Conveyor system with multiple robotic single-piece sorters and buffer conveyors

Abstract

The conveyor system includes a first robotic single-piece sorter, a second robotic single-piece sorter, and a pick-up area, parcels in a stream of bulk parcels from the pick-up area being joined and transferred by the first robotic single-piece sorter or the second robotic single-piece sorter. The conveyor system further includes a first placement conveyor located downstream of the pickup area and configured to receive the parcels transferred by the first robotic single-piece sorter. The conveyor system further includes a second placement conveyor downstream of the pickup area and the first placement conveyor and configured to receive the parcels transferred by the second robotic single-piece sorter and to receive the parcels from the first placement conveyor. The buffer conveyor is located between the first placement conveyor and the second placement conveyor and used for adjusting the speed at which the parcels unloaded by the first placement conveyor are transferred to the second placement conveyor.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. patent application serial number 63 / 343,765 filed on May 19, 2022, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The present invention relates to parcel handling within a sorting facility or the like. In particular, the present invention relates to a conveyor system including a plurality of robotic piece sorters for transferring parcels from a bulk parcel stream to a piece sorted parcel stream. Background Art

[0004] In a parcel sorting facility, parcels are unloaded from trucks or other vehicles at an unloading location, sorted, and then loaded onto trucks or other vehicles at a loading location for delivery to the intended recipient. Therefore, within a sorting facility, there is typically a complex system of conveyors and equipment to facilitate the transportation and sorting of parcels within the facility.

[0005] When packages are first introduced into a conveyor and equipment system, they are randomly placed on the conveyor in a "bulk stream." Therefore, within a sorting facility, the first step is typically to convert the bulk package flow into a single-piece package flow, wherein the packages are placed at substantially equal intervals and arranged along the conveyor (i.e., in a single file line) for subsequent processing. A variety of single-piece sorters exist in the art, many of which employ various combinations of belt conveyors and / or roller conveyors to achieve the desired single-piece sorting of packages. However, such prior art systems have certain drawbacks. For example, a surge in the number of packages may overwhelm the mechanical system, and the packages may not be fully single-piece sorted. The unsingled packages may then interfere with subsequent processing, including downstream sorting.

[0006] U.S. Patent No. 10,646,898, incorporated herein by reference, describes a system and method for identifying and transferring packages from a bulk package stream on a first conveyor (or "pick conveyor") to a single-piece package stream on a second conveyor (or "place conveyor"). Specifically, a robotic piece sorter (or robot) receives packages via the pick conveyor, engages each package, and then places it on the place conveyor. However, due to cycle time limitations (i.e., the time required to transfer a package from the pick conveyor to the place conveyor each time), a conveyor system containing only a single robotic piece sorter may not always provide the throughput required to effectively process a large number of packages.

[0007] Therefore, there remains a need for improved systems to transfer packages from bulk package flow to single piece package flow. Summary of the invention

[0008] The present invention is a conveyor system that includes a plurality of robotic piece sorters (or robots) for transferring packages from a bulk package flow to a piece package flow.

[0009] An exemplary conveyor system made in accordance with the present invention includes: a pick conveyor defining a pick area for a bulk package flow; a placement conveyor located downstream of the pick area; a first robotic separator (or first robot) and a second robotic separator (or second robot) working in parallel to transfer packages in the pick area to a single piece sortation flow on the placement conveyor; and a vision and control subsystem operably connected to the first robot and the second robot so that the vision and control subsystem can communicate instructions to control the operation of these components.

[0010] The vision and control subsystem includes a first (or target) camera configured to acquire one or more images of a predetermined area of ​​interest (i.e., a pick area) and any packages located therein. In some embodiments, the target camera is positioned such that the field of view of the target camera includes the pick area and at least a portion of a pick conveyor located upstream of the pick area. Each image acquired by the target camera is processed within the vision and control subsystem to determine the location of packages located within the pick area (if any packages are present), and in some embodiments, to determine the proximity of these packages relative to each other and / or the location of one or more packages located upstream of the pick area. Based on the determined location of the packages within the pick area, the vision and control subsystem communicates instructions to cause the first robot and the second robot to continuously transfer the packages within the pick area to the placement conveyor.

[0011] In some embodiments, after transferring a package from the pick area to the placement conveyor, the vision and control subsystem communicates instructions to index the placement conveyor to make room on the placement conveyor for other packages to be delivered. Because a package does not have to be completely transferred from the pick area to the placement conveyor before the transfer process of another package in the pick area begins, the package transfer throughput rate of the system of the present invention is improved relative to known conveyor systems that include only a single robotic piece sorter.

[0012] To reduce system downtime associated with transferring a package from a pick area to a placement conveyor, in some embodiments, the system includes a package transfer routine that includes a robot selection subroutine that causes the vision and control subsystem to select a first robot or a second robot to transfer a package in the pick area based on a priority queue and also taking into account the availability of the first robot and the second robot, the priority queue including one or more entries that assign a priority to the first robot or the second robot. In the event that multiple packages are located in the pick area, the robot selection subroutine may also cause the vision and control subsystem to select one of the multiple packages for transfer by the selected robot based on the proximity of the package in the multiple packages to the selected robot. To reduce system downtime associated with image acquisition and processing, in some embodiments, the vision and control subsystem limits the number of times a target camera is selectively activated in a given time to acquire images of a group of multiple packages located in the pick area based on the spacing of the packages relative to each other.

[0013] In some embodiments, the package transfer routine includes a package pick-up and travel subroutine that is selectively executed to reduce system downtime associated with transferring packages located upstream of a pick-up area of ​​a pick-up conveyor to the pick-up area. The pick-up and travel subroutine reduces downtime by causing the pick-up conveyor to travel a calculated distance to move a package located upstream of the pick-up area into the pick-up area immediately before (i.e., simultaneously with) the first robot or the second robot moving another package out of the pick-up area. In some embodiments, the calculated distance is based on image data corresponding to an image acquired by a target camera. In some embodiments, the system may further include a sensor configured to obtain a reading regarding the presence of a package within the pick-up area of ​​the pick-up conveyor. In some embodiments, the travel of the pick-up conveyor may be stopped in response to the sensor obtaining a reading indicating the presence of one or more packages within the pick-up area.

[0014] In some embodiments, the vision and control subsystem further includes a second (or confirmation camera) configured to acquire images of an area (or placement area) of the placement conveyor to which packages transferred from the pickup area are delivered. Each image acquired by the confirmation camera is processed within the vision and control subsystem to confirm that the package was properly transferred to the placement conveyor. In determining whether the package was properly transferred to the placement conveyor, in some embodiments, the vision and control subsystem can be configured to determine whether the first robot or the second robot transferred multiple packages simultaneously and / or whether the packages transferred to the placement conveyor are oriented in a manner that satisfies one or more predetermined criteria.

[0015] In some embodiments, placing a conveyor includes a plurality of conveyors.

[0016] In some embodiments, the system includes an upstream conveyor configured to receive the bulk package flow and transfer the package flow downstream toward the pickup area. In some embodiments, the upstream conveyor includes a plurality of conveyors. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 is a schematic diagram of an example conveyor system made in accordance with the present invention, the example conveyor system including a plurality of robotic piece sorters;

[0018] Figure 2 yes Figure 1 A perspective view of an exemplary conveyor system;

[0019] Figure 3 yes Figure 1 A top view of a pick-up conveyor of an exemplary conveyor system;

[0020] Figure 4 It is shown Figure 1 The first robotic piece sorter and the second robotic piece sorter of the exemplary conveyor system of Figure 1 A diagram of a movement cycle of a pick conveyor to a place conveyor in an exemplary conveyor system of FIG.

[0021] Figure 5 is used for Figure 1 Schematic diagram of vision and control subsystems of an exemplary conveyor system;

[0022] Figure 6 Is used for initialization Figure 1 A flowchart of an exemplary routine for performing package transfer using an exemplary conveyor system;

[0023] Figure 7 yes Figure 1 A flow chart of an exemplary routine for engaging and transferring packages in an exemplary conveyor system of;

[0024] Figure 8 yes Figure 1 A flow chart of an exemplary routine for confirming a package transfer in an exemplary conveyor system of;

[0025] Fig. 9 yes Figure 1 an exemplary subroutine for evaluating and diverting packages in an exemplary conveyor system of;

[0026] Fig.10 yes Figure 1 Another top view of a pick-up conveyor of an exemplary conveyor system;

[0027] Fig.11 is used to make Figure 1an exemplary subroutine for picking up a conveyor of an exemplary conveyor system of;

[0028] Fig.12 is a perspective view of another exemplary conveyor system made in accordance with the present invention, comprising a plurality of robotic piece sorters;

[0029] Fig.13 is a perspective view of another exemplary conveyor system made in accordance with the present invention, comprising a plurality of robotic piece sorters;

[0030] Fig.14 is a schematic diagram of another exemplary conveyor system made in accordance with the present invention, comprising a plurality of robotic piece sorters;

[0031] Fig.15 is a schematic diagram of another exemplary conveyor system made in accordance with the present invention, comprising a plurality of robotic piece sorters;

[0032] Fig.16 is a schematic diagram of another exemplary conveyor system made in accordance with the present invention, comprising a plurality of robotic piece sorters;

[0033] Fig.17 is a schematic diagram of another exemplary conveyor system made in accordance with the present invention, comprising a plurality of robotic piece sorters;

[0034] Fig.18 is a perspective view of another exemplary conveyor system made in accordance with the present invention, comprising a plurality of robotic piece sorters and a buffer conveyor; and

[0035] Fig.19 is a perspective view of another exemplary conveyor system made in accordance with the present invention, which includes a plurality of robotic piece sorters and a buffer conveyor. DETAILED DESCRIPTION

[0036] The present invention is a conveyor system that includes a plurality of robotic piece sorters (or robots) for transferring packages from a bulk package flow to a piece package flow.

