchased. These items can be provided as repair or replacement parts for existing equipment, on a one-time basis, or repeatedly, such as by subscription or under a demand- as-needed agreement. These parts can be provided directly to customers that are end users of heavy equipment, or to intermediaries, such as distributors of heavy equipment, who then provide the needed parts to end users at other remote locations. In one example, a customer, such as an end user at a remote mine site or other work site, or a distributor of heavy equipment, can utilize a web browser to access a website operated by the manufacturer or by a distributor of equipment operated by the manufacturer, select items from a catalog to be purchased, and participate in a checkout process to ultimately order the items. The manufacturer can operate a fulfillment network including various facilities to process such orders. For example, the manufacturer can operate a facility to prepare shipments of the purchased items. A shipment carrier can obtain such shipments from the manufacturer and deliver the shipments to respective distributors or directly to the purchasing customers.

[0003] Facilities operated by the manufacturer can include one or more automated part picking and processing stations configured to implement various fulfillment processes for automatically fulfilling orders submitted by customers. These processes can operate on items to perform various tasks, such as preparing items for shipment. At one or more points in these processes, items can be physically picked from one location (e.g., from a part receptacle such as a tote) and placed in another location (e.g., on a conveyor or into a sort bin or shipping box). There is a need for an automated part picking and processing system and method for implementation in a material handling facility operated by a manufacturer, where the system and method is capable of reliably and adaptively picking appropriate quantities of various types of items, such as items having various shapes, sizes, and weights, inspecting quantities and other aspects of the picked parts, packaging and labeling the picked parts, and placing the picked parts into containers.

[0004] One example of an automated material handling facility is shown in U.S. Patent No. 6,785,905. U.S. Patent No. 9,600,798 generally shows a facility that uses a series of automated devices, such as automated guided vehicles, mobile drive units, robotic arms, automated sorters, etc., to facilitate item receiving, loading, sorting, transportation, and other aspects of material handling. However, the disclosed system and method do not include any means for determining that the appropriate number of parts have been sorted at any particular sortation station, and also lack the ability to bag the parts of multiple orders that are ultimately to go to different end locations in a single package or multiple packages for initial distribution to a distributor and then subsequent distribution to one or more different end locations.

[0005] The system and method for automated sorting, inspection, and packaging of parts presented in the present invention solves one or more of the above problems and / or other problems with the prior art. SUMMARY

[0006] In one aspect, the present invention relates to an automated part sorting and handling system. The system can include a conveyor belt; a first robotic arm configured for sorting parts from a part receptacle and placing the sorted parts on the conveyor belt; a first vision device disposed above or adjacent to the conveyor belt and configured for determining a number of parts sorted by the first robotic arm from the part receptacle and placed on the conveyor belt; and an automated packaging and labeling machine configured for receiving the parts sorted by the first robotic arm and conveyed by the conveyor belt to the automated packaging and labeling machine, packaging the sorted parts, printing a label with information associated with the packaged parts, and placing the label on the packaging for the parts. The system can also include a second robotic arm configured for sorting the part packaging from the conveyor belt and placing the packaging in a container. The system can also include a memory, and one or more processors communicatively coupled to the conveyor belt, the first and second robotic arms, the first vision device, the automated packaging and labeling machine, and the memory, wherein the memory includes program instructions executable by the one or more processors to implement a sorting process configured to: (a) receive information from the first vision device regarding a number of parts sorted by the first robotic arm and placed on the conveyor belt; (b) based on the received information regarding the number of sorted parts, selectively control the first robotic arm to retrieve the number of sorted parts from the conveyor belt; and (c) when the number of parts sorted by the first robotic arm is different from a predetermined number of parts specified in the program instructions, selectively control the first robotic arm to place one or more retrieved parts back into the part receptacle.

