Material handling device with article scanning station

Abstract

Methods and apparatus for delivering items to a plurality of storage locations are provided. Articles are fed into the device at an input station having a scanning station. The scanning station evaluates one or more characteristics of each item. The item is then loaded onto a delivery mechanism, which delivers the item to the storage location. Once in the appropriate storage location, the delivery mechanism unloads the item to the storage location and returns to receive another item to be delivered.

Description

[0001] Related Applications

[0002] This application claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application No. 63 / 349,587, filed on June 6, 2022. The entire disclosure of the foregoing application is incorporated herein by reference. Technical Field

[0003] The present invention relates to a material handling system, and more particularly to a system operable to receive and sort articles using a plurality of automatic carriers. The system may include a station for scanning articles to identify characteristics of the sorted articles. Background Art

[0004] Sorting and retrieving items to fulfill customer orders can be laborious and time consuming. Many large organizations have vast storage areas where many items are stored. Sorting and retrieving items from hundreds or thousands of storage areas requires a great deal of labor to perform manually. In many areas, automated picking has been developed to reduce labor costs and improve customer service by reducing the time it takes to fulfill customer orders.

[0005] In many automated material handling systems, the throughput of the material handling system is determined, among other things, by the rate at which each object is accurately identified and fed into the system. One problem that can arise is distinguishing pieces as the feed rate increases. It is therefore desirable to provide a system for accurately reading items to be sorted at a high rate while also distinguishing adjacent pieces in the work process. Summary of the invention

[0006] This Summary is provided to introduce some concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] The present invention provides aspects that may form part of a material handling system. The system may include one or more of the aspects of the present invention, as further described below.

[0008] According to one aspect, the present invention may provide an apparatus for sorting a plurality of articles. The apparatus includes a plurality of sorting destinations and a plurality of delivery carriers for delivering the articles to the sorting destinations. A controller provides a control signal for controlling the operation of the carriers.

[0009] According to another aspect, the present invention may include a track system for guiding a delivery vehicle to a sorting destination.

[0010] According to another aspect, the present invention may include a scanner for scanning the articles to detect a characteristic of each article, wherein the detected characteristic is a characteristic determined for the article and used by the controller to identify a sorting destination to which the article is to be sorted.

[0011] According to another aspect of the present invention, a method for sorting a plurality of articles is provided. The method may include the steps of loading the articles onto a carrier for delivery to an output bin and driving the carrier to the output bin. The method may also include the steps of unloading the articles from the carrier into the output bin and monitoring the position of the articles on the carrier.

[0012] In another aspect, the present invention provides an apparatus for sorting a plurality of articles, comprising a plurality of delivery vehicles guided by a track to deliver the articles to one or more destinations. The apparatus may include a loading station for loading the articles onto the vehicles. Before the articles are loaded onto the vehicles, the articles may be analyzed to detect a first characteristic. A recirculation system may be provided for recirculating the articles from points along the track to an input station.

[0013] According to another aspect, a method for delivering an item to one or more destinations is provided. The method may include the step of conveying the item through a first conductive wall. The first conductive wall separates a first conveying section from a second conveying section. As the item is conveyed through the first conductive wall, the item may be conveyed under the first wall or through an opening in the first conductive wall. An RFID scanner scans an RFID tag on the first item on the second conveying section while the first item is supported on a non-conductive support. A destination of the first item may be determined based on the step of scanning the RFID tag.

[0014] The method optionally includes the step of conveying the first article through a second conductive wall separating the second conveying section from the third conveying section.When the article is conveyed through the second conductive wall, the article may be conveyed under the second wall or through an opening in the second conductive wall.

[0015] The method may include the step of loading the items from the third conveying section onto a delivery mechanism. The delivery mechanism may be displaced to deliver the items to a determined destination. After the delivery mechanism is displaced to the determined destination, the items may be unloaded into the delivery destination.

[0016] According to another aspect, a system includes a material handling device including an input station having a conveyor and a scanning station. The conveyor may include a first section for receiving an article, a second section for receiving the article from the first section, and a third section for receiving the article from the second section. The second section may include a non-conductive element for supporting the article on the second section.

[0017] The scanning station can be configured to scan items on the second segment of the conveyor. Optionally, the scanning station can include one or more conductive walls and an RFID scanner along the second segment. For example, the scanning station can include a first conductive wall that extends across the conveyor to separate the first segment from the second segment. Similarly, the scanning station can include a second conductive wall that extends across the conveyor to separate the second segment from the third segment.

[0018] The system may further include a delivery mechanism for receiving one of the items from the third segment of the conveyor and delivering the item to the storage location. Optionally, the system further includes a central controller operable to receive information about the identification of the item scanned in the scanning station from the scanning station. Based on the scanned information, the central controller may be configured to determine the storage location of the item. Optionally, the central controller provides a control signal to the delivery mechanism to deliver the item to the determined storage location.

[0019] In yet another embodiment, the system may include a conveyor and a delivery mechanism for delivering items from the conveyor to a storage location. When the items are conveyed toward the delivery mechanism, the RFID scanner can scan the RFID tags on the items. The system may include a housing positioned along the conveyor. Optionally, the housing includes a first wall that extends across the width of the conveyor and is configured to allow items on the conveyor to pass from an input position to a scanning area. The first wall is preferably formed of a conductive material. The housing may include a second wall that extends across the width of the conveyor and is spaced from the first wall so that the scanning area is between the first wall and the second wall. Optionally, the second wall is configured to allow items on the conveyor to pass from the scanning area to a loading position. Preferably, the second wall is formed of a conductive material.

[0020] The conveyor of the system may be configured such that in the scanning area, the article is supported on a movable surface to move the article through the scanning area. The system may include a fixed support surface for supporting the movable surface. Preferably, the movable surface and the fixed support surface are formed of a non-conductive material.

[0021] In one embodiment, the system may include a conveyor having an input area configured so that items in the input area are supported on a movable surface and a fixed support surface supporting the movable surface. The fixed support may be formed from any of a variety of materials, but preferably, the support surface is formed from a conductive material, such as a metal.

[0022] Similarly, the system may include a conveyor having an output area configured such that items in the output area are supported on a movable surface and a fixed support surface supporting the movable surface. The fixed support may be formed from any of a variety of materials, but preferably the support surface is formed from an electrically conductive material, such as a metal.

[0023] The system may include a central controller configured to operate the RFID scanner to scan an article while the article is between the first conductive wall and the second conductive wall and the article is located on the non-conductive fixed support. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The foregoing summary and the following detailed description of the preferred embodiments of the present invention will be best understood when read in conjunction with the accompanying drawings, wherein like reference numerals will be used throughout the drawings to refer to the same or like parts:

[0025] Figure 1 is a perspective view of a material handling device incorporating aspects of the present invention.

[0026] Figure 2 yes Figure 1 A side view of a track of an illustrated material handling device.

[0027] Figure 3 yes Figure 1 A partially cutaway plan view of an illustrated material handling device.

[0028] Figure 4 yes Figure 1 A side elevation view, partially cut away, of an illustrated material handling device.