[0037] Figure 1 is a schematic diagram of an example conveyor system 10 made in accordance with the present invention and including a plurality of robotic piece sorters.

[0038] Figure 2 yes Figure 1 A perspective view of an exemplary conveyor system 10 is shown.

[0039] Figure 3 yes Figure 1 1. A top view of a pick-up conveyor 14 of an exemplary conveyor system.

[0040] Figure 5 is used for Figure 1 Schematic diagram of an exemplary vision and control subsystem 30 of system 10 .

[0041] Now refer to Figures 1 to 3 and Figure 5 , the exemplary conveyor system 10 (or system 10) generally includes: a pick conveyor 14, which is configured to receive a bulk package flow, such as a bulk package flow from an upstream conveyor 12; a placement conveyor 16, which is located downstream of the pick conveyor 14; a first robotic separator 20 (or first robot 20) and a second robotic separator (or second robot 22), which work in parallel to continuously transfer packages from the pick conveyor 14 to a single-piece sorting flow on the placement conveyor 16; and a vision and control subsystem 30, which is operably connected to the pick conveyor 14, the first robot 20 and the second robot 22, so that the vision and control subsystem 30 can convey instructions to control the operation of these components.

[0042] It is important to recognize that in the following discussion and in the claims of this application, the term "package" is not intended to be limiting and may include any article, substance, or object that can be transported, loaded, and / or unloaded in the manner specified in this disclosure. It is also important to recognize that in the following discussion and in the claims of this application, the term "pick-up conveyor" is not intended to be limiting and may include any form of chute, conveyor, or conveying surface, whether static or moving, that defines a "pick-up area" where a package can be retrieved and transferred to a drop conveyor.

[0043] Figure 4 is a diagram illustrating a movement cycle performed by the first robot 20 and the second robot 22 for transferring a package from the pick conveyor 14 to the place conveyor 16 of the system 10 .

[0044] Now refer to Figures 1 to 5 , the vision and control subsystem 30 includes a first (or target) camera 34 that can be selectively activated to acquire a predetermined area of ​​interest (i.e., the pick area) of the pick conveyor 14 and any packages (e.g., Figure 3 In the exemplary embodiment, the target camera 34 is positioned such that the field of view of the target camera 34 includes the pickup area 15 and at least a portion of the pickup conveyor 14 located upstream of the pickup area 15. In the exemplary embodiment, the pickup area 15 of the pickup conveyor 14 is defined by two independent areas and can therefore be characterized as including two independent areas: a first area 15a and a second area 15b, as shown in FIG. Figure 1 and Figure 3As shown. Each image acquired by the target camera 34 is processed within the vision and control subsystem 30 to determine the location of a package located within the pick area 15 (if a package is present). In some embodiments, the images acquired by the target camera 34 can also be used to evaluate the proximity of multiple packages located within the pick area 15 relative to each other and / or the distance of packages located upstream of the pick area 15 at a given time, as further described below. Based on the determined location of the package within the pick area 15, the vision and control subsystem 30 conveys instructions to the first robot 20 or the second robot 22 to continuously transfer the packages within the pick area 15 to the placement conveyor 16. Unlike conveyor systems of known structures that employ a single robot single-piece sorter, in the system 10 of the present invention, a package does not have to be completely transferred from the pick area 15 to the placement conveyor 16 before starting the transfer process of another package within the pick area 15. Instead, by using two robots 20, 22, one package in the pick area 15 can be picked up by one robot (for example, Figure 2 The second robot 22 in the embodiment of the present invention is engaged, while another robot (e.g., Figure 2 The first robot 20 in FIG. 1 is transferring another package to the placement conveyor 16 or returning from such a transfer, such as Figure 2 and Figure 4 As shown. Thus, by using a plurality of robotic piece sorters 20, 22, the parcel throughput rate (i.e., the rate at which parcels are transferred to the placement conveyor 16 in a piece sorting stream) is improved relative to known conveyor systems that employ only a single robotic piece sorter. As described in more detail below, to further improve the parcel throughput rate, the vision and control subsystem 30 also utilizes the determined location of the parcels within the pick area 15 and the proximity of the parcels to each other to selectively activate the target camera 34, the first and second robots 20, 22, and, in some embodiments, the pick conveyor 14 in a manner that reduces downtime associated with image acquisition and processing, transfer of the parcels to the placement conveyor 16 (i.e., piece sorting of the parcels), and delivery of the parcels to the pick area 15, respectively.

[0045] Now refer to Figure 1 , Figure 2 and Figure 5 In the exemplary embodiment, vision and control subsystem 30 further includes a second (or confirmation) camera 36 that can be selectively activated to acquire one or more images of placement area 17 of placement conveyor 16 and any packages located therein.

[0046] The placement area 17 of the placement conveyor 16 corresponds to the area in the placement conveyor 16 where the packages transferred by the first robot 20 and the second robot 22 are delivered. Each image acquired by the confirmation camera 36 is processed within the vision and control subsystem 30 to confirm that the package is transferred to the placement conveyor 16, as described below with reference to Figure 8 Further description.

[0047] Refer again Figure 1 and 2 In the exemplary embodiment, the system 10 includes an upstream conveyor 12 that includes a plurality of conveyors, each of which is configured to receive a bulk package stream and transfer it downstream to a pick-up conveyor 14. Specifically, in the exemplary embodiment, the upstream conveyor 12 includes: a feed conveyor 12a that initially receives the bulk package stream; and a depalletizing conveyor 12b, such as the depalletizing conveyor described in commonly assigned U.S. patent application Ser. No. 17 / 092,660 (now U.S. Pat. No. 11,203,493), which is incorporated herein by reference. The depalletizing conveyor 12b is positioned to receive packages unloaded from the feed conveyor 12a and is oriented at a predetermined angle to separate vertically stacked packages prior to unloading onto the pick-up conveyor 14, such as the depalletizing conveyor described in the commonly assigned U.S. patent application Ser. No. 17 / 092,660 (now U.S. Pat. No. 11,203,493). ... Figure 2 In some embodiments, the feed conveyor 12a may be used as a blocking conveyor, such as the blocking conveyor also described in U.S. Patent Application Serial No. 17 / 092,660 (now U.S. Patent No. 11,203,493), which can be selectively activated and deactivated (or "traveled") to regulate the unloading of packages to the depalletizing conveyor 12b. Figure 2 As best shown in FIG. 1 , in this exemplary embodiment, the proximal end of the pick conveyor 14 is located below the distal end of the depalletizing conveyor 12 b so that packages unloaded from the distal end of the depalletizing conveyor 12 b fall onto the pick conveyor 14 at a predetermined distance to further facilitate separation of packages stacked on each other.

[0048] Now refer to Figure 1 , Figure 2 and Figure 5In the exemplary embodiment, the first robot 20 and the second robot 22 are both in the form of robotic arms. More specifically, in the exemplary embodiment, the first robot 20 and the second robot 22 are both six-axis articulated robotic arms. One suitable robot that can be used as the first robot 20 and the second robot 22 is the M-10iD / 12 robot manufactured and available from FANUC America of Rochester Hills, Michigan. The first robot 20 and the second robot 22 each include an end effector 20a, 22a that is configured to engage and hold a package in association with the robot 20, 22 corresponding to the end effector 20a, 22a during transfer from the pick conveyor 14 to the place conveyor 16. For example, the end effectors 20a, 22a of the first robot 20 and the second robot 22 may include one or more vacuum suction cups that are in fluid communication with a vacuum source and configured to engage with the package. In this regard, suitable end effectors that may be used as the end effectors 20a, 22a of the first robot 20 and the second robot 22 include, but are not limited to, those described in U.S. Patent Application Publication No. 2020 / 0262069, which is incorporated herein by reference.

[0049] Now refer to Figure 1 , Figure 2 , Figure 4 and Figure 5 , in order to transfer the package from the pick-up area 15 of the pick-up conveyor 14 to the placement area 17 of the placement conveyor 16, the first robot 20 and the second robot 22 are positioned near the pick-up area 15. In this regard, and in this exemplary embodiment, the first robot 20 and the second robot 22 are each mounted to the frame 25 to support the first robot 20 and the second robot 22 in an inverted (or hanging) orientation above the pick-up area 15. Of course, the first robot 20 and the second robot 22 may be alternatively positioned or mounted without departing from the spirit or scope of the present invention, for example, as described below with reference to Fig.11 and Figures 13 to 16 As demonstrated by the conveyor systems 300, 500, 600, 700 and 800 described herein. Figure 4As shown, when transferring a package from the pick-up area 15 to the placement area 17, the first robot 20 and the second robot 22 each follow the same general motion cycle, which in this case includes three motions: a first motion, moving from a predetermined initial (or "home") position to a target package within the pick-up area 15 to initiate the transfer of the target package; a second motion, moving from an engagement point with the target package to a position above the placement area 17 of the placement conveyor 16 to deliver the target package; and a third motion, returning to the home position from a position above the placement area 17 of the placement conveyor 16. In this exemplary embodiment, when in the "home" position, the first robot 20 is centrally located relative to the first area 15a of the pick-up area 15, and the second robot 22 is centrally located relative to the second area 15b of the pick-up area 15.

[0050] Now refer to Figure 1 , Figure 2 and Figure 5 In the exemplary embodiment, the vision and control subsystem 30 generally includes a first vision unit 31, a second vision unit 35, and a controller 40. The first vision unit 31 and the second vision unit 35 are operably connected to the controller 40, so that the controller 40 can convey instructions to the first vision unit 31 and the second vision unit 35 and receive data from the first vision unit 31 and the second vision unit 35.