[0007] In another aspect, the present disclosure relates to an automated part handling system. The automated part handling system can include a conveyor, a first robotic arm configured to pick parts from a part receptacle and place the picked parts on the conveyor, and a first vision device disposed above or adjacent to the conveyor and configured to determine a quantity of parts picked by the first robotic arm from the part receptacle and placed on the conveyor. The system can also include a memory and one or more processors communicatively coupled to the conveyor, the first robotic arm, and the first vision device, wherein the memory includes program instructions executable by the one or more processors to implement a picking process configured to: (a) receive information from the first vision device regarding the quantity of parts picked by the first robotic arm and placed on the conveyor; (b) based on the received information regarding the quantity of picked parts, selectively control the first robotic arm to retrieve the quantity of picked parts from the conveyor; and (c) selectively control the first robotic arm to place one or more retrieved parts back into the part receptacle when the quantity of parts picked by the first robotic arm differs from a predetermined quantity of parts specified in the program instructions.

[0008] In yet another aspect, the present disclosure is directed to a method of picking and inspecting parts using an automated parts handling system. The automated parts handling system can include a conveyor belt; a first robotic arm configured for picking parts from part receptacles and placing the picked parts on the conveyor belt; a first vision device arranged above or near the conveyor belt and configured for determining a number of parts picked by the first robotic arm from the part receptacles and placed on the conveyor belt; an automated packaging and labeling machine configured for receiving the parts picked by the first robotic arm and conveyed by the conveyor belt to the automated packaging and labeling machine, packaging the picked parts, printing a label with information associated with the packaged parts, and placing the label on the packaging for the parts; a second robotic arm configured for picking a package of parts from the conveyor belt and placing the package in a container; a memory; and one or more processors communicatively coupled to the conveyor belt, the first and second robotic arms, the first vision device, the automated packaging and labeling machine, and the memory. The method can include implementing a picking process using the one or more processors executing program instructions stored in the memory, including: (a) receiving information from the first vision device regarding a number of parts picked by the first robotic arm and placed on the conveyor belt; (b) based on the received information regarding the number of picked parts, selectively controlling the first robotic arm to retrieve a plurality of picked parts from the conveyor belt; and (c) when the number of parts picked by the first robotic arm differs from a predetermined number of parts specified in the program instructions, selectively controlling the first robotic arm to place one or more of the retrieved parts back into the part receptacles. BRIEF DESCRIPTION OF DRAWINGS

[0009] Figure 1 FIG. illustrates an exemplary automated parts picking and handling station; and

[0010] Figure 2 is a flowchart illustrating an exemplary method performed by the automated parts picking and handling station of Figure 1 DETAILED DESCRIPTION

[0011] Figure 1 FIG. illustrates an exemplary automated parts picking and handling station 100 configured with a first robotic arm 120 for picking parts from a plurality of part receptacles, e.g., with an automated storage and retrieval system (e.g., AutoStore® M ​standardized tote or container for use in conjunction with the automated storage and retrieval system, one or more vision devices for checking that the number of picked parts is correct, one or more conveyors for conveying the picked parts to the automated packaging and labeling machine 180, and further conveyors for further conveying the packaged parts to another inspection station having one or more vision devices. The automated part picking and handling station 100 can also include a second robotic arm 140 configured for retrieving the packaged parts from the conveyor 36 after the parts are packaged by the automated packaging and labeling machine 180, printing a label for each part package, and affixing the label to the package. The second robotic arm 140 can be configured for retrieving these packaged parts from the conveyor 36 and placing the packaged parts into a shipping container 170. In various embodiments according to the present application, a fulfillment network can include multiple automated part picking and handling stations (each station can be configured in a similar manner to the automated part picking and handling station 100 Figure 1