[0029] Figure 5 yes Figure 4 An enlarged partial side elevational view of an illustrated material handling device.

[0030] Figure 6 yes Figure 5 An enlarged partial cross-sectional view of an illustrated material handling device. DETAILED DESCRIPTION

[0031] Some parts of the following detailed description are presented according to the operation of the binary digital signal stored in the memory of a specific device or a special computing device or platform. In the context of this specific specification, the term "specific device" etc. includes a general-purpose computer, which is programmed to perform a specific function according to the instructions from the program software. In this case, the operation or processing involves the physical manipulation of physical quantities. Usually, although not necessarily, such an amount can take the form of an electrical signal or magnetic signal that can be stored, transferred, combined, compared or otherwise manipulated. Mainly for general reasons, it has been proven to be convenient sometimes to refer to such signals as bits, data, values, elements, symbols, characters, items, numbers, etc. However, it should be understood that all of these or similar terms are associated with appropriate physical quantities and are merely convenient labels. Unless otherwise specifically stated, as will be apparent from the following discussion, it should be understood that throughout this specification, discussions using terms such as "processing", "calculation", "determination" refer to the actions or processes of specific devices (such as special-purpose computers or similar special-purpose electronic computing devices). Thus, in the context of the present invention, a special purpose computer or similar special purpose electronic computing device is capable of manipulating or transforming signals, which are typically represented as physical electronic or magnetic quantities within the memory, register or other information storage device, transmission device or display device of the special purpose computer or similar special purpose electronic computing device.

[0032] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0033] Reference now Figures 1 to 3 , an apparatus for sorting articles is generally indicated at 10. The apparatus 10 includes a plurality of delivery carriers 200 that travel along a track system 100 to deliver articles to a plurality of destinations or sorting locations, such as an output bin 45. The articles are loaded onto the carriers at a loading station 165, where each carrier receives articles to be delivered to a bin 45. An inlet station 50 continuously feeds the articles to the loading station 165. The inlet station 50 may include one or more scanning elements for detecting one or more characteristics of the articles.

[0034] The carrier 200 travels from the loading station 165 along the track 110 to the destination. The track may include a horizontal upper rail 135 and a horizontal lower rail 140 operating as a return leg. A plurality of parallel vertical track legs 130 may extend between the upper rail and the lower return leg. The boxes 45 may be arranged in a row between the vertical track legs 130. Alternatively, the boxes may be arranged in multiple rows between the vertical track legs.

[0035] The vehicle 200 is a semi-autonomous vehicle that may have an onboard power source and an onboard motor to drive the vehicle along the track 110. The vehicle may include a loading / unloading mechanism, such as a conveyor 212, for loading pieces onto and unloading pieces from the vehicle.

[0036] Since the system 10 includes multiple vehicles 200, the positioning of the vehicles is controlled to ensure that different vehicles do not collide with each other. In one embodiment, the system 10 uses a central controller 350 that tracks the position of each vehicle 200 and provides control signals to each vehicle to control the advancement of the vehicle along the track. The central controller 350 can also control the operation of various elements along the track, such as a door 150 that redirects a vehicle from a horizontal direction of travel to a vertical direction of travel or vice versa.

[0037] Intake Station

[0038] At the introduction station 50, articles are introduced into the system by continuously loading the articles onto the carrier 200. In one embodiment, each article is scanned at the introduction station to detect one or more features of the article. These features are used to determine the identity of the article. Once the article is identified, various characteristics of the article can be retrieved from a central database, and the article can then be processed based on the known characteristics of the article. For example, the introduction station 50 may include a scanning station 80 that scans a product code such as a bar code. Once the product code is determined, the system retrieves information about the product from the central database. This information is then used to control further processing of the article, as discussed further below.

[0039] like Figure 1 and Figures 3 to 6 As shown, the intake station 50 may include a scanning station 70 for automatically detecting the characteristics of the item. Specifically, the intake station 70 may include an input conveyor 52 for receiving the item and conveying the item to the scanning station 70 operable to detect one or more physical characteristics of the item. The loading conveyor 58 conveys the item from the scanning station 70 to the loading station 165, where the item is loaded onto a carrier 200 or transferred to a reject box 325.

[0040] The input conveyor 52 can be any of a variety of conveying devices designed to convey articles. In particular, the input conveyor can be designed to receive articles dropped onto the conveyor. For example, the input conveyor 52 can be a horizontal conveyor belt or a horizontal roller track formed by a plurality of generally horizontal rollers that are driven to advance the articles along the conveyor and away from the rollers.

[0041] The input conveyor 52 can be configured so that the operator can select items from the supply of items located adjacent to the input conveyor. For example, a separate supply conveyor can deliver a stable stream of items to the introduction station 50. The operator can continuously select items from the supply conveyor and place the items on the input conveyor 52. Alternatively, a large container of items can be placed adjacent to the input conveyor 52, such as a box or other container. The operator can select items one at a time from the supply box and place each item on the input conveyor. Further, the input conveyor 52 can cooperate with a supply assembly that continuously supplies items to the input conveyor. For example, the supply conveyor can transmit a continuous stream of items toward the input conveyor 52. The input conveyor can include a sensor for sensing when the items are transmitted away from the input conveyor. In response, the system can control the operation of both the supply conveyor and the input conveyor 52 to drive the items forward from the supply conveyor to the input conveyor. In this way, the items can be manually supplied to the input conveyor by the operator or automatically supplied to the input conveyor by a separate supply mechanism that can be operated to supply items to the input conveyor.

[0042] The ingestion station may include a scanning station 70 for detecting one or more characteristics of each item prior to being loaded onto a carrier for delivery or sorting.

[0043] Various factors can be detected to evaluate how the item will be handled. For example, the item usually needs to be identified so that the system can determine the location or box to which the item is to be delivered. This is usually done by determining the unique product code of the item. The system may include a scanning element for scanning product identification marks on the product. By way of example, the item can be marked with one or more of a variety of marks, including but not limited to machine-readable optical labels, such as bar codes (e.g., QR or UPC codes), printed alphanumeric characters, or unique graphic identifiers. The scanning station 70 may include a scanner or reader for reading such markings. For example, a barcode reader, an optical reader, or an RFID reader may be provided to scan the item to read the identification mark.

[0044] Once the product identification mark is determined (manually or automatically), the system retrieves information about the product and then controls the further processing of the item based on the information stored in the central database.

[0045] As can be seen above, a variety of different input mechanisms can be used to attempt to determine product identification marks on an item. In the present example, the scanning system 70 includes one or more optical readers that are operable to scan the item to obtain optical image data of the item. The system then processes the optical image data to detect the presence of product identification marks. If a product identification mark is detected, the system analyzes the mark to determine a product identification number or code.