[0051] The first vision unit 31 includes a target camera 34, which is positioned so that the pickup area 15 is located within the field of view of the target camera 34, and the target camera 34 is configured to obtain a two-dimensional and / or three-dimensional image of the pickup area 15. Figure 2 2, but the target camera 34 is mounted to the frame 25 and is directly above the pick-up area 15. The second vision unit 35 includes a confirmation camera 36, ​​which is positioned so that the placement area 17 of the placement conveyor 16 is within the field of view of the confirmation camera 36, ​​and the confirmation camera 36 is configured to obtain a two-dimensional and / or three-dimensional image of the placement conveyor 16. In this exemplary embodiment, the confirmation camera 36 is located above the placement conveyor 16 and is also mounted to the frame 25. Those skilled in the art will readily appreciate that the target camera 34 and / or the confirmation camera 36 can be alternatively mounted or positioned without departing from the spirit or scope of the present invention. Suitable cameras for the first vision unit 31 and the second vision unit 35 include a three-dimensional image sensor manufactured and distributed by ifmEffector, Inc. of Malvern, Pennsylvania.

[0052] Now refer to Figure 5In the exemplary embodiment, the image of the pickup area 15 acquired by the target camera 34 is processed locally in the first vision unit 31. To this end, the first vision unit 31 further includes a processor 32, which is configured to execute instructions (routines) stored in a memory component 33 or other computer-readable medium to process the image acquired by the target camera 34. Although the target camera 34 is generally referred to herein and shown in the figures as including only a single camera, embodiments in which the target camera 34 includes multiple cameras can be envisioned. Of course, the processor 32 of the first vision unit 31 can also include multiple processors. For example, in some embodiments, each corresponding camera of the first vision unit 31 can have a processor associated therewith to process the image acquired by the camera. Similarly, in the exemplary embodiment, the image of the placement conveyor 16 acquired by the confirmation camera 36 is processed locally in the second vision unit 35. To this end, the second vision unit 35 further includes a processor 37, which is configured to execute instructions (routines) stored in a memory component 38 or other computer-readable medium to process the image acquired by the confirmation camera 36. Although the confirmation camera 36 is generally referred to herein and shown in the figures as including only a single camera, embodiments in which the confirmation camera 36 includes multiple cameras can be envisioned. Of course, the processor 37 of the second visual unit 35 may also include multiple processors. For example, in some embodiments, each corresponding camera of the second visual unit 35 may have a processor associated therewith to process the image acquired by the camera. Suitable processors for the first visual unit 31 and the second visual unit 35 include processors provided in the JetsonNano computer manufactured and distributed by Nvidia Corporation of Santa Clara, California, but other processors suitable for performing the operations described herein may also be used instead.

[0053] Although it is generally preferred that the target camera 34 and the confirmation camera 36 are each provided with their own processors 32, 37, those skilled in the art will appreciate that in alternative embodiments, a single processor may be used to perform the respective operations of the processor 32 of the first vision unit 31 and the processor 37 of the second vision unit 35 described herein. In this regard, in some embodiments, the system 10 may include only a single vision unit, of which the target camera 34 and the confirmation camera 36 are both components.

[0054] Still refer to Figure 5 , the controller 40 includes a processor 42 configured to execute instructions stored in a memory component 43 or other computer-readable medium.

[0055] In the exemplary embodiment, the controller 40 is a programmable logic controller or other industrial controller. The controller 40 is connected to the first vision unit 31 and the second vision unit 35 through a wired connection (e.g., an Ethernet connection) or through a wireless connection (e.g., through a network) using known interfaces and protocols to facilitate the transmission of data from the first vision unit 31 and the second vision unit 35 to the controller 40 and the communication of instructions from the controller 40 to the first vision unit 31 and the second vision unit 35.

[0056] Although it is generally preferred that the controller 40, the first vision unit 31, and the second vision unit 35 are each provided with its own processor 32, 37, 42, in alternative embodiments, a single processor may be used to perform the respective operations described for the processor 32 of the first vision unit 31, the processor 37 of the second vision unit 35, and the processor 42 of the controller 40. In this regard, in some embodiments, the first vision unit 31 and the second vision unit 35 may be components of the controller 40, or may be characterized as including only the target camera 34 and the confirmation camera 36, ​​respectively.

[0057] Now refer to Figure 5 In some embodiments, the system 10 may also include a reject mechanism 60 positioned and configured to push packages across the surface of the pick conveyor 14. For example, the reject mechanism may be mounted to the pick conveyor 14 so that when activated, the reject mechanism moves over the pick area 15 to push packages that the vision and control subsystem 30 determines to be "non-transferable" (e.g., packages that exceed certain predetermined dimensions or have a certain shape) off the pick conveyor 14. Thus, as Figure 5 As shown, the reject mechanism 60 is operably connected to the controller 40 so that the reject mechanism can be selectively activated in response to instructions (or signals) communicated from the controller 40. In addition, in some cases, the controller 40 can communicate instructions to cause the reject mechanism 60 to slightly move (or "bump") one or more packages located in the pick area 15 to reposition the packages. In other cases, the controller 40 can communicate instructions to cause the reject mechanism 60 to move completely across (or "fully sweep") the pick area 15 to completely push one or more packages located in the pick area 15 away from the pick conveyor 14. In some embodiments, whether the reject mechanism 60 is selectively activated, always activated, or activated to bump or fully sweep packages can be based on the controller 40 of the vision and control subsystem 30 determining that one or more packages located in the pick area 15 do not meet one or more predetermined criteria (e.g., package weight or size criteria). Suitable rejection mechanisms that may be used within system 10 include the rejection mechanisms described in U.S. Patent Application Publication No. 2020 / 0377309 (now U.S. Patent No. 11,014,767), which is incorporated herein by reference. Figures 1 to 3 and Figure 5 In the exemplary embodiment, the system 10 further includes a sensor 62, such as a photoelectric sensor, located at a predetermined distance from the far end of the pick-up conveyor 14. The sensor 62 is configured to detect the presence of a package in the pick-up area 15 (e.g., Fig.10 ) and obtain a reading about the package. Figure 5 As shown, the sensor 62 is operably connected to the controller 40 of the vision and control subsystem 30 so that the readings obtained by the sensor 62 are transmitted to the controller 40 for subsequent processing. The sensor 62 can be selectively activated to obtain readings in response to instructions (or signals) communicated from the controller 40, or substantially continuously obtain readings. As described in further detail below, in some embodiments, the readings obtained by the sensor 62 are processed by the controller 40 to identify when the travel of the pick conveyor 14 should be stopped during the pick and travel subroutine, as described below with reference to Figure 7 and Fig.10 Further description.

[0058] Figure 6 Is used for initialization Fig.10 A flow chart of an exemplary routine for performing package transfer using an exemplary conveyor system.

[0059] It should be understood that, unless otherwise indicated, the routines and subroutines described herein correspond to a set of instructions stored in the storage component 43 and executable by the processor 42 of the controller 40 .

[0060] Now refer to Figure 5 and Figure 6 To ensure that the various components of the system 10 are operable and / or positioned to facilitate the package transfer operations described herein, in the exemplary embodiment, the vision and control subsystem 30 first performs a system startup routine before the first robot 20 and the second robot 22 transfer any packages from the pick conveyor 14 to the place conveyor 16. Figure 6As shown in decision 102 in FIG. 1 , in the exemplary embodiment, the system startup routine begins with the vision and control subsystem 30 determining whether each of the feed conveyor 12a, the depalletizing conveyor 12b, the pick conveyor 14 (in some embodiments), the placement conveyor 16, the first robot 20, the second robot 22, the destination camera 34, and the confirmation camera 36 (if being used) are operational. In this regard, the processor 42 of the controller 40 can execute instructions that cause the controller 40 to determine whether the above-mentioned components are activated (e.g., as indicated by whether the controller 40 generally receives feedback (or signals) from the respective components) and / or whether one or more predetermined criteria are met (e.g., as indicated by the nature of the feedback (or signals) received from these components). In some embodiments, the vision and control subsystem 30 can also determine whether the reject mechanism 60 and / or the sensor 62 are operational as part of decision 102. If the component inspected by the vision and control subsystem 30 is determined to be inoperable, then in the exemplary embodiment, the controller 40 will generate an alarm to notify the operator of the malfunction of the component, such as Figure 6 In some embodiments, the alarm generated by the controller 40 may be in the form of a visual prompt displayed on a display (not shown) operably connected to the controller 40 and / or an audible prompt emitted from a speaker (not shown) operably connected to the controller 40.

[0061] Now refer to Figures 4 to 6 After determining that the first robot 20 and the second robot 22 are operable, the vision and control subsystem 30 evaluates whether the first robot 20 and the second robot 22 are each in their home position, such as Figure 6 As shown in decision 106 in .

[0062] For each robot determined not to be in the home position, the controller 40 communicates a command (or signal) to cause the robot to perform a homing sequence, which returns the robot to its home position, as shown in block 108. Once the homing sequence for each robot initially determined not to be in the home position is completed, the vision and control subsystem 30 re-evaluates the positioning of the first robot 20 and the second robot 22 to determine whether both are in the home position, as shown in block 108. Figure 6 In this regard, in some embodiments, the controller 40 may process information (e.g., coordinate data) received from the first robot 20 and the second robot 22 to determine the positioning of the first robot 20 and the second robot 22. In this embodiment, if after completing the homing sequence, it is again determined that either robot is not in the homing position, the controller 40 will generate an alarm to notify the operator that the first robot 20 and / or the second robot 22 is not properly positioned, such as Figure 6 As shown in block 112 in FIG.