[0012] As Figure 1 ​As shown, an automated part picking and handling system according to exemplary embodiments of the present application can include one or more automated part picking and handling stations 100, each of which can include one or more conveyors 22, 24, 32, 34, 36 configured to move parts between different locations where different automated part handling functions are performed. A first robotic arm 120 having a proximal base 121 and a distal portion gripping attachment 122 can be configured to pick parts from a part receptacle (not shown) and place the picked parts at a first end 42 of one of the conveyors 22, the first robotic arm 120 being pivotable or rotatable relative to the proximal base. First vision devices 160, 164 can be disposed above or adjacent to the conveyor 22 and configured to determine the number of parts picked by the first robotic arm 120 from the part receptacle and placed on the conveyor 22. The first vision devices 160, 164 can include, for example, a vision hood 160 positioned above the conveyor 22 at a location where the first robotic arm 120 places picked parts on the conveyor 22, and one or more cameras 164 or other optical sensing devices positioned on or adjacent to the conveyor 22 at one or more locations downstream of the first end 42 of the conveyor 22 at which the first robotic arm 120 is configured to be able to retrieve one or more picked parts on the conveyor 22. Alternative implementations can include only a single vision device, such as a vision hood 160, disposed above or adjacent to the first end 42 of the conveyor 22 at a location where the first robotic arm 120 places picked parts picked from the part receptacle. Further implementations can include multiple cameras 164 or other vision devices or optical or proximity sensors disposed at different locations along the conveyor 22 and configured to identify the number of parts moving along the conveyor 22 and other characteristics of the parts. In some embodiments, the cameras and other vision devices can operate in conjunction with machine learning software to perform various checks on parts moving along the conveyor 22, such as determining whether picked parts are the correct parts and whether the picked parts have any defects.

[0013] The first vision devices 160, 164 may include one or more vision hoods, cameras, and / or other optical sensors positioned above or near the conveyor belt 22 such that parts moving on the conveyor belt 22 pass over the one or more vision devices at a rate of speed and distance within the detection capabilities of the different vision devices. For example, a vision device configured to simply count the number of parts placed on the conveyor belt 22 by the first robotic arm 120 may be arranged along a section of the conveyor belt 22 moving at a first speed rate, while a further vision device configured to perform a more extensive inspection, such as determining whether a picked part is the correct part or whether the part has any visually identifiable defects, may be arranged along a section of the conveyor belt 22 moving at a second speed slower than the first speed.

[0014] like Figure 1 As shown, one or more parts picked up from the parts receiving seat by the first robotic arm 120 and placed at one end 42 of the conveyor belt 22 can move along the conveyor belt 22, past the first vision devices 160, 164, and in some cases can be retrieved by the first robotic arm 120 from the conveyor belt 22 at or downstream of the vision devices (e.g., one or more cameras 164) to return to the parts receiving seat. Situations that may lead to the retrieval of parts from the conveyor belt 22 (discussed in more detail below) may include the vision devices identifying that the number of parts picked by the first robotic arm 120 is incorrect, or that one or more parts are not the correct parts, or have unacceptable defects. After passing all desired checks, the parts on the conveyor belt 22 can be moved to a position in the automatic packaging and labeling machine 180 by the pusher feeder 26 configured to move the parts from the conveyor belt 22 to the position. The automatic packaging and labeling machine 180 can be configured to receive parts pushed from conveyor belt 22 by pusher feeder 26, package the parts, print labels with information associated with the packaged parts, and place the labels on the packaging for the parts.

[0015] After the parts are packaged and the packages are labeled by the automated packaging and labeling machine 180, the packages of parts can then be moved by one or more additional conveyors 32, 34, 36 along any desired path or according to other handling parameters to another location within range of a second robotic arm 140. The second robotic arm 140 has a proximal base 141 about which the second robotic arm 140 can pivot or rotate and is equipped with a part gripping attachment 142 that can be configured for retrieving each part package from the conveyor 36 and placing each part package into a container 170 located on another conveyor 24. A second vision device 166 can be disposed in a location above the conveyor 36 in which the second robotic arm 140 is configured to pick the part packages from the conveyor, the second vision device being configured to generate signals indicative of the location and orientation of the part packages on the conveyor. The second vision device 166 can be configured to provide information used by the second robotic arm 140 and part gripping attachment 142 so that the exact location of each part package as well as the size, orientation, and configuration of each package is known for directing the operation of the second robotic arm 140. In addition, the automated part picking and handling station 100 can include a third vision device 162 disposed above or near the container 170 on the other conveyor 24. The third vision device 162 can be configured to provide information about where to place each part package in the container 170 for the most efficient arrangement of the part packages in the container 170 and to avoid over packaging of the container.