[0046] For example, Figure 1 to Figure 2 and Figure 4 As shown in the embodiment of FIG. 1 , the scanning station 70 may include a plurality of scanning elements 85 positioned along the feed conveyor 70. The imaging elements are spaced apart from each other and arranged around the feed conveyor so that the scanning elements can scan the entire article as the article is conveyed toward the loading station 165. Specifically, the scanning station 80 includes one or more cameras 85 oriented along a horizontal axis to scan the front and back sides of the article. In particular, the scanning station may include a plurality of imaging elements 85 positioned along the leading edge of the feed conveyor and a plurality of imaging elements positioned along the trailing edge of the feed conveyor. In addition, the scanning station 80 may include one or more cameras 85 oriented along a vertical axis to scan the top of the article as the article is conveyed along the feed conveyor 70. Further, additional imaging elements may be provided to scan the front and rear surfaces of the article as the article is conveyed by the feed conveyor 70. In addition, the feed conveyor 70 may include gaps between adjacent conveyors. The article may be conveyed over the gaps, and the camera below the conveyor may scan the article through the gaps so that the bottom surface of the article may be scanned by the inspection station. As such, the scanning station may include an array of sensors, reading elements, scanning elements, or detectors positioned about the travel path such that the scanning station may automatically scan articles for identifying indicia while the articles are conveyed along the path.

[0047] As described above, the scanning station 80 can analyze each item to try to find a product identification mark to identify the item based on the mark. If the product identifier is determined, the system can determine the destination of the item and the item can be electronically marked as eligible for classification. Similarly, parameters for how the item should be handled by the carrier can also be determined based on the information of the product code stored in the database. Conversely, if no product identifier is determined for the item, the item can be electronically marked as ineligible for classification.

[0048] In addition to the scanning camera 85, the scanning station may also include a scanning element that does not require a line of sight to read a tag or identification element. For example, the scanning station may include a scanning element that can scan through an article to identify the identification characteristics of the article. An exemplary scanning element that can scan through an article without requiring a line of sight is a radio frequency identification scanner or RFID scanner. The scanning station may include a single RFID scanner 80 to scan the article as it passes through the scanning station 70. The system can simultaneously scan the article using a scanning camera and compare the scan information from the scanning camera and the RFID reader to confirm the identification characteristics of the article (e.g., a product code number). Alternatively, the scanning camera can be used to scan articles that do not have an RFID tag, while the RFID scanner 80 can be used to identify articles to which an RFID tag is attached. In addition, although the scanning station is illustrated as having both an RFID scanner 80 and a camera 85, the camera can be removed in applications where all processed articles will have RFID tags.

[0049] refer to Figures 3 to 6 In this example, the scanning station 70 includes a plurality of RFID readers. Specifically, the scanning station includes an overhead RFID reader 80, which is vertically positioned above the scanning area 75 to direct the scanning field F1 downwardly toward the items in the scanning area. Optionally, the system may also include a front RFID reader 81, which is positioned adjacent to the leading edge of the scanning area 75 to direct the scanning field F2 across the scanning area from the front of the scanning station. Optionally, the system may also include a rear RFID reader 82, which is positioned adjacent to the trailing edge of the scanning area 75 to direct the scanning field F3 across the scanning area from the rear of the scanning station.

[0050] The RFID reader 80 can be any of a variety of readers that include an antenna for sending signals toward the scanning area 75 and receiving signals returned from the RFID tags in the scanning area. In this example, all of the RFID readers 80, 81, 82 are configured identically. One exemplary RFID reader is sold by SICK Product and Competence Center Americas LLC of Minneapolis, Minnesota under the product number RFU62x.

[0051] The inlet station 50 includes a plurality of conveyors configured to convey articles from an input area to a loading area where the articles are loaded onto carriers. In this example, the inlet station includes an input conveyor 52 positioned at the far left end of the inlet station (when the articles are loaded from the loading area). Figure 3 , Figure 4 and Figure 6 Observation). The input conveyor 52 is configured to receive and support articles that fall onto the input conveyor and to convey the articles toward the scanning area 75. The input conveyor may include any of a variety of configurations. In the present example, the input conveyor includes an endless conveyor driven around a plurality of rollers. The motor 62 drives the input conveyor 52 in response to a signal from the central controller 350. The input conveyor 52 is positioned adjacent to a scanning entry conveyor 54 that receives articles from the input conveyor and conveys the articles from the input area into the scanning area 75. In particular, the discharge end of the input conveyor may be positioned outside of the scanning station 70 so that the input conveyor conveys the articles toward the entrance of the scanning station but does not enter the scanning station.

[0052] The scanning entry conveyor 54 can extend from the input conveyor 52 to the loading station so that the scanning entry conveyor conveys the article from the input conveyor through the entire length of the scanning station. However, in the present example, the system may include multiple conveyors that convey the article from the input conveyor 52 to the loading station 165. For example, the system may include a scanning exit conveyor 56 that receives the article from the scanning entry conveyor and conveys the article toward the loading station 165. A gap 60 can be formed between the scanning entry conveyor 54 and the scanning exit conveyor 56. The gap 60 is a space through which the camera below the conveyor can pass to read the bottom side of the article. In addition, the gap provides an opening through which the fields F1, F2, F3 can pass through the articles in the scanning area without being interfered by the elements supporting the conveyed articles.

[0053] The system may also include a loading conveyor 58 that receives items from the scanning discharge conveyor 56. The loading conveyor is operable to load items onto a carrier positioned in the loading station 165, such as Figure 4 Example.

[0054] The scanning-in conveyor 54, the scanning-out conveyor 56, and the loading conveyor 58 can be configured in various configurations. In the present example, each of these conveyors includes an endless conveyor belt driven around a plurality of rollers. In addition, each of the scanning-in conveyor 54, the scanning-out conveyor 56, and the loading conveyor 58 can be driven independently. However, in the present example, the motor 64 drives a single belt, which interconnects the scanning-in conveyor 54, the scanning-out conveyor 56, and the loading conveyor 58.

[0055] The scanning station 70 optionally includes a housing 72, which can be used as a gauge or limiting device to limit the size of the items being processed. For example, as described above, the scanning station can have a housing surrounding a scanning area 75. Specifically, the housing can have one or more walls forming an outer shell. For example, the housing can include a front wall extending vertically along the front edge of the scanning station and a rear wall extending vertically along the rear edge of the scanning station. The rear wall can also separate the scanning area 75 from the return conveyor 400, which will be further described below. The top wall can extend between the top edges of the front wall and the rear wall of the housing. In addition, as shown in FIG. Figure 1 As shown, the left side of the housing may include a wall connecting the front wall and the rear wall. The left wall may include an opening sized to receive a maximum height of an article to be processed by the machine. In this way, the entry opening may have a height that limits or prevents articles having a height exceeding a height threshold from entering the housing, so that articles that are physically too large to be processed cannot be fed into the system through the introduction station.