[0063] Now refer to Figure 5 to Figure 6If, after completing the homing sequence, it is determined that both the first robot 20 and the second robot 22 are in the home position, the controller 40 transmits an instruction (or signal) to cause the placement conveyor 16 to travel a predetermined distance, such as Figure 6 As shown in block 114 in FIG. 1 , any packages located on the placement conveyor 16 are moved further downstream, thereby providing additional space in the placement area 17 so that packages transferred from the pick-up area 15 by the first robot 20 or the second robot 22 can be delivered. Figure 6 As shown in block 116 of FIG. 1 , in this embodiment, before the first robot 20 or the second robot 22 transfers any packages from the pick-up area 15, the controller 40 determines whether the placement conveyor 16 has completed traveling (e.g., based on a signal or other information received from the placement conveyor 16, the passage of a predetermined duration, etc.). In this exemplary embodiment, once the controller 40 determines that the placement conveyor 16 has completed traveling, the system 10 executes a pick-up (or package transfer) routine, such as Figure 6 As shown in block 118 in , as further described below.

[0064] Figure 7 yes Fig.10 Flowchart of an exemplary routine for engaging and transferring packages in an exemplary conveyor system of FIG.

[0065] Now refer to Figures 1 to 3 , Figure 5 and Figure 7 , in this exemplary embodiment, to initiate transfer of packages from the pick conveyor 14 to the place conveyor 16, the destination camera 34 is selectively activated in response to instructions (or signals) communicated from the controller 40 to acquire an image of the pick area 15 within the field of view of the destination camera 34 and any packages located on the area, e.g. Figure 3 Packages 50a, 50b, 50c, such as Figure 7 As shown in block 120 in FIG.

[0066] Then, in the exemplary embodiment, the processor 32 of the first vision unit 31 processes the image. Then, the first vision unit 31 transmits the image data to the controller 40. Based on the image data received from the first vision unit 31, the controller 40 determines whether any packages are located in the pickup area 15, such as Figure 7 In the exemplary embodiment, if no package is detected within the pick-up area 15, the controller 40 communicates instructions to cause the upstream conveyor 12 (which in this case is again defined by the feed conveyor 12a and the depalletizing conveyor 12b) and the pick-up conveyor 14 to travel a predetermined distance to move the package located downstream toward the pick-up area 15 of the pick-up conveyor 14, as shown in FIG. Figure 7Once the upstream conveyor 12 and the pickup conveyor 14 have traveled a predetermined distance, the target camera 34 acquires another image to determine whether any packages are located within the pickup area 15. The above process is repeated until the target camera 34 acquires an image indicating that one or more packages are located within the pickup area 15.

[0067] Still refer to Figure 1 , Figure 2 , Figure 5 and Figure 7 Once the vision and control subsystem 30 determines that one or more packages are located in the pick area 15 of the pick conveyor 14, the controller 40 communicates instructions to cause the first robot 20 and the second robot 22 to continuously transfer the packages located in the pick area 15 of the pick conveyor 14 to the placement conveyor 16. In order to reduce the downtime associated with transferring packages from the pick area 15 to the placement conveyor 16 and thereby improve the package throughput rate, in the exemplary embodiment, the controller 40 selectively communicates the package transfer instructions to the first robot 20 and the second robot 22 by following the robot selection subroutine, such as Figure 7 126, 128, 130 and blocks 132, 134 in FIG. 126. When the robot selection subroutine is executed, the robot selection subroutine causes the controller 40 to determine which robot of the first robot 20 and the second robot 22 should be selected to transfer the package, and which package in the pickup area 15 should be transferred by the selected robot if multiple packages are located in the pickup area 15 at a given time. In the exemplary embodiment, the selection resulting from the execution of the robot selection subroutine is based on a priority queue, the availability of each robot, and / or the proximity of the package to the selected robot, as further described below.

[0068] Still refer to Figure 1 , Figure 2 , Figure 5 and Figure 7 , the robot selection subroutine begins when the controller 40 determines whether the first robot 20 or the second robot 22 has priority to engage and transfer the package from the pick-up area 15, such as Figure 7126 in the decision. In the exemplary embodiment, whether the first robot 20 or the second robot 22 has priority to engage and transfer a package at a given time is determined by a priority queue, which contains one or more entries at a given time corresponding to the order in which the first robot 20 and / or the second robot 22 will be given initial priority to engage and transfer packages from the pick conveyor 14. To reduce processing time, in the exemplary embodiment, at least the initial entry of the priority queue is predetermined and corresponds to which robot will first engage and transfer a package within the pick area 15. Subsequent entries of the priority queue can be predetermined, or filled and assigned by the controller 40 during the package transfer process.

[0069] Now refer to Figure 1 , Figure 2 , Figure 4 , Figure 5 and Figure 7 Once the priority is determined, the controller 40 then determines whether the robot with the priority is actually available to transfer the package to the placement conveyor 16, such as Figure 7 128, 130 in FIG. 12. If a robot with priority is available, the controller 40 will select that robot to complete the transfer of the package from the pick-up area 15 to the placement conveyor 16. However, if the robot with priority is busy or otherwise unable to transfer the package to the placement conveyor 16, the controller 40 will evaluate whether a robot without priority is available to transfer the package and select that robot to complete the transfer of the package, provided that the robot without priority is not busy or otherwise unavailable. For example, Figure 2 For example, if the first robot 20 has priority but is returning from transferring the first package 50a to the placement conveyor 16, and the second robot 22 is in place, the controller 40 will select the second robot 22 to complete the transfer of the selected package (in this case, package 50b) in the pick area 15 to the placement conveyor 16. By determining and selecting the first available robot to complete the transfer of the package, the robot selection subroutine thus effectively reduces or eliminates the situation where the selected package is delayed due to the unavailability of the robotic single piece sorter, and in this way reduces or eliminates the downtime associated with transferring the package from the pick area 15 of the pick conveyor 14 to the placement area 17 of the placement conveyor 16.

[0070] Now refer to Figures 1 to 3 , Figure 5 and Figure 7, after the controller 40 selects the first robot 20 or the second robot 22, the controller 40 determines which package in the pick-up area 15 of the pick-up conveyor 14 will be transferred by the selected robot to the placement conveyor 16. In the event that the image data received from the first vision unit 31 indicates that there is only one package in the pick-up area 15, the controller 40 will communicate instructions to the selected robot to engage the package and transfer it to the placement conveyor 16. However, in the event that the image data received from the first vision unit 31 by the controller 40 indicates that there are multiple packages in the pick-up area 15 (e.g., Figure 3 As shown in FIG. 1 ), in this exemplary embodiment, the controller 40 will select a package to be transferred to the placement conveyor 16 based on the proximity of the package to the selected robot. Specifically, in this exemplary embodiment, the controller 40 is configured to select the package closest to the selected robot for transfer, such as Figure 7 , as shown in blocks 132, 134 in . In the exemplary embodiment, the location data associated with each respective package corresponds to the coordinates of the package within the pick-up area 15 (e.g., x-coordinate values ​​and y-coordinate values). In some embodiments, the location data may further include an indication of whether each respective package is located within the first area 15a or the second area 15b of the pick-up area 15. In such an embodiment, the controller 40 may therefore determine which package is closest to the selected robot based on the coordinates of each respective package, which area of ​​the pick-up area 15 the package is located in, or a combination thereof.

[0071] Now refer to Figure 3 , Figure 5 and Figure 7 In an embodiment, when processing the image acquired by the target camera 34 , the first vision unit 31 may first generate position data of each corresponding package within the picking area 15 , and then transmit it to the controller 40 .

[0072] The coordinates of the package determined to be closest to the selected robot are included in the instructions communicated from the controller 40 to the selected robot, which instructions cause the selected robot to engage the selected package and transfer it to the placement conveyor 16, such as Figure 7 As shown in blocks 136 and 138 in FIG. Figure 3 As may be best illustrated by the bounding boxes 13a and 13b that respectively surround packages 50a and 50b in FIG. 1 , in the exemplary embodiment, the first vision unit 31 is configured to identify and generate location data for only two packages at a time that are located within the pickup area 15. However, it should be understood that in alternative embodiments, the first vision unit 31 may be configured to identify and generate location data for more than two packages that are located within the pickup area 15 without departing from the spirit or scope of the present invention.

[0073] Now refer to Figure 5 and Figure 7 Once the controller 40 communicates instructions to the selected robot to engage and transfer the selected package, the vision and control subsystem 30 verifies whether the selected package has been successfully engaged and transferred by the selected robot outside the picking area 15. To do this, in the exemplary embodiment, the controller 40 determines whether both the selected package and the selected robot are outside the field of view of the target camera 34, such as Figure 7 140, 142 in FIG. 14A . In this regard, the controller 40 communicates instructions to cause the first vision unit 31 to evaluate whether the selected robot and the selected package are both outside the field of view of the destination camera 34, and communicates the results of such evaluation to the controller 40. To initiate the process, in some embodiments, the controller 40 may communicate instructions to cause the destination camera 34 to acquire another image of the pickup area 15. In such an embodiment, the processor 32 of the first vision unit 31 then processes the image and transmits image data to the controller 40, the image data indicating whether the selected robot and the selected package are outside the field of view of the destination camera 34, thereby indicating that the selected package has been successfully engaged and transferred outside the pickup area 15. If the controller 40 determines that the selected robot or the selected package is not outside the field of view of the destination camera 34, the above process may be repeated after a predetermined period of time to provide the selected robot with additional time to transfer the selected package. In the exemplary embodiment, if the selected robot or the selected package is no longer outside the field of view of the destination camera 34 after a predetermined period of time or after a predetermined number of iterations of acquiring and processing additional images of the pickup area 15, the controller 40 will communicate instructions to restart the package transfer routine (which was initiated by Figure 7 Conversely, if the controller 40 determines that the selected robot and the selected package are outside the field of view of the target camera 34, then in the exemplary embodiment, the controller 40 will continue to perform additional verification steps (such as Figure 7 ), and communicates instructions to restart the package transfer routine to initiate the transfer and piece sorting of additional packages.