[0016] The automated part picking and handling station 100 can include a control unit located near the station or remotely and in wired or wireless communication with various sensors and control devices such as solenoids, motors, pumps, and actuators. The control unit associated with the automated part picking and handling station 100 can include one or more processors and one or more memories communicatively coupled to the conveyors 22, 24, 32, 34, 36, the first robotic arm 120 and the second robotic arm 140, the vision devices 160, 162, 164, 166, the automated packaging and labeling machine 180. The memories associated with the control unit can include program instructions executable by the one or more processors to implement a picking process. In various exemplary implementations of the present application, the picking process can be configured to: (a) receive information from the first vision devices 160, 164 regarding the number of parts picked by the first robotic arm 120 and placed on the conveyor 22; (b) based on the received information regarding the number of parts picked, selectively control the first robotic arm 120 to retrieve the number of picked parts from the conveyor 22; and (c) selectively control the first robotic arm 120 to place the one or more retrieved parts back into the part receptacle when the number of parts picked by the first robotic arm 120 differs from a predetermined number of parts specified in the program instructions. Those of ordinary skill in the art will recognize that the one or more memories can include instructions that, when executed by the one or more processors, cause the first robotic arm 120 to retrieve the parts to be returned to the part receptacle only after a determination has been made as to whether the number of parts picked and placed on the conveyor is consistent with the predetermined number of parts included in the instructions.

[0017] The automated part picking and handling station 100 can also include a second vision device 166 disposed above the conveyor 36 in a position configured for the second robotic arm 140 to pick part packages from the conveyor 36. The second vision device 166 can be configured to generate signals indicative of the precise location, configuration, and orientation of the part packages on the conveyor 36, thereby assisting the second robotic arm 140 and the gripper attachment 142 in quickly positioning and picking each part package from the conveyor 36 for transfer into the container 170. Additionally, the automated part picking and handling station 100 can include a third vision device 162 disposed above the container 170 on the other conveyor 24. The third vision device 162 can be configured to provide information regarding where to place each part package in the container 170 for the most efficient arrangement of the part packages in the container 170 and to avoid overpacking of the container.

[0018] The picking process implemented by the one or more processors executing program instructions stored in memory can include controlling the first robotic arm 120 to rotate or pivot about the proximal base 121 and controlling the gripper attachment 122 at the distal end of the first robotic arm 120 to retrieve all of the picked parts placed on the conveyor belt 22 by the first robotic arm 120 and to place all of the retrieved parts back into the part receptacle when the number of picked parts exceeds a predetermined number of parts specified in the program instructions. In other alternative implementations, the instructions stored in memory can cause the one or more processors to control the first robotic arm 120 to retrieve all of the picked parts placed on the conveyor belt 22 by the first robotic arm 120 and to place all of the retrieved parts back into the part receptacle when the number of picked parts is greater than one. In further alternative implementations, the instructions stored in memory can cause the one or more processors to control the first robotic arm 120 to retrieve a plurality of picked parts exceeding a predetermined number of parts placed on the conveyor belt 22 by the first robotic arm 120 and to place only the retrieved parts exceeding the predetermined number of parts back into the part receptacle.

[0019] The automated part picking and handling system 100 can include first vision devices 160, 164, where the first vision devices 160, 164 can include a vision hood 160 positioned over or adjacent to the first end 42 of the conveyor belt 22 at a location where the first robotic arm 120 and gripper attachment 122 place picked parts on the conveyor belt 22 and one or more cameras 164 positioned over or adjacent to the conveyor belt 22 at a location downstream from where the first robotic arm 120 places picked parts on the conveyor belt. The automated part picking and handling system 100 can also include a push feeder 26 disposed over the conveyor belt 22 and adjacent to the automated packaging and labeling machine 180, the push feeder 26 configured to be operated by the one or more processors to accumulate a predetermined number of parts moving along the conveyor belt before moving the predetermined number of parts into the automated packaging and labeling machine 180 for packaging and labeling. The one or more processors executing program instructions stored in memory can be configured to operate the push feeder 26 such that different types of parts conveyed along the conveyor belt 22 are pushed from the conveyor belt 22 into different entry points or receptacles of the automated packaging and labeling machine 180 or are grouped according to other part characteristics before being pushed into the automated packaging and labeling machine 180.