[0056] In addition, the housing can be configured to act as a shielding element to shield items outside the housing 72 from being scanned by the RFID readers 80, 81, 82. Specifically, the walls of the housing can be formed of a conductive material. In this example, the conductive material has a thickness equal to or greater than 1×10 4 Siemens / meter. In contrast, non-conductive materials are materials with electrical conductivity less than 1×10 4 Siemens / meter of electrical conductivity. In this way, the wall will shield the RFID readers 80, 81, 82 to limit the readers from reading RFID tags on items on the input conveyor 52, the return conveyor 400, or the carriers 200 operating in the sorting area. In addition, the housing can include a right wall similar to the left wall, which has a discharge opening similar to the entry opening in the left wall. The size of the discharge opening can be designed so that items can be discharged from the discharge conveyor to the carriers in the loading area. The right wall can also be conductive similar to the left wall, so that the right wall limits the ability of the readers 80, 81, 82 to read RFID tags on items on the carriers 200 loaded in the loading column.

[0057] Although the scanning housing is described as shielding around the scanning area, it should be understood that the amount of shielding can vary depending on the application. For example, the housing may include a rear wall to shield items on the return conveyor 400 from the RFID scanners 80, 81, 82, but the housing may not include a front wall. In addition, it should be understood that in some applications, the shielding provided by the housing may not be necessary. Therefore, it should be understood that the amount and extent of shielding material can be modified or eliminated depending on the application.

[0058] refer to Figures 4 to 5 , the input conveyor includes a horizontally extending support element 53 that supports a section of the conveyor belt to form a horizontal support surface for supporting items conveyed by the input conveyor. Similarly, the scanning entry conveyor 54 includes a horizontally extending support element 55 that supports a section of the conveyor belt to form a horizontal support surface for supporting items conveyed by the scanning entry conveyor. In addition, the scanning exit conveyor 56 includes a horizontally extending support element 57 that supports a section of the conveyor belt to form a horizontal support surface for supporting items conveyed by the scanning exit conveyor. Further, the loading conveyor 58 may also include a horizontally extending support element 59 that supports a section of the conveyor belt to form a horizontal support surface for supporting items conveyed by the loading conveyor. The support elements 53, 55, 57, 59 can be any of a variety of elements configured to support a horizontal conveyor belt. For example, the support element can be a plate or a similar flat guide.

[0059] The conveyor in the introduction station 50 can be configured to improve the ability of the RFID reader to read the RFID tag on the article while the article is in the scanning area 75, while minimizing the possibility of the RFID reader reading the RFID tag on the article outside the scanning area. For example, the conveyor belts 52, 54, 56, 58 can be formed of non-conductive materials. In addition, the support elements of the conveyor in the scanning area can be formed of non-conductive materials. For example, the support elements 55 and 57 can be formed of non-conductive materials. Exemplary materials are ultra-high molecular weight (UHMW) polyethylene or Delrin. Although the support elements outside the area can be constructed of any of a variety of materials including conductive and non-conductive materials, in this example, the support elements 53, 59 for the input conveyor 52 and the loading conveyor 58 are formed of conductive materials such as metal. In this way, when the article is conveyed along the introduction station, when the article is outside the scanning area 75, the article is supported by the conductive element, and when the article is conveyed in the scanning area, the article is supported by the non-conductive element, or is not supported by any element.

[0060] The system may include a plurality of sensors for controlling the flow of items through the introduction station. For example, the system may include a first sensor 65 upstream of the housing 72. The system may also include a second sensor 66 adjacent to the entrance of the scanning station. In addition, the system may include a third sensor 68 within or downstream of the scanning area 75. The sensor provides a signal for controlling the flow of items through the introduction station. The sensor may be any of a variety of sensors. For example, the sensor may be an I / R sensor having a transmitter on the front side of the conveyor and a receiver on the rear side of the conveyor, so that the sensor provides a beam across the width of the conveyor. Alternatively, the sensor may be a reflective sensor that provides a detection plan that extends across the width of the conveyor.

[0061] When the first sensor detects the leading edge of the article, the sensor provides a signal to the central controller 350 indicating that the article is positioned adjacent to the entrance of the scanning station. If there is an article in the scanning station, the central controller provides a signal to the first motor 62 to stop the input conveyor. In this way, the articles are assembled outside the scanning station to ensure that only a single article is in the scanning area at this time. When the article passes the second sensor, the second sensor adjacent to the exit conveyor detects the leading edge and the trailing edge of the article. In response to the signal from the second sensor, the central controller 350 controls the operation of the scan entry conveyor, the scan exit conveyor, and the loading conveyor. Specifically, once the trailing edge of the article passes the second sensor, the second motor is operated for a predetermined time to ensure that the article is loaded onto the carrier 200 waiting at the loading station. Once the article has left the scanning area, the central controller provides a signal to drive the first motor to convey the article from the assembly point outside the scanning station toward the scanning area.

[0062] As described above, the scanning station 70 can be configured to analyze each item as it passes through the intake station to detect various characteristics of the item. The system can make a qualification decision based on one or more characteristics detected or determined by the system. If the item is not eligible for classification, the item can be directed to the reject area 325 to await further processing.

[0063] Typically, the items directed to the reject area 325 are then manually processed. An operator picks up each piece, identifies the piece, and transports the item to the appropriate destination. Since manually processing rejected items is time consuming and labor intensive, it is desirable to reduce the number of items directed to the reject area. Many of the items directed to the reject area 325 may simply be scanned in error. Although the item cannot be sorted without sufficient identification information, the necessary information can be read during a subsequent scan.

[0064] Since it may be desirable to reprocess some ineligible items, the information detected during identification can be used to identify different classes of ineligible items. A first type of ineligible item is a rejected item that is directed to a reject area. In the following discussion, these items will be referred to as rejected items. A second type of ineligible item is an item that is not eligible for sorting but is eligible for reprocessing. In the following discussion, these items will be referred to as reprocessed items.

[0065] The decision as to whether an item is marked for rejection, reprocessing, or classification can be made based on various characteristics. In the present example, the decision to mark an item as rejected is based on the physical characteristics of the item. Specifically, if the item is not qualified due to physical characteristics (e.g., having a linear dimension such as height, width, or length that exceeds a threshold), the system electronically marks the item as rejected and directs the item to the rejection area 325 for manual processing. Similarly, if the scanning station includes a scale, the item is marked as rejected if the weight exceeds the weight threshold. On the other hand, if the item passes the physical characteristics-based identification but fails due to the inability to recognize the product identification element, the element is electronically marked as reprocessing so that the item can be reprocessed to attempt to read the product identification information. For example, depending on the orientation of the product, the imaging element 85 may not be able to properly read a barcode or other identification mark. However, since the scanning station has determined that the item meets the physical parameters for processing the item, the system can transport the item to an alternative output, such as a box for receiving items to be reprocessed. Items that are sorted or transported to the reprocessing bin can be manually returned to the intake station 50 so that an operator can re-enter the items. Alternatively, the system can transport these items through the system to a reintroduction component, such as a conveyor 400, which returns the items to the incoming conveyor 52 of the intake station 50.

[0066] As can be seen from the above, the inlet station 50 can be configured with a wide range of options. The options are not limited to the configurations described above, and may include additional features.

[0067] Additionally, in the foregoing description, the system is described as having a single inlet station 50. However, it may be desirable to incorporate multiple inlet stations positioned along the system 10. By using multiple inlet stations, the feed rate of pieces may be increased. Additionally, the inlet stations may be configured to handle different types of items.