[0074] Now refer to Figure 2 , Figure 5 and Figure 7 In this exemplary embodiment, to further verify the successful engagement of the selected robot with the selected package, the controller 40 also determines whether the selected robot is pneumatically engaged with the selected package, such as Figure 7, as shown in decisions 144 and 146 in . Therefore, in some embodiments, the end effector 20a of the first robot 20 and the end effector 22a of the second robot 22 each include a vacuum sensor (not shown). The vacuum sensor of each robot is operably connected to the controller 40 so that the vacuum sensor provides vacuum pressure feedback to the controller 40, which in turn uses the feedback to determine whether the end effector of the selected robot is pneumatically engaged with the selected package. If the controller 40 determines that the end effector of the selected robot is not pneumatically engaged with the selected package, the controller 40 will convey an instruction to repeat the above-mentioned package transfer routine. Otherwise, the system 10 will verify whether the selected package has been successfully transferred and delivered to the placement conveyor 16 by executing a confirmation (or package placement) routine, such as Figure 7 As shown in block 148 in and further described below. Figure 1 , Figure 2 , Figure 5 and Figure 8 , in order to begin verifying the placement of the selected package on the placement conveyor 16, the confirmation camera 36 is selectively activated in response to an instruction (or signal) communicated from the controller 40 to obtain an image of the placement area 17 of the placement conveyor 16, such as Figure 8 The processor 37 of the second vision unit 35 then processes the image of the placement area 17. The second vision unit 35 then transmits the image data to the controller 40. Based on the image data received from the second vision unit 35, the controller 40 initially determines whether the selected package has been delivered to the placement conveyor 16, such as Figure 8 152 in the decision. If the controller 40 determines that the selected package has not been delivered to the placement conveyor 16, the controller 40 communicates an instruction (or signal) to cause the confirmation camera 36 to obtain another image of the placement area 17 and effectively restart the confirmation routine. Otherwise, the system 10 continues to the next step of the confirmation routine.

[0075] Still refer to Figure 1 , Figure 2 , Figure 5 and Figure 8 In the exemplary embodiment, before advancing the placement conveyor 16 to provide space for subsequent packages to be delivered, the system 10 executes a piece sorting confirmation subroutine to confirm that the packages are correctly piece sorted, such as Figure 8 As shown in decisions 154, 156, 162, 164 and blocks 158, 160, 166, 168. Figure 8As shown in decision 154 in FIG. 1 , in the exemplary embodiment, the single piece sorting confirmation subroutine includes the controller 40 determining whether the selected robot inadvertently transfers multiple packages from the pick conveyor 14 to the placement conveyor 16 at the same time based on the image data received from the second vision unit 35. If the controller 40 determines to transfer multiple packages, the controller 40 then determines whether the first robot 20 or the second robot 22 is available, such as Figure 8 Similarly, the availability of each robot can be determined based on whether the robot is in place. Based on the determined availability of the first robot 20 and the second robot 22, the controller 40 then communicates instructions to cause the first robot 20 or the second robot 22 to engage and hold a package previously detected in the placement area 17, such as Figure 8 158, 160 in FIG. 15. In some embodiments, the package to be engaged may be selected based on the location of the package on the placement conveyor 16. For example, in some embodiments, the package closest to the center of the placement area 17 may be engaged and held. After holding a package, the controller 40 communicates an instruction (or signal) to cause the confirmation camera 36 to acquire another image of the placement area 17 and effectively restart the confirmation routine. The robot holds the package until the placement conveyor 16 travels, at which time the robot holding the package returns the package to the placement area 17 of the placement conveyor 16, as shown in FIG. Figure 8 As shown in blocks 176 and 178.

[0076] Still refer to Figure 1 , Figure 2 , Figure 5 and Figure 8 In the exemplary embodiment, the single piece sorting confirmation subroutine further includes the controller 40 determining whether the orientation of the package transferred by the first robot 20 or the second robot 22 on the placement conveyor 16 during the package transfer routine meets one or more predetermined criteria (e.g., positioned at a certain angle, positioned upright, etc.) based on the image data received from the second vision unit 35, as shown in decision 162. If the controller 40 determines that the orientation of the package does not meet the predetermined criteria, the controller 40 then determines whether the first robot 20 or the second robot 22 is available, such as Figure 8 Based on the determined availability of the first robot 20 and the second robot 22, the controller 40 then communicates instructions to cause the first robot 20 or the second robot 22 to engage and redirect the package in a manner that meets predetermined criteria, such as Figure 8 As shown in blocks 166, 168 in FIG. Once the package is reoriented, the controller 40 communicates instructions to cause the confirmation camera 36 to acquire another image of the placement area and effectively restart the confirmation routine to confirm that the package has been properly oriented.

[0077] Still refer to Figure 1, Figure 2 , Figure 5 and Figure 8 After confirming that there are no multiple packages in the placement area 17 and the packages in the placement area 17 are oriented correctly, the controller 40 conveys instructions to make the placement conveyor 16 travel a predetermined distance, such as Figure 8 174 in the process. Therefore, any package on the placement conveyor 16 is moved further downstream to make room in the placement area 17 for another package to be transferred. As described above, after the placement conveyor 16 travels, the package held by the first robot 20 or the second robot 22, if applicable, is transferred back to the placement conveyor 16. Therefore, in this exemplary embodiment, after the placement conveyor 16 travels, the controller determines whether the package is held by the first robot 20 or the second robot 22, as shown in FIG. Figure 8 If the controller 40 determines that the package is held by one of the robots, the controller 40 transmits an instruction to cause the robot holding the package to deliver the package to the placement conveyor 16, as shown in the decision 173 and 177 in FIG. Figure 8 After delivery, the controller 40 communicates instructions to cause the confirmation camera 36 to acquire another image of the placement area 17 of the placement conveyor 16 and effectively restart the confirmation routine to confirm that the delivered package has been properly oriented. If the placement conveyor 16 has traveled and the first robot 20 or the second robot 22 is not holding a package, the system 10 will continue to transfer any remaining packages that need to be transferred to the placement conveyor 16 by executing the package assessment subroutine, such as Figure 8 As shown in block 179 of Fig. 9 Further description.

[0078] Now refer to Figure 7 and Fig. 9 , Fig. 9 The package evaluation subroutine outlined in is preferably described above with reference to Figure 7 The package transfer routine described in the embodiment of the present invention is implemented in a part of the package transfer routine described in the embodiment of the present invention, and defines the part, which occurs after the above confirmation routine is executed. Fig. 9 As shown, in this exemplary embodiment, the package assessment subroutine begins when the controller 40 determines whether there are any remaining packages in the system 10 that need to be transferred to the placement conveyor 16, such as Fig. 9 To this end, the processor 42 of the controller 40 evaluates whether the latest image data received from the first vision unit 31 indicates that there is more than one package in the picking area 15, such as Fig. 9 If the controller 40 determines that the latest image data received from the first vision unit 31 does not indicate the presence of more than one package, the controller 40 will communicate instructions to cause the above-mentioned package transfer routine to perform a new cycle (which begins with Figure 7120 in block 120), as indicated in Fig. 9 In some embodiments, if no packages are detected within the pickup area 15 of the pickup conveyor 14 within a predetermined time period and / or after a predetermined number of upstream conveyors 12 and pickup conveyors 14 have traveled, the controller 40 may determine that no packages remain during decision 180 and communicate an instruction to stop operation of the system 10.

[0079] Instead, now refer to Figures 1 to 3 , Figure 5 and Fig. 9 If the controller 40 determines that the latest image data received from the first vision unit 31 indicates that there are multiple packages, the controller 40 will process the image data to determine whether the packages are spaced a predetermined distance (e.g., 200 mm) from each other, such as Fig. 9 184 in the decision. By looking at Figure 2 and Figure 3 Perhaps best demonstrated, in the event that the image data indicates that multiple packages are present, the image data will include data associated with a first package 50a that has been engaged and transferred to the placement conveyor 16 and a second package 50b that remains in the pick up area 15 and needs to be transferred. The predetermined distance can be selected based on the minimum amount of space between the packages required for the first vision unit 31 to discern the first package 50a from the second package 50b and provide accurate position data regarding the location of the second package 50b that remains in the pick up area 15.

[0080] Still refer to Figures 1 to 3 , Figure 5 and Fig. 9 If the controller 40 determines that the first package 50a and the second package 50b are not separated by a predetermined distance, in order to facilitate the generation of more accurate position data of the second package 50b remaining in the pick-up area 15, the controller 40 will convey instructions to start a new cycle of the above-mentioned package transfer routine, thereby causing the target camera 34 to capture an additional image of the second package 50b within the pick-up area 15 and causing the first vision unit 31 to process the image. On the other hand, if the controller 40 determines that the first package 50a and the second package 50b are separated by a predetermined distance, the system 10 skips such additional image capture and processing steps. Instead, the controller 40 will determine which robot has priority in engaging and transferring the second package 50b, and then convey instructions to cause the robot determined to have priority to engage the second package 50b and transfer it to the placement conveyor 16, as shown. Fig. 9 After transferring the second package 50b to the placement conveyor 16, the controller 40 will communicate an instruction to restart the confirmation routine (which is started by Figure 8 150 in FIG. 1 ). Figure 7 , Figure 8 and Fig. 9 The parcel transfer and confirmation routines outlined in the respective sections can then be repeated to transport any remaining parcels within the system 10 that need to be transferred to the placement conveyor 16. By adjusting the engagement of the first vision unit 31 in the manner described above to acquire and process additional images of the pick-up area 15, rather than acquiring and processing new images prior to transferring each parcel located in the pick-up area 15, the system 10 is able to significantly reduce downtime associated with image acquisition and processing and increase parcel transfer throughput. For example, assuming that it takes approximately 250 ms (milliseconds) for the first vision unit 31 to acquire and process an image of the pick-up area 15 and the parcels therein, and that there are 50 instances in an hour where a parcel within the pick-up area 15 meets the above-described spacing conditions, the system 10 will save approximately 12,500 ms (12.5 seconds) of image acquisition and processing time per hour. If it is assumed that the above-described parcel transfer and confirmation routine takes approximately two seconds on average, the system 10 will be able to transfer approximately 6.25 more parcels per hour than if the first vision unit 31 were required to acquire and process an image each time a parcel needs to be transferred.