[0020] The automated parts picking and handling system 100 can also include one or more memories further comprising program instructions executable by the one or more processors to implement a picking process further configured to: (d) control the first robotic arm 120 to selectively pick parts from the one or more part containers for packaging and labeling by the automated packaging and labeling machine 180, wherein the parts to be packaged in a single package are intended for a final destination that is different from the initial destination of the container. This feature of the system enables the selection and packaging of parts that will ultimately be sent from a first destination, such as a machine distributor, to a final destination, such as a remote mine site or other location where a customer has ordered parts. An exemplary implementation of the picking and handling method that can be performed by the automated parts picking and handling system 100 will be described in the following sections.

[0021] Industrial Utility

[0022] The method of picking and inspecting parts according to different implementations of the present application can employ the automated parts picking and handling system 100. The automated parts picking and handling system 100 can include one or more conveyors 22, 24, 32, 34, 36, a first robotic arm 120 configured to pick parts from a parts receptacle and place the picked parts on a conveyor of the one or more conveyors, and a first vision device 160, 164 arranged above the conveyor 22 and configured to determine a quantity of parts picked by the first robotic arm 120 from the parts receptacle and placed on the conveyor. An automated packaging and labeling machine 180 can be configured to receive the parts picked by the first robotic arm 120 and conveyed by the conveyor 22 to the automated packaging and labeling machine 180, package the picked parts, print a label with information associated with the picked and packaged parts, and place the printed label on the package of parts.

[0023] In Figure 2 In one exemplary implementation of the present application shown in the flowchart of FIG. 2, the method 200 can include the first robotic arm 120 picking one or more parts from a parts receptacle, such as a tote, in step 210. Then, in step 212, the first robotic arm 120 can place the picked parts on the conveyor 22. Then, in step 214, the picked parts can pass under or near one or more vision devices, cameras, or other optical sensors. Then, in step 216, the one or more processors of the control unit executing the picking process instructions retrieved from the one or more memories can receive signals from the one or more vision devices and determine whether the first robotic arm 120 has picked an incorrect quantity of parts.

[0024] As Figure 2If it is determined that the first robotic arm 120 picked the incorrect number of parts from the part receptacle (step 216: Yes), then at step 218 the first robotic arm 120 can receive instructions to retrieve the partial or full number of parts placed on the conveyor belt and to place them back into the part container so that the process of picking and inspecting the parts begins again at step 210 each time the number of parts picked does not coincide with the predetermined number of parts. If, however, it is determined that the first robotic arm 120 picked the correct number of parts from the part receptacle (step 216: No), then at step 220 the picked parts are conveyed along the conveyor belt 22 to the automated bagging and labeling machine (automatic bagger) 180.

[0025] At step 222, the automatic bagger 180 can print warehouse task information or other information associated with the parts being packaged into the part storage bag onto the label. Then, at step 224, the automatic bagger 180 can seal the parts in the storage bag, label the storage bag with the printed label, and place the bag on another conveyor belt 32, 34, 36 to be indexed to a packaging location. As Figure 1 the exemplary automated part picking and processing station 100 of Figure 2 As shown in the schematic representation of the exemplary method of

[0026] In another alternative implementation of the method of picking and inspecting the parts, the method can include controlling the first robotic arm 120 to retrieve all of the picked parts placed on the conveyor belt 22 by the first robotic arm 120 and to place all of the retrieved parts back into the part receptacle when the number of picked parts is greater than one. In this implementation, the program instructions for operating the first robotic arm 120 can specify that only a single part be picked from the part receptacle each time, such that any indication that more than one part was picked and placed on the conveyor belt 22 in the part processing is identified as an error, resulting in an immediate instruction to place all of the picked parts back into the part receptacle. Each time an error occurs in the part processing according to this implementation, the first robotic arm 120 can return all of the picked parts on the conveyor belt 22 to the original part receptacle or another intermediate part receptacle and repeat the process in an attempt to pick only a single part.