[0068] refer to Figures 1 to 3 , the inlet station 50 includes a conveyor that continuously conveys articles to the loading station 165. The loading station is a location along the track 110 that provides an entry point for loading articles onto the carrier 200. At the loading station 165, the carrier is aligned with the conveyor so that the articles unloaded from the conveyor are received on the delivery carrier 200 positioned at the loading station. After the articles are loaded onto the delivery carrier, if the articles are electronically marked as eligible for transportation, the delivery carrier moves away from the loading station 165. Then, another carrier moves to the position at the loading station to receive the next article. If the article is not electronically marked as eligible for transportation, the article is unloaded from the carrier 200 into the reject box 325.

[0069] The reject box 325 is positioned so that it is opposite the conveyor of the incoming station 50. In addition, the reject box 325 is aligned with the carrier 200 waiting at the loading station 165. In this way, a clear path from the incoming station 50 to the reject box 325 is provided without requiring the carrier to move along the track 110.

[0070] Reintroducing components

[0071] The system may include an optional reintroduction conveyor for items that are eligible for transport but not for sorting. Figures 1 to 3 , eligible items can be transported from the loading station 165 to the reintroduction conveyor or sorting station 100. Specifically, the carrier carrying the eligible items moves upward along the track 110 to the upper track 135. If the items on the carrier are marked for re-evaluation, the carrier travels along the track to the reintroduction conveyor. The carrier 200 then unloads the items onto the reintroduction conveyor 400, which transports the items back toward the introduction conveyor so that the items can be reprocessed by the introduction assembly in order to make the items eligible for sorting.

[0072] The reintroduction assembly 400 includes a path between the track and the induction station 50 to facilitate the return of the re-evaluation items to the induction station. The reintroduction assembly 400 can include any of a number of conveyor mechanisms. The mechanism can be driven or static, motorized or non-motorized.

[0073] Classification Station

[0074] Items eligible for sorting are transported by carriers to the sorting station through the inlet station 50. Figure 1 to Figure 2 , the system includes a sorting station 100, such as an array of bins 45 for receiving pieces.

[0075] Track 110 includes a horizontal upper rail 135 and a horizontal lower rail 140. A plurality of vertical legs 130 extend between the upper horizontal legs and the lower horizontal legs 140. During transport, the carrier travels upward along a pair of vertical legs from a loading station 165 to the upper rail 135. The carrier then travels along the upper rail 114 until it reaches a column with an appropriate box or destination. The carrier then travels downward along two front vertical columns and two parallel rear columns until it reaches the appropriate box or destination, and then unloads the items into the box or destination area. The carrier then continues downward along the vertical legs until it reaches the lower horizontal legs 140. The carrier then follows the lower rail back toward the loading station.

[0076] Track 110 includes a front track 115 and a rear track 120. Front track 115 and rear track 120 are parallel tracks that cooperate to guide the vehicle around the track. Figures 2 to 3 As shown, each vehicle includes four wheels 220: two front wheels and two rear wheels. The front wheels travel in the front track, while the rear wheels travel in the rear track. It should be understood that in the discussion of tracks, the front track 115 and the rear track 120 are similarly configured as opposing tracks that support the front and rear wheels of the vehicle. Therefore, a description of a portion of the front track or rear track also applies to the opposing front track or rear track.

[0077] Reference now Figures 1 to 3 , a loading row 160 is formed adjacent to the output end of the intake station 50. The loading row 160 is formed by a pair of front vertical rails 130 and a corresponding set of rear vertical rails. A loading station 165 is located along the loading row. The loading station 165 is a position along the track in which the carrier 200 is aligned with the discharge end of the loading conveyor 58 of the intake station 50. In this way, articles from the intake station can be loaded onto the carrier as it is conveyed from the input station toward the carrier.

[0078] The details of the track may be substantially similar to the track as described in US Pat. No. 7,861,844. The entire disclosure of US Pat. No. 7,861,844 is incorporated herein by reference.

[0079] As mentioned above and with reference to Figure 2, the track includes a plurality of vertical legs extending between a horizontal upper rail 135 and a lower rail 140. An intersection is formed at each section of the track at which one vertical leg intersects with one horizontal leg. Each intersection includes a pivotable door having a smoothly curved inner seat and a flat outer seat having teeth corresponding to the teeth of the drive surface of the track. The door pivots between a first position and a second position. In the first position, the door is closed so that the straight outer seat of the door is aligned with the straight outer branch of the intersection. In the second position, the door is open so that the curved inner seat of the door is aligned with the curved branch of the intersection.

[0080] In the above description, the sorting station 100 is described as a plurality of output bins 45. However, it should be understood that the system may include various types of destinations other than simply output bins. For example, in certain applications, it may be desirable to sort items into storage areas, such as areas on a storage shelf. Alternatively, the destination may be an output device that delivers the items to another location.

[0081] As described above, the system is operable to sort various items into a plurality of destinations. One type of destination is a bin; a second type is a shelf or other location on which the items are to be stored; and a third type of destination is an output device that can be used to transport the items to a different location. The system may include one or more of each of these types or other types of destinations.

[0082] Delivery Vehicle

[0083] Each delivery vehicle 200 is a semi-autonomous vehicle having an onboard drive system including an onboard power source. Each vehicle includes a mechanism for loading and unloading items for delivery. An embodiment of a vehicle that can operate with system 10 is illustrated and described in U.S. Pat. No. 7,861,844, which is incorporated herein by reference.

[0084] The carrier 200 may incorporate any of a variety of mechanisms for loading items onto the carrier and unloading items from the carrier into a box. Additionally, the loading / unloading mechanism 210 may be specifically customized for a particular application. However, in this example, the loading / unloading mechanism 210 is one or more conveyor belts extending along the top surface of the carrier. The conveyor belts are reversible. Driving the belts in a first direction displaces items toward the rear end of the carrier; driving the belts in a second direction displaces items toward the front end of the carrier.

[0085] The conveyor motor installed on the lower side of the carrier drives the conveyor belt. Specifically, the conveyor belt 212 is driven around the front roller at the leading edge of the carrier and the rear roller at the rear edge of the carrier. The conveyor motor is connected to the front roller to drive the front roller, thereby operating the conveyor belt.

[0086] The vehicle includes four wheels for transporting the vehicle along track 110. The wheels are mounted on two parallel spaced axles so that two wheels are disposed along the leading edge of the vehicle and two wheels are disposed along the trailing edge of the vehicle.

[0087] Each wheel may include an external gear that cooperates with the drive surface of the track. The external gear is fixed relative to the axle to which it is mounted. In this way, rotating the axle operates to rotate the gear. Therefore, when the vehicle moves vertically, the gear cooperates with the drive surface of the track to drive the vehicle along the track.

[0088] The vehicle includes an onboard motor for driving the wheels. More specifically, the drive motor is operatively connected to the wheel axle to rotate the wheel axle, which in turn rotates the gears of the wheels.