[0081] Fig.10 yes Figure 1 Another top view of a pick conveyor of the exemplary conveyor system 10.

[0082] Fig.11 is an exemplary subroutine that the system 10 may execute to pick up a package from the pick up area 15 and advance the pick up conveyor 14 during a package transfer routine.

[0083] Now refer to Figure 7 , Fig. 9 and Fig.11 In the exemplary embodiment, the system 10 selectively employs a parcel pick and go subroutine during the transfer of parcels from the pick conveyor 14 to the place conveyor 16 to reduce downtime associated with transferring parcels to the pick area 15 of the pick conveyor 14. In this regard, the pick and go subroutine reduces downtime by causing the pick conveyor 14 to travel at least a calculated distance to transfer parcels located upstream of the pick area 15 (e.g., Fig.10 The package 50d in the first robot 20 is moved to the picking area 15, and then (simultaneously) the first robot 20 or the second robot 22 moves another package (for example, Fig.10 The calculated distance may also be characterized as a "predetermined distance" because the calculated distance is determined before advancing the pick conveyor 14 to move the upstream package to the pick area 15. In the exemplary embodiment, this pick and advance subroutine is performed by the vision and control subsystem 30. Fig.11 The pick-up and travel subroutines outlined in the above referenced Figure 7 The package transfer routine described in the description is implemented and defined in the part. Therefore, it should be understood that Fig.11 The corresponding actions and determinations made during the pick and go subroutines shown in Figure 7 It should also be understood that Fig.11 The corresponding actions and determinations outlined in do not necessarily follow immediately, but in some cases, can be Figure 7 In addition, it should be understood that certain actions or determinations in the package transfer routine outlined in the above are temporarily separated from each other. Fig.11 Some actions of the subroutines outlined in the Figure 7 The actions in the package transfer routine outlined in are consistent or correspond.

[0084] Now refer to Fig.10 and Fig.11 , the pick and go subroutine begins with: the target camera 34 is selectively activated in response to instructions (or signals) transferred from the controller 40 to acquire the pick area 15 and any packages located therein (e.g., Fig.10 50c and 50d) in the image, such as Fig.11 Although indicated by different reference numerals, it will be appreciated that in some embodiments, Fig.11 The selective activation of the target camera 34 indicated by block 196 in Figure 7 Based on the image data received from the first vision unit 31 after processing the image acquired by the target camera 34, the controller 40 continues to identify the location of the package to be transferred to the placement conveyor 16 (e.g., as described above with reference to Figure 7 126, 128, 130 and blocks 132, 134 in the manner described above) and calculating the total distance (as Fig.10 As shown by the double-headed arrow d in FIG. 1 , the pick-up conveyor 14 must travel to pick up the packages located upstream of the pick-up area 15 (e.g., Fig.10 The package 50d) is moved to the pickup area 15, such as Fig.11 In the exemplary embodiment, the total distance d calculated by the controller 40 is based at least in part on image data corresponding to an image obtained by the target camera 34 and received by the controller 40 .

[0085] Still refer to Fig.10 and Fig.11 Before advancing the pick-up conveyor 14 the calculated total distance d, the controller 40 determines whether a single or multiple packages must be transferred from the pick-up area 15 before advancing the pick-up conveyor 14, such as Fig.11As shown in decision 200 in FIG. 4 . If the controller 40 determines that only one package needs to be transferred at the moment (e.g., Fig.10 ), the controller 40 will communicate instructions to cause the package to be engaged and transferred out of the pick-up area 15 by the first robot 20 or the second robot 22, and the controller 40 will communicate instructions to cause the pick-up conveyor to travel the calculated total distance d immediately after the package is removed from the pick-up area 15. However, if the controller 40 determines that the package was not successfully engaged and transferred out of the pick-up area 15 (e.g., as described above with reference to Figure 7 The pick and move routine will be terminated. Fig.10 and Fig.11 If the controller 40 determines that there are multiple packages to be transferred, the controller 40 will continue to determine whether the packages are spaced a predetermined distance (e.g., 200 mm) from each other. Fig.11 If it is determined that the packages are not separated by the predetermined distance, the pick and go subroutine is aborted. Conversely, if the controller 40 determines that the packages are separated by the predetermined distance, the controller 40 will communicate instructions to cause each package to be engaged and transferred out of the pick area 15 by the first robot 20 or the second robot 22, and also cause the pick conveyor 14 to travel the calculated total distance d immediately after the last package in the pick area 15 is transferred out, as shown in decision 202. Fig.11 However, if the controller 40 determines that any package has not been successfully engaged and transferred out of the pickup area 15 (e.g., as described above with reference to FIG. Figure 7 ), the pick and move routine will be aborted.

[0086] Although Fig.11 The subroutines outlined in do not reflect this, but in certain embodiments, if during the travel of the pick conveyor 14, the controller 40 receives a reading from the sensor 62 indicating that one or more packages are located within the pick area 15, the travel of the pick conveyor 14 may be stopped prematurely to avoid package overflow (e.g., packages are transferred off the pick conveyor 14 and / or onto the placement conveyor 16). In this regard, upon receiving a reading from the sensor 62 indicating that one or more packages are present in the pick area 15, the controller 40 will communicate an instruction to stop the travel of the placement conveyor 16. In addition, embodiments are also contemplated in which the upstream conveyor 12 also travels simultaneously with the pick conveyor 14 during the pick and travel subroutines.

[0087] As an example of improved parcel throughput, during a preliminary evaluation of the throughput generated by the system 10 described above executing the routines and subroutines in the manner described above over a predetermined time interval, compared to the throughput data generated by a system that only employed a single robotic piece sorter to piece-sort and transfer parcels from one conveyor to another conveyor over the same time interval, it was found that the system 10 of the present invention was able to piece-sort and transfer a total of approximately 2,000 parcels, while the single robotic piece sorter system was only able to piece-sort and transfer a total of approximately 1,500 parcels. Based on the above data, the parcel transfer throughput of the system 10 of the present invention was improved by approximately 25% compared to the single robotic piece sorter system.

[0088] It should also be understood that the first robot 20, the second robot 22, and the vision and control subsystem 30 may be used in conjunction with alternative conveyor arrangements and in conjunction with some or all of the similarly executed routines and subroutines described above to accommodate different sorting applications and / or to further increase parcel transfer throughput. In this regard, Figures 12 to 19 Various alternative conveyor systems 300, 400, 500, 600, 700, 800, 900, 1000 are shown that also utilize multiple robotic piece sorters to transfer and piece sort packages. Throughout this application, like components have like reference numerals. Although Figures 12 to 18 1000, but it is understood that the various conveyor systems 300, 400, 500, 600, 700, 800, 900, 1000 shown in these figures will also include and utilize the vision and control subsystem 30 described above. In addition, to avoid unnecessary repetition, it is understood that some embodiments are contemplated in which some or all of the respective conveyors mentioned in the following discussion of the systems 300, 400, 500, 600, 700, 800, 900, 1000 are operably connected to the controller 40 of the vision and control subsystem 30 so that the controller 40 can communicate instructions to control the operation of these conveyors.

[0089] Now refer to Fig.12 , the conveyor system 300 (or system 300) includes a pick-up conveyor 14, a first robot 20 and a second robot 22. However, unlike the above reference Figure 1 and Figure 2Unlike the described system 10, the placement conveyor in the system 300 is defined by a plurality of conveyors, and thus can be characterized as comprising a plurality of conveyors. Specifically, in this exemplary embodiment, the placement conveyor of the system 300 includes: a first placement conveyor 316, which receives a package from the first robot 20; and a second placement conveyor 318, which receives a package from the second robot 22 and is placed side by side with the first placement conveyor 316. Since the first robot 20 and the second robot 22 transfer the packages to different conveyors, the rate of transferring the packages from the picking conveyor 14 is further increased because two different packages (one transferred by the first robot 20 and the other transferred by the second robot 22) can be transferred simultaneously or in close proximity without the risk of two packages being stacked together or placed in a non-single-piece sorting manner. In addition, compared with the above reference Figure 1 and Figure 2 Unlike the described system 10, in the system 300, the first robot 20 and the second robot 22 are mounted on the ground in an upright rather than an inverted position.

[0090] Now refer to Fig.13 , and refer to the above Fig.12 Like the system 300 described above, the conveyor system 400 (or system 400) also includes placement conveyors 416, 418, which are defined by and can therefore be characterized as including the following: a first placement conveyor 416 that receives a package from the first robot 20; and a second placement conveyor 418 that receives a package from the second robot 22. However, as described above with reference to Fig.12 Unlike the described system 300, in this system 400, the first placement conveyor 416 and the second placement conveyor 418 are arranged linearly so that the packages transferred to the first placement conveyor 416 are subsequently transferred downstream to be ultimately received by the second placement conveyor 418. In this exemplary embodiment, the system 400 further includes a buffer conveyor 420 located between the first placement conveyor 416 and the second placement conveyor 418, and the buffer conveyor 420 can selectively travel (i.e., move a predetermined distance and / or drive for a predetermined period of time) to adjust the rate at which the packages unloaded by the first placement conveyor 416 are subsequently transferred to the second placement conveyor 418. In fact, by using the buffer conveyor 420, the first robot 20 can continue to place packages on the first placement conveyor 416, and then these packages are transferred downstream to the second placement conveyor 418 through the buffer conveyor 420, even if the second robot 22 is not operating. Additionally, it should be noted that more than one buffer conveyor may be placed between the first placement conveyor 416 and the second placement conveyor 418 , each buffer conveyor being independently controlled to better control the movement of packages from the first placement conveyor 416 to the second placement conveyor 418 .