[0027] In yet another alternative implementation of the method of picking and inspecting parts according to the present application, one or more processors executing program instructions stored in one or more memories can control the first robotic arm 120 to retrieve a number of picked parts that exceeds a predetermined number of parts placed on the conveyor belt 22 by the first robotic arm 120 and to place the retrieved parts back into the part receptacle. In this implementation, the program instructions can also specify a number of parts expected during a predetermined time period and / or along a predetermined section of the conveyor belt 22 during a continuous process of picking parts from one or more part receptacles using the first robotic arm 120, moving the picked parts along the conveyor belt 22, and pushing the picked parts from the conveyor belt 22 into the automated packaging and labeling machine 180. The one or more processors executing the program instructions according to this implementation can also be configured to adjust the number of expected parts during a particular time period or along a predetermined section of the conveyor belt 22 according to customer requirements.

[0028] The control system associated with the automated part picking and handling system 100 can include, without limitation, one or more computer systems, one or more data storage devices, one or more wired and / or wireless networks, control system software (programs, modules, drivers, user interfaces, etc.), one or more vision devices (e.g., vision masks and cameras or other optical sensors), one or more handheld, mobile, and / or fixed readers, scanners, or scanning devices, which scanning devices can be capable of scanning, receiving, or otherwise detecting the presence of these markers or tags (e.g., barcodes, RFID tags, etc.) on individual items or products and / or individual segments (positions) of the conveyor belts 22, 24, 32, 34, 36. If desired, the ID of a particular product or part can be obtained by any suitable ID sensor (e.g., a barcode reader, an RFID device) that reads an ID tag (e.g., a barcode tag, an RFID tag, or some other scannable or readable mechanism, marker, or tag) attached to the product or part. For example, items can be marked or tagged with barcodes, Universal Product Codes (UPCs), Stock Keeping Unit (SKU) codes, serial numbers, and / or other designations (including proprietary designations) that can serve as item identifiers. The item ID can identify the item by type, and / or can identify individual items within an item type. The ID sensor used for this purpose can form or be part of an optical sensor, or can be provided separately from such a sensor, e.g., when the optical sensor is a 3D image sensor. The precise location of a part on the conveyor belt can also be obtained by attaching a location ID tag to each segment / section of the conveyor belt and reading the location ID tag with an appropriate location ID sensor included in the control system. Other devices can also be used to determine the location of a part relative to the conveyor belt, such as a rotary encoder coupled to a shaft of the conveyor belt. The item ID and the conveyor belt location ID can be communicated to the control system via wired and / or wireless communication. The control system can associate the sensing information for each part, the ID of that part, and the location of that part on the conveyor belt with one another. The control system can then reference the associated information against program instructions executed by one or more processors during part picking and inspection processes performed by various implementations of the present invention.

[0029] Various embodiments of systems and methods for automatically picking and inspecting parts in an automated part picking and handling system as described herein can be executed on one or more computer systems that can interact with various other devices. Note that the above references to Figure 1 and 2Any of the components, acts, or functions described herein can be implemented via one or more computer systems according to various embodiments. An exemplary computer system can include one or more processors coupled to one or more system memories via an input / output (I / O) interface. In various embodiments, the methods described herein can be implemented in software, hardware, or a combination thereof. It will be apparent to those of ordinary skill in the art having the benefit of this disclosure that various modifications and changes can be made. The various embodiments described herein are illustrative rather than limiting. Many variations, modifications, additions, and improvements can be possible.

[0030] It will be apparent to those skilled in the art that various modifications and variations can be made in the methods and / or systems of the present application without departing from the scope of the application. Other embodiments of the methods and / or systems will be apparent to those skilled in the art from consideration of the specification and practice of the methods and / or systems disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the application being indicated by the following claims and their equivalents.