[0089] The vehicle 200 may be powered by an external power source, such as contacts along the rails, which provide the power required to drive the vehicle. However, in this example, the vehicle includes an onboard power source that provides the necessary power for both the drive motor and the transport motor. Additionally, in this example, the power source is rechargeable. Although the power source may include a power source such as a rechargeable battery, in this example, the power source is composed of one or more supercapacitors.

[0090] As discussed further below, the vehicle also includes a processor for controlling the operation of the vehicle in response to signals received from the central processor. In addition, the vehicle includes a wireless transceiver so that the vehicle can continuously communicate with the central processor as it travels along the track. Alternatively, in some applications, it may be desirable to incorporate multiple sensors or indicators positioned along the track. The vehicle may include a reader for sensing sensor signals and / or indicators and a central processor for controlling the operation of the vehicle in response to the sensors or indicators.

[0091] operate

[0092] The system 10 operates as follows. Items are processed at the inlet station 50 to identify characteristics of the item that indicate where the item should be sorted. As previously described, items may also be processed to determine whether the item is eligible for transport by a carrier based on the item's physical characteristics. The central controller maintains data associated with various data to identify the destination bin or location for the items being processed.

[0093] As previously described, the incoming station 50 can process the items automatically or manually before loading them onto the carrier. In manual mode, an operator manually enters information about the piece and then places the piece on a conveyor. The system electronically tags the piece with the classification information, and the conveyor conveys the piece toward the loading station. Alternatively, if the input system is an automatic system, the piece is automatically scanned to identify the relevant classification characteristics. For example, the input station can use a scanner, such as an RFID scanner, to read an RFID tag on the piece, and optionally, the input station can also include an imaging device, such as a high-speed line scan camera, which is combined with an OCR engine to read the information on the piece.

[0094] The method for loading an item onto a carrier 200 may include a step of monitoring the item as it is being conveyed toward the carrier. For example, the monitoring step may include a step of detecting the item at one or more locations as it is being conveyed toward the loading station 165.

[0095] In this example, as the items are transferred from the input location 51 to the loading station 165, the items are monitored at multiple locations. The items are monitored using one or more sensors (such as infrared detectors) that extend across the width of the path along which the items are transferred. Each sensor can send a signal to the central controller indicating the presence of an item at the sensor. Thus, based on the signals that the central controller 350 receives from the sensors, the central controller can determine when the leading edge of the item passes the sensor and when the trailing edge of the item passes the sensor.

[0096] The central controller may control the movement of the articles along the path from the input location to the loading station based on signals received from the sensors 65, 66, 68. In particular, the central controller may control the rate at which the articles advance along the induction station based on signals received from the sensors.

[0097] The method may also include the step of selectively staging articles at one or more locations along the path from the input location 51 to the loading location 165. For example, the exit sensor 68 may detect the leading edge of the articles as they are conveyed along the input path. If the empty carrier 200 is not positioned in the loading location 165, the articles will be staging adjacent to the loading location while the system waits for the empty carrier to arrive at the loading location. For example, if the carrier is not positioned in the loading location, the system may stop the loading conveyor 58 after detecting an article at the exit sensor 68.

[0098] The method may also include the step of controlling movement of items through the scanning area 75 based on signals received from one or more of the sensors 65, 66, 68. For example, the central controller 350 may control operation of the conveyors 54, 56 in the scanning area based on signals received from the sensors 66, 68.

[0099] The conveyors may be controlled to group the items adjacent to the scanning station 70. For example, the system may stop one or more conveyors to stop an item adjacent to the entrance of the scanning station so that the item does not enter the scanning area 75 when another item is in the scanning area. In one approach, the controller may group the items adjacent to the entrance of the scanning station in response to signals received from the entry sensor 66 and the exit sensor 68. For example, in a sequence of two items, if the leading item has passed the entry sensor 66 but has not passed the exit sensor 68, the central controller will control one or more conveyors to ensure that the following item does not enter the scanning area until a predetermined time after the leading item has passed the exit sensor.

[0100] The predetermined time may be based on the departure sensor detecting the leading edge or the trailing edge of the preceding item. For example, the following item may not advance into the scanning area 75 until a predetermined time after the departure sensor 68 detects the leading edge of the preceding item. Alternatively, the following item may not advance into the scanning area 75 until a predetermined time after the departure sensor detects the trailing edge of the preceding item.

[0101] In addition to controlling the staging of articles based on signals from the exit sensor 68, the central controller 350 may also control the handling of articles based on signals received from the input sensor 65 or the entry sensor 66. For example, upon receiving a signal from the entry sensor 66 indicating the presence of a rear article at the entry sensor, the controller may staging articles along the inlet path upstream of the scanning area 75 until a signal is received from the exit sensor indicating that the front article has advanced out of the scanning area. Alternatively, the rear articles may be staging along the inlet path until the front article has advanced out of the scanning station 70.

[0102] The controller may control the rear objects to gather objects along the inlet path based on the signal received from the input sensor 65. For example, once the central processor 350 receives a signal from the input sensor indicating that an object is at the input sensor, the central controller 350 may control the movement of the objects along the inlet path to gather the objects adjacent to the entrance of the scanning housing if the leading object has not yet left the exit sensor 68, as described above. The central controller 350 may gather the rear objects by advancing the objects a certain time or distance after detecting the leading edge of the objects, or alternatively after detecting the trailing edge of the objects.

[0103] In view of the foregoing, a method for processing articles may include the steps of feeding articles onto a conveyor to follow an inlet path extending between an input location 51 and a loading location 165. The process may include feeding a first article having a first passive RFID tag onto the conveyor and conveying the first article to a scanning station 70 to scan the first article.

[0104] The step of conveying the first item into the scanning station 70 may optionally include the step of advancing the first item into a conductive housing having one or more walls adjacent to the conveyor and one or more RFID readers 80, 81, 82. For example, the conductive housing may have a first conductive wall 73A that extends upward across an incoming path adjacent to the entrance of the scanning station 70. An opening may be formed between the first wall 73A and the incoming conveyor to form an opening through which the item enters the scanning area 75. Optionally, the conductive housing 72 may include a second conductive wall 73B that extends upward across an incoming path adjacent to the exit of the scanning station 70. An opening may be formed between the second conductive wall and the incoming conveyor through which the item exits the scanning area 75. The housing 72 may optionally include a front wall 74A that extends upward and spans the distance between the first wall 73A and the second wall 73B. The front wall may extend vertically above the one or more RFID readers 80. In addition, the housing may include a rear wall 74B that is opposite the front wall 74A and extends upward and spans the distance between the first wall 73A and the second wall 73B. The rear wall 74B may extend vertically above the one or more RFID readers 80 to provide a conductive wall between the scanning area 75 and items on the return conveyor 400 .

[0105] The scanning step may include the step of conveying the first article through the scanning area 75 along the guide path while scanning the first article using the RFID reader.

[0106] Optionally, the scanning step may include the step of scanning the first item while the item is supported by a non-conductive conveyor having a non-conductive support. For example, the scanning step may include the step of transmitting a radio frequency signal toward an RFID tag on the item while the first item is supported on a non-conductive conveyor including a substantially planar non-conductive support.