[0091] Still refer to Fig.13 , in the system 400, the upstream conveyor 412 is a chute that defines an inclined path along which the bulk package flow can slide downward (under the action of gravity) toward the pick-up conveyor 14. Therefore, in this exemplary embodiment, the upstream conveyor 412 does not need to travel in order to deliver the packages loaded thereon to the pick-up conveyor 14. The foregoing arrangement can increase the package transfer throughput by reducing the downtime associated with the pick-up conveyor 14, thereby reducing the time that the first robot 20 and the second robot 22 wait to receive the package from the upstream conveyor 412.

[0092] Now refer to Fig.14 , the conveyor system 500 (or system 500) includes the above reference Fig.12 The system 300 described above has the same components as those of the system 300 and further includes Figure 1 , Figure 2 and Figure 5 The upstream conveyor 12 of the described system 10, the first downstream conveyor 520 located downstream of the first placement conveyor 316, and the second downstream conveyor 522 located downstream of the second placement conveyor 318. In the exemplary embodiment, the second downstream conveyor 522 is defined by the first inductive conveyor, which receives the packages unloaded from the second placement conveyor 318 and the first downstream conveyor 520. In the exemplary embodiment, the first downstream conveyor 520 is defined by the second inductive conveyor 520a and the merging conveyor 520b, and can therefore be characterized as including the second inductive conveyor 520a and the merging conveyor 520b. The second inductive conveyor 520a is located downstream of the first placement conveyor 316, so that the packages unloaded from the first placement conveyor 316 are guided to the second inductive conveyor 520a. The merging conveyor 520b has a proximal end located downstream of the second induction conveyor 520a to receive packages unloaded therefrom, and has a distal end located near the second downstream conveyor 522 so that the packages unloaded from the merging conveyor 520b are guided onto the second downstream conveyor 522.

[0093] Now refer to Fig.15 , the conveyor system 600 (or system 600) includes: Figure 1 , Figure 2 and Figure 5 The upstream conveyor 12 of the system 10 described above; Fig.12 and Fig.14The described systems 300 and 500 include first and second placement conveyors 316, 318; a first induction conveyor 620; a second induction conveyor 622 and a throw and catch conveyor 624. Unlike the above-described systems 10, 300, 400 and 500, in the system 600, the pick-up conveyor is defined by a first pick-up conveyor 613 and a second pick-up conveyor 614, and thus can be characterized as including the first pick-up conveyor 613 and the second pick-up conveyor 614. The first pick-up conveyor 613 is located immediately downstream of the upstream conveyor 12, and the second pick-up conveyor 614 is located immediately downstream of the first pick-up conveyor 613. Therefore, in this exemplary embodiment, the packages that are not transferred from the first pick-up conveyor 613 are subsequently directed to the second pick-up conveyor 614. In this exemplary embodiment, the first robot 20 is configured to engage and transfer the package from the first pick conveyor 613 to the first placement conveyor 316, and the second robot 22 is configured to engage and transfer the package from the second pick conveyor 614 to the second placement conveyor 318.

[0094] Still refer to Fig.15 , the first induction conveyor 620 is located immediately downstream of the first placement conveyor 316, so that the packages unloaded from the first placement conveyor 316 are directed onto the first induction conveyor 620. Similarly, the second induction conveyor 622 is located immediately downstream of the second placement conveyor 318, so that the packages unloaded from the second placement conveyor 318 are directed onto the second induction conveyor 622. The throw and catch conveyor 624 is located immediately downstream and transfers the packages in a different direction, in this case, the direction is generally perpendicular to the direction in which the first induction conveyor 620 and the second induction conveyor 622 transfer the packages. Due to this change in direction, the packages unloaded from the first induction conveyor 620 or the second induction conveyor 622 to the throw and catch conveyor 624 are automatically redirected in a manner more suitable for the subsequent sorting process. For example, in some embodiments, the throw and catch conveyor 624 can be used to redirect parcels unloaded from the first induction conveyor 620 and the second induction conveyor 622 so that the parcels are more easily loaded into an inclined tray conveyor (not shown) located downstream of the throw and catch conveyor 624. The automatic redirection facilitated by the throw and catch conveyor 624 can thus be used to reduce or alleviate the need for the first robot 20 and the second robot 22 to redirect parcels transferred to the first placement conveyor 316 and the second placement conveyor 318, respectively.

[0095] Now refer to Fig.16 The conveyor system 700 (or system 700) includes the above reference Fig.15The system 600 is similar to the conveyor arrangement described above, except that the conveyor is downstream of the first placement conveyor 316 and the second placement conveyor 318. In this regard, the system 700 includes a first strip conveyor 720 immediately downstream of the first placement conveyor 316 and a second strip conveyor 722 immediately downstream of the second placement conveyor 318. The first strip conveyor 720 and the second strip conveyor 722 each include a plurality of conveyor belts that can be driven at different speeds to redirect the packages in a desired manner when transported by the first strip conveyor 720 and the second strip conveyor 722. The system further includes a center merge conveyor 724 that is immediately downstream of the first strip conveyor 720 and the second strip conveyor 722 and is configured to collect the packages unloaded from these conveyors. The automatic redirection facilitated by the first strip conveyor 720, the second strip conveyor 722, and the center merge conveyor 724 can be used to reduce or alleviate the need for the first robot 20 and the second robot 22 to redirect packages transferred to the first placement conveyor 316 and the second placement conveyor 318, respectively. In the exemplary embodiment, the system 700 further includes an inductive conveyor 726 located immediately downstream of the center merge conveyor 724 to divert packages unloaded from the center merge conveyor 724 for subsequent processing.

[0096] Now refer to Fig.17 The conveyor system 800 (or system) includes the above reference Fig.16 The same conveyor arrangement as described above for system 700, except that the central merging conveyor 724 and the inductive conveyor 726 are removed and replaced by the above referenced conveyor. Fig.15 The throw and catch conveyor 624 of the described system 600 is replaced. The automatic redirection facilitated by the first belt conveyor 720, the second belt conveyor 722, and the throw and catch conveyor 624 can be used to reduce or alleviate the need for the first robot 20 and the second robot 22 to redirect packages transferred to the first placement conveyor 316 and the second placement conveyor 318, respectively.

[0097] Now refer to Fig.18 , the conveyor system 900 (or system 900) includes the above reference Fig.13 The system 400 described above is similar to the conveyor, except that a different upstream conveyor 912 is used, and the positioning of the first placement conveyor 916 and the second placement conveyor 918 relative to the buffer conveyor 920 is reversed. Fig.13 Similar to the system 400 described above, the buffer conveyor 920 controls the movement of packages from the first placement conveyor 916 to the second placement conveyor 918. In this regard, in at least some embodiments, the buffer conveyor 920 will also be operably connected to the controller 40 ( Figure 5) and operates in response to instructions (signals) received from the controller 40. In addition, it should be noted again that more than one buffer conveyor can be placed between the first placement conveyor 416 and the second placement conveyor 418, each buffer conveyor being controlled by the controller 40 ( Figure 5 ) Independent control.

[0098] Still refer to Fig.18 , and refer to the above Fig.13 Similar to the upstream conveyor 412 of the described system 400, the upstream conveyor 912 in the system 900 is also a chute that defines an inclined path along which the bulk package flow can slide downward (under the action of gravity). However, in the system 900, instead of transferring the bulk package flow to a single pick-up conveyor, the chute of the upstream conveyor 912 is divided into two parts 912a, 912b to divide the bulk package flow into discrete batches, which are directed to the first pick-up area 914a or the second pick-up area 914b. In this exemplary embodiment, the first robot 20 is configured to engage and transfer the package from the first pick-up area 914a to the first placement conveyor 916 (in response to instructions (signals) received from the controller 40), and the second robot 22 is configured to engage and transfer the package from the second pick-up area 914b to the second placement conveyor 918 (in response to instructions (signals) received from the controller 40). In this regard, the first pick-up area 914a is aligned with the first placement conveyor 916 and the second pick-up area 914b is aligned with the second placement conveyor 918. Thus, in the system 900, the first robot 20 and the second robot 22 do not pick up packages from a single area (where all packages in the bulk package stream are delivered), but rather pick up packages from different areas (where discrete batches of packages in the bulk package stream are received).

[0099] Still refer to Fig.18In the exemplary embodiment, the first pick-up area 914a and the second pick-up area 914b are defined by a first trapdoor rejection mechanism 960a and a second trapdoor rejection mechanism 960b, respectively. Each trapdoor rejection mechanism 960a, 960b is configured to selectively switch between a closed position and an open position. In use, each corresponding trapdoor rejection mechanism 960a, 960b is usually in a closed position to temporarily support a package directed to the trapdoor rejection mechanism before being subsequently transferred by the first robot 20 or the second robot 22, but can be selectively switched to an open position to allow a package identified as "non-transferable" to pass through the trapdoor rejection mechanism 960a, 960b. Therefore, each trapdoor rejection mechanism 960a, 960b is operably connected to the controller 40 so that each trapdoor rejection mechanism 960a, 960b can selectively switch between a closed position and an open position in response to an instruction (or signal) communicated from the controller 40. Suitable trapdoor rejection mechanisms that may be used within system 900 include those described in US Patent Application Serial No. 17 / 748,479, which is incorporated herein by reference.