Claims

1. An automated part picking and handling system (100), comprising: a conveyor belt; a first robotic arm (120) configured to pick parts from part receptacles and place the picked parts on the conveyor belt; a first vision device (160, 164) disposed proximate the conveyor belt and configured to determine a number of parts picked by the first robotic arm (120) from the part receptacles and placed on the conveyor belt; an automated bagger (180) configured to receive the parts picked by the first robotic arm (120) and conveyed by the conveyor belt to the automated bagger, package the picked parts, print a label with information associated with the packaged parts, and place the label on the package for the parts; a second robotic arm (140) configured to pick the part packages from the conveyor belt and place the packages in a container (170); a memory; and one or more processors communicatively coupled to the conveyor belt, the first and second robotic arms, the first vision device, the automated bagger, and the memory, wherein the memory comprises program instructions executable by the one or more processors to implement a picking process configured to: (a) receive information from the first vision device regarding a number of parts picked by the first robotic arm and placed on the conveyor belt; (b) based on the received information regarding the number of picked parts, control the first robotic arm to retrieve the number of picked parts from the conveyor belt; and (c) when the number of parts picked by the first robotic arm differs from a predetermined number of parts specified in the program instructions, control the first robotic arm to place one or more of the retrieved parts back into the part receptacles.

2. The automated part picking and handling system of claim 1, further comprising a second vision device (166) disposed proximate the conveyor belt at a location where the second robotic arm (140) is configured to pick the part packages from the conveyor belt, the second vision device configured to generate a signal indicating a location of the part packages on the conveyor belt.

3. The automated part picking and handling system of claim 1, further comprising a third vision device (162) disposed proximate the container (170) and configured to provide information regarding where to place the part packages in the container, most efficiently arrange the part packages in the container, and avoid overpacking of the container. ​ 4. The automated part picking and handling system of claim 1, wherein the picking process implemented by the one or more processors includes controlling the first robotic arm (120) to retrieve all picked parts placed on the conveyor belt by the first robotic arm (120) and to place all the retrieved parts back into the part receptacle when the number of picked parts exceeds the predetermined number of parts.

5. The automated part picking and handling system of claim 1, wherein the picking process implemented by the one or more processors includes controlling the first robotic arm (120) to retrieve all picked parts placed on the conveyor belt by the first robotic arm and to place all the retrieved parts back into the part receptacle when the number of picked parts is greater than one.

6. The automated part picking and handling system of claim 1, wherein the picking process implemented by the one or more processors includes controlling the first robotic arm (120) to retrieve the number of picked parts placed on the conveyor belt by the first robotic arm exceeds the predetermined number of parts and to place the retrieved parts back into the part receptacle.

7. The automated part picking and handling system of claim 1, wherein, the first vision device includes a vision hood (160) positioned on the conveyor belt at a location where the first robotic arm (120) places the picked parts on the conveyor belt and one or more cameras (164) positioned on the conveyor belt at a location downstream of where the first robotic arm places the picked parts on the conveyor belt.

8. The automated part picking and handling system of claim 1, further comprising a push feeder (26) disposed above the conveyor belt adjacent to the automated bagger (180) and configured to be operated by the one or more processors to accumulate a predetermined number of parts moving along the conveyor belt prior to moving the predetermined number of parts into the automated bagger (180) for packaging and labeling.

9. The automated part picking and handling system of claim 1, wherein the memory further comprises program instructions executable by the one or more processors to implement a picking process further configured to: (d) control the first robotic arm (120) to pick parts from a part receptacle to be packaged by the automated bagger (180), wherein the parts to be packaged in a single package by the automated bagger are intended for a final destination different from an initial destination of the container.

10. An automated part handling system, comprising: a conveyor belt; a first robotic arm (120) configured to pick parts from a part receptacle and place the picked parts on the conveyor belt; a first vision device (160, 164) disposed proximate the conveyor and configured to determine a number of parts picked by the first robotic arm (120) from the part receptacle and placed on the conveyor; a memory; and one or more processors communicatively coupled to the conveyor, the first robotic arm, and the first vision device, wherein the memory includes program instructions executable by the one or more processors to implement a picking process configured to: (a) receive, from the first vision device, information regarding the number of parts picked by the first robotic arm and placed on the conveyor; (b) based on the received information regarding the number of picked parts, control the first robotic arm to retrieve the number of picked parts from the conveyor; and (c) when the number of parts picked by the first robotic arm differs from a predetermined number of parts specified in the program instructions, control the first robotic arm to place one or more retrieved parts back into the part receptacle.

Images