[0107] The step of scanning the first item may include the step of transmitting a radio frequency signal toward one or more conductive walls separating the first item from one or more items on the introduction path. Alternatively, the step of scanning the first item may include the step of transmitting a radio frequency signal toward one or more conductive walls separating the first item from one or more items carried on the delivery carrier 200.

[0108] The method may also include the step of feeding a second object having a second RFID tag onto the conveyor to follow the introduction path. After the first object enters the scanning station, the conveyor may advance the second object to a position adjacent to the scanning station. For example, when the first object is within the housing, the central controller 350 may control the introduction conveyor to gather the second object at the entrance so that at least a portion of the second object remains outside the housing 72.

[0109] After the step of scanning the first article, the method may include the step of scanning the second article. The step of scanning the second article may optionally include the step of controlling the timing of transmitting the radio frequency signal until after the first article is conveyed out of the housing.

[0110] After the first object is transferred out of the housing, the first object may be loaded onto one of the carriers 200 at the loading station.

[0111] In preparation for receiving an item, the carrier 200 moves along the track toward a loading station 165 in the loading row 160. When the carrier 200 moves to the loading station 165, the home position sensor detects the presence of the carrier and sends a signal to the central processor 350 indicating that the carrier is located at the loading station.

[0112] Once the carrier is positioned at the loading station, the input station transfers the item onto the carrier. When the item is transferred onto the carrier 200, the loading mechanism on the carrier loads the item onto the carrier. Specifically, the input station transfers the item into contact with the conveyor belt 212 on the carrier. The conveyor belt 212 rotates toward the rear side of the carrier, thereby driving the item backward on the carrier.

[0113] After the article is loaded onto the carrier, the carrier moves away from the loading station. Specifically, once the onboard controller detects that the article is properly loaded onto the carrier, the onboard controller sends a signal to start the drive motor.

[0114] The carrier may travel from the loading location 165 to one bin 45 and then transfer the first item to the first bin 45. After delivering the first item to the first bin, the carrier may return to the loading location 165 to receive another item for delivery.

[0115] Although the boxes may be arranged in any of a variety of configurations, in this example, the boxes are arranged in one or more arrays arranged along the aisle in which the carrier travels. The step of delivering the first item may include the steps of driving the carrier 200 along a vertical loop to deliver the first item and then returning to a loading position.

[0116] Optionally, the vertical loop may include a first vertical segment leading upward in the aisle, a horizontal segment extending horizontally in the aisle away from the first vertical segment, a second vertical segment extending in the aisle away from the end of the first horizontal segment, and a second horizontal segment extending in the aisle away from the second vertical segment.

[0117] Since the carrier moves upward along the loading column from the loading station, it is not necessary to determine the destination of the carrier until the carrier arrives at the first door along the upper rail 135. For example, if an automatic system is used to scan and determine the characteristics for classifying articles at the introduction station 50, it may take some processing time to determine the relevant characteristics and / or communicate this information with the central controller to receive the destination information. The time spent on transferring the article to the carrier and then transferring the carrier upward along the loading column will usually be enough time to determine the relevant characteristics of the article. However, if the characteristic is not determined by the time when the carrier arrives on the upper rail, the system can declare that the article is not qualified for classification, and the carrier can be guided to the reintroduction station 400 to unload the article onto the unloading assembly. The carrier travels downward along the second column from the reintroduction station 400 to the lower rail 140, and then returns to the loading column.

[0118] Once the item is eligible for sorting, the central controller 350 determines the appropriate box 45 for the item. Based on the location of the box for the item, the route of the carrier 200 is determined. Specifically, the central controller determines the route of the carrier and transmits information about the box to which the item is to be delivered to the carrier. The central controller then controls the carrier and / or the doors along the track to guide the carrier to the appropriate column. Once the carrier reaches the appropriate column, the carrier moves down along the column to the appropriate box. The carrier stops at the appropriate box 45, and the on-board controller sends an appropriate signal to the conveyor motor to drive the conveyor belt 212, which drives the item forward to unload the item into the box. Specifically, the top of the carrier is aligned with the gap between the appropriate box 45 and the bottom edge of the box directly above the appropriate box.

[0119] Those skilled in the art will recognize that the above-described embodiments may be changed or modified without departing from the broad inventive concepts of the present invention. For example, in the foregoing discussion, the system is described as a series of vehicles guided by tracks. However, it should be understood that the system need not include tracks. For example, the vehicles may travel along the ground instead of along the tracks. The vehicles may be guided along the ground by one or more sensors and / or controllers. Optionally, the vehicles may be guided in response to signals from other vehicles and / or a central controller, such as a computer that monitors each vehicle and controls the movement of the vehicles to prevent the vehicles from colliding with each other. In addition, the central controller may provide signals that guide each vehicle along a path to a storage location or a transfer location.

[0120] In addition to systems in which the vehicle moves along the ground without tracks, the system can incorporate a guide assembly that includes one or more rails or other physical guides that contact a mechanism on the vehicle to guide the vehicle along a path. For example, the vehicle can each include one or more contact elements, such as wheels, rollers, guide tabs, pins, or other elements that can engage the guide assembly. The guide assembly can be a linear element, such as a straight track, or it can be a curved element. The guide assembly can be bent in a horizontal plane so that the rail stays in a plane, or the guide can be bent vertically so that the rail is in a single plane. The guide assembly can include a plurality of guides or rails that are vertically spaced apart from each other so that the vehicle can move horizontally at multiple vertical heights. The guide can also include a lift for moving the vehicle between the vertically spaced rails.

[0121] As can be seen from the above, the system can be incorporated into various systems that use physical guide mechanisms to guide carriers along an open area by orienting the path to guide the carriers to a storage location or a transfer location. As described above, the movement of each carrier can be controlled in response to a determination of one or more physical characteristics of the items carried by each respective carrier.

[0122] In addition, although the foregoing discussion describes the delivery mechanism as one or more carriers, it should be understood that a variety of delivery mechanisms can be used to deliver items from the incoming station to the destination or storage location. For example, the delivery mechanism can include a movable arm, a crane, a shuttle carrier or other delivery carrier.

[0123] In view of the foregoing, a system may include a method or apparatus having a combination of one or more of the features described below.

[0124] The system may include an input station having a conveyor and a scanning station. The conveyor may include an input section for receiving an item, a scanning section for receiving an item from the input section, and an output section for receiving an item from the scanning section. The scanning section may include a non-conductive element for supporting an item on the scanning section.

[0125] The scanning station may be configured to scan items on a scanning section of the conveyor. Optionally, the scanning station may include one or more conductive walls and an RFID scanner along the scanning section.

[0126] The system may further include a delivery mechanism for receiving one of the items from the output section of the conveyor and delivering the item to the storage location. Optionally, the system also includes a central controller operable to receive information about the identification of the item scanned in the scanning station from the scanning station. Based on the scanned information, the central controller may be configured to determine the storage location of the item. Optionally, the central controller provides a control signal to the delivery mechanism to deliver the item to the determined storage location.