[0100] Still refer to Fig.18 In this exemplary embodiment, the package is delivered to the first robot 20 and the second robot 22 along a first direction, and the first placement conveyor 916 and the second placement conveyor 918 receive the package and transfer it away from the first robot 20 and the second robot 22 along a second direction substantially perpendicular to the first direction.

[0101] Now refer to Fig.19 , the conveyor system 1000 (or system 1000) is similar to the above reference Fig.18 The conveyor systems described are substantially the same. The upstream conveyor 1012 in the system 1000 is also a chute that defines an inclined path along which a flow of bulk packages can slide downward (under the action of gravity). In addition, the chute of the upstream conveyor 1012 is divided into two parts 1012a, 1012b to divide the flow of bulk packages into discrete batches, which are directed to the first pick-up area 1014a or the second pick-up area 1014b. In this exemplary embodiment, the first robot 20 is again configured to engage the package and transfer it from the first pick-up area 1014a to the first placement conveyor 1016 (in response to instructions (signals) received from the controller 40), and the second robot 22 is configured to engage the package and transfer it from the second pick-up area 1014b to the second placement conveyor 1018 (in response to instructions (signals) received from the controller 40). The buffer conveyor 1020 controls the movement of the package from the first placement conveyor 1016 to the second placement conveyor 1018. In this regard, in at least some embodiments, the buffer conveyor 1020 will also be operably connected to the controller 40 ( Figure 5) and operates in response to instructions (signals) received from the controller 40.

[0102] Still refer to Fig.19 In this exemplary embodiment, the first pick-up area 1014a and the second pick-up area 1014b are again defined by a first trapdoor rejection mechanism 1060a and a second trapdoor rejection mechanism 1060b, respectively. Fig.18 As in the exemplary system 900 described above, each trapdoor reject mechanism 1060a, 1060b of the exemplary system 1000 is configured to selectively transition between a closed position and an open position. In use, each respective trapdoor reject mechanism 1060a, 1060b is normally in a closed position to temporarily support a package directed to the trapdoor reject mechanism prior to subsequent transfer by the first robot 20 or the second robot 22, but can be selectively transitioned to an open position to allow a package identified as "non-conveyable" to pass through the trapdoor reject mechanism 1060a, 1060b.

[0103] Still refer to Fig.19 In the exemplary embodiment, an additional conveyor module 1080 is incorporated into the second placement conveyor 1018, downstream of the location where the second robot 22 places the package on the second placement conveyor 1018. The additional conveyor module 1080 is configured to transfer packages along the longitudinal axis of the placement conveyor 1018 and selectively transfer packages in a transverse direction relative to the longitudinal axis, such as Fig.19 As shown by arrow A in FIG. 1080 , for example, module 1080 may be in the form of a conveyor belt with integrated rollers that enable movement in the lateral direction. As another example, the module may be a move and transfer module marketed and sold by Regal Beloit, Inc. of the United States under the registered trademark MODSORT®. By using this module 1080, packages may be selectively removed from the package flow on the second placement conveyor 1018. In this regard, in at least some embodiments, module 108 will also be operably connected to controller 40 ( Figure 5 ) and operates in response to instructions (signals) received from the controller 40. For example, if a package is successfully engaged and transferred by the first robot 20 or the second robot 22, but is subsequently determined to be undeliverable for some reason (e.g., too heavy), the module 1080 can be activated to move the package in a lateral direction, where the package can be discharged into a reject slot (not shown) or otherwise delivered to another location for subsequent processing.

[0104] Those skilled in the art will recognize that other embodiments and implementations are possible without departing from the teachings of the present invention. This detailed description, especially the specific details of the exemplary embodiments and implementations disclosed therein, is given primarily for clarity of understanding, and no unnecessary limitations should be understood therefrom, as modifications will be apparent to those skilled in the art after reading this disclosure, and modifications may be made without departing from the spirit or scope of the present invention.

Claims

1. A conveyor system comprising: the first robotic single-piece sorter; a second robotic single piece sorter; a pick area from which parcels in a stream of bulk parcels can be engaged and transferred by either the first robotic piece sorter or the second robotic piece sorter; a first placement conveyor located downstream of the pick area and configured to receive packages diverted by the first robotic piece sorter; a second placement conveyor located downstream of the pick area and the first placement conveyor, the second placement conveyor configured to receive packages transferred by the second robotic piece sorter and further configured to receive packages from the first placement conveyor; a buffer conveyor, located between the first placement conveyor and the second placement conveyor, for regulating the rate at which packages unloaded by the first placement conveyor are transferred to the second placement conveyor; as well as A vision and control subsystem operatively connected to the first robotic piece sorter, the second robotic piece sorter, and the buffer conveyor, the vision and control subsystem comprising: a first camera for acquiring one or more images of the pickup area and any packages located in the pickup area, and A controller including a processor for executing instructions stored in a memory component to (i) receive and process image data corresponding to an initial image of the pick area captured by the first camera, (ii) selectively communicate instructions to the first robotic piece sorter to cause the first robotic piece sorter to engage a package in a bulk package flow located in the pick area and transfer the package to the first placement conveyor, (iii) selectively communicate instructions to the second robotic piece sorter to cause the second robotic piece sorter to engage a package located in the pick area and transfer the package to the second placement conveyor, and (iv) selectively communicate instructions to the buffer conveyor to cause the buffer conveyor to travel and transfer packages from the first placement conveyor to the second placement conveyor.

2. The conveyor system of claim 1, wherein: The first robot single piece sorter and the second robot single piece sorter are both six-axis robotic arms.

3. The conveyor system of claim 1, wherein: The picking area includes a first picking area and a second picking area, wherein the first robotic piece sorter engages a package located in the first picking area and transfers the package to the first placement conveyor, and the second robotic piece sorter engages a package located in the second picking area and transfers the package to the second placement conveyor.

4. The conveyor system of claim 3, wherein: The first pick area is aligned with the first placement conveyor, and wherein the second pick area is aligned with the second placement conveyor.

5. The conveyor system of claim 3, wherein: The first pick-up area is defined by a first portion of the chute and the second pick-up area is defined by a second portion of the chute.

6. The conveyor system of claim 1, wherein: Packages are delivered to the first robotic piece sorter and the second robotic piece sorter along a first direction, and wherein the first placement conveyor and the second placement conveyor receive the packages and transfer the packages away from the first robotic piece sorter and the second robotic piece sorter along a second direction, the second direction being substantially perpendicular to the first direction.

7. The conveyor system of claim 1, wherein: The buffer conveyor includes a plurality of buffer conveyors, each of which is independently controlled by the vision and control subsystem to control the movement of packages from the first placement conveyor to the second placement conveyor.

8. The conveyor system of claim 1 , further comprising an additional conveyor module incorporated into the second placement conveyor and configured to transfer packages both along a longitudinal axis of the second placement conveyor and selectively in a transverse direction relative to the longitudinal axis.

9. A conveyor system comprising: the first robotic single-piece sorter; a second robotic single piece sorter; a pick area including a first pick area and a second pick area, packages in a bulk package flow from the first pick area being engageable and diverted by the first robotic piece sorter, and packages in a bulk package flow from the second pick area being engageable and diverted by the second robotic piece sorter; a first placement conveyor located downstream of the pick area and configured to receive packages diverted from the first pick area by the first robotic piece sorter; a second placement conveyor located downstream of the pick-up zone and the first placement conveyor, the second placement conveyor being configured to receive packages transferred from the second pick-up zone by the second robotic piece sorter and further configured to receive packages from the first placement conveyor; as well as A buffer conveyor, located between the first placement conveyor and the second placement conveyor, is used to adjust the rate at which packages unloaded from the first placement conveyor are transferred to the second placement conveyor.

10. The conveyor system of claim 9, further comprising: a vision and control subsystem operatively connected to the first robotic piece sorter, the second robotic piece sorter, and the buffer conveyor, the vision and control subsystem comprising: a first camera for acquiring one or more images of the pickup area and any packages located in the pickup area, and A controller including a processor for executing instructions stored in a memory component to (i) receive and process image data corresponding to an initial image of a pick area captured by the first camera, (ii) selectively communicate instructions to the first robotic piece sorter to cause the first robotic piece sorter to engage a package in a bulk package stream located in the first pick area and transfer the package to the first placement conveyor, (iii) selectively communicate instructions to the second robotic piece sorter to cause the second robotic piece sorter to engage a package located in the second pick area and transfer the package to the second placement conveyor, and (iv) selectively communicate instructions to the buffer conveyor to cause the buffer conveyor to travel and transfer packages from the first placement conveyor to the second placement conveyor.

11. The conveyor system of claim 9, wherein: The first robot single piece sorter and the second robot single piece sorter are both six-axis robotic arms.

12. The conveyor system of claim 9, wherein: The first pick area is aligned with the first placement conveyor, and wherein the second pick area is aligned with the second placement conveyor.

13. The conveyor system of claim 9, wherein: The first pickup area is defined by a first portion of the chute, and the second pickup area is defined by a second portion of the chute.

14. The conveyor system of claim 9, wherein: Packages are delivered to the first robotic piece sorter and the second robotic piece sorter along a first direction, and wherein the first placement conveyor and the second placement conveyor receive the packages and transfer the packages away from the first robotic piece sorter and the second robotic piece sorter along a second direction substantially perpendicular to the first direction.

15. The conveyor system of claim 10, wherein: The buffer conveyor includes a plurality of buffer conveyors, each of which is independently controlled by the vision and control subsystem to control the movement of packages from the first placement conveyor to the second placement conveyor.

16. The conveyor system of claim 9, further comprising an additional conveyor module incorporated into the second placement conveyor and configured to divert packages both along a longitudinal axis of the second placement conveyor and selectively in a transverse direction relative to the longitudinal axis.

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