[0127] The system may also optionally include a first plurality of storage locations separated from a second plurality of storage locations by an aisle. The delivery mechanism may be configured to move within the aisle. The delivery mechanism may include one or more carriers, shuttle carriers, cranes, or movable arms, each of which may be displaced within the aisle to deliver an item.

[0128] In some applications, the delivery mechanism can be a delivery vehicle that can be displaced vertically and horizontally in an aisle. Alternatively, as described above, the delivery mechanism can include multiple delivery vehicles that can be displaced in an aisle. In addition, multiple vehicles can be displaced to different delivery locations along separate paths at the same time. Optionally, the separate paths can be in an aisle.

[0129] The system may include a housing including a plurality of conductive walls adjacent to the scanning area. The housing may include a first conductive wall extending substantially across the entire width of the conveyor. Optionally, the first conductive wall may be configured to allow the conveyor to convey items from the input area to the scanning area.

[0130] The housing may optionally include a second conductive wall extending substantially across the entire width of the conveyor.The second conductive wall may be configured to allow the conveyor to convey items from the scanning area to the output area.

[0131] The system may include a conveyor having a scanning section adjacent to the RFID scanner. The scanning section may include a first conveyor belt and a non-conductive element in the form of one or more generally flat horizontal elements below the conveyor belt. Alternatively, the generally flat horizontal element may be a generally horizontal planar support supporting the underside of the conveyor belt.

[0132] As described above, the system may include an RFID scanner that is directed toward a conductive housing that extends along a scanning area to prevent the RFID scanner from receiving RF signals from RFID tags outside the scanning area. The RFID scanner can scan items in the scanning area while the items are supported on a non-conductive element. The non-conductive element is optionally formed of a material having a conductivity of less than 10,000 Siemens per meter. Further, the non-conductive element is optionally formed of a material having a conductivity of less than 1,000 Siemens per meter. In some embodiments, the non-conductive element is optionally formed of a material having a conductivity of less than 1 Siemens per meter. In an exemplary embodiment, the non-conductive element is optionally formed of plastic.

[0133] The system may include a conveyor section in the scanning area supported by a non-conductive support. Additionally, the system may include an input section including a conveyor belt and a conductive support below the conveyor belt for supporting items on the input section. Similarly, the system may optionally include an output section including a conveyor belt and a conductive section below the conveyor belt for supporting items on the output section.

[0134] The system may optionally include one or more sensors for controlling the handling of items as they move through the system. For example, the system may include a first sensor for detecting the presence of an item on an input segment of a conveyor for conveying items past an RFID scanner. The central controller may be configured to receive a signal from the first sensor and control the input segment in response to the signal from the first sensor.

[0135] Optionally, the system may include a second sensor for detecting the presence of an item on the conveyor, such as an item in a scanning segment adjacent to the RFID scanner. The central controller may be configured to receive a signal from the second sensor and control the input segment in response to the signal from the second sensor. Additionally, in some applications, the central controller may be configured to control the operation of the input segment and the scanning segment to mass the items outside the scanning area while the second item is in the scanning area. Optionally, the central controller may be configured to control the operation of the input segment and the scanning segment in response to the signal from the first sensor and the second sensor to mass the items so that at least a portion of the first item is positioned outside the housing.

[0136] The system may further include a third sensor positioned along the conveyor. The third sensor may be positioned to detect the presence of an item on an output section of the conveyor downstream of the scanning area. The system may be configured such that the central controller is configured to receive a signal from the third sensor and, in response to the signal from the third sensor, control operation of the scanning section and the output section such that the entire length of an item is outside of the scanning area before a portion of another item enters the scanning area.

[0137] The central controller can be configured to control the operation of the RFID scanner to scan the scanning area during the time window. The time window can be determined based on signals received from one or more sensors along the conveyor. For example, the beginning of the time window can be determined based on a signal from a sensor adjacent to the scanning area. Alternatively, the end of the time window can be based on a signal from a sensor downstream of the scanning area.

[0138] In yet another embodiment, the system may include a conveyor and a delivery mechanism for delivering items from the conveyor to a storage location. When the items are conveyed toward the delivery mechanism, the RFID scanner can scan the RFID tags on the items. The system may include a housing positioned along the conveyor. Optionally, the housing includes a first wall that extends across the width of the conveyor and is configured to allow items on the conveyor to pass from an input position to a scanning area. The first wall is preferably formed of a conductive material. The housing may include a second wall that extends across the width of the conveyor and is spaced from the first wall so that the scanning area is between the first wall and the second wall. Optionally, the second wall is configured to allow items on the conveyor to pass from the scanning area to a loading position. Preferably, the second wall is formed of a conductive material.

[0139] The conveyor of the system may be configured such that in the scanning area, the article is supported on a movable surface to move the article through the scanning area. The system may include a fixed support surface for supporting the movable surface. Preferably, the movable surface and the fixed support surface are formed of a non-conductive material.

[0140] In one embodiment, the system may include a conveyor having an input area configured so that items in the input area are supported on a movable surface and a fixed support surface supporting the movable surface. The fixed support may be formed from any of a variety of materials, but preferably, the support surface is formed from a conductive material, such as a metal.

[0141] Similarly, the system may include a conveyor having an output area configured such that items in the output area are supported on a movable surface and a fixed support surface supporting the movable surface. The fixed support may be formed from any of a variety of materials, but preferably the support surface is formed from an electrically conductive material, such as a metal.

[0142] The system may include a central controller configured to operate the RFID scanner to scan an article while the article is between the first conductive wall and the second conductive wall and the article is located on the non-conductive fixed support.

[0143] According to another aspect, a method for delivering an article to one or more destinations is provided. The method may include the step of conveying a first article along a first conveying section. The article is conveyed from the first conveying section through a first conductive wall and onto a second conveying section. The first conductive wall separates the first conveying section from the second conveying section. As the article is conveyed through the first conductive wall, the article may be conveyed under the first wall or through an opening in the first conductive wall.

[0144] The method may include the step of transmitting an RF signal toward an RFID tag on a first article on the second conveying section while the first article is supported on the non-conductive support.

[0145] The method may further include the step of receiving an RF signal from an RFID tag on the first item while the first item is supported on the non-conductive support.

[0146] The method may further include the step of determining a destination of the first item based on the step of receiving the RF signal from the RFID tag.

[0147] The first article may be conveyed through a second conductive wall separating the second conveying section from the third conveying section.When the article is conveyed through the second conductive wall, the article may be conveyed under the second wall or through an opening in the second conductive wall.

[0148] The method may include the step of loading the items from the third conveying section onto a delivery mechanism. The delivery mechanism may be displaced to deliver the items to a determined destination. After the delivery mechanism is displaced to the determined destination, the items may be unloaded into the delivery destination.

[0149] Optionally, the step of conveying the articles along the first conveyor section comprises supporting the articles with an electrically conductive support.

[0150] Optionally, the step of conveying the article along a third conveying section is downstream of the scanning area.

[0151] According to another aspect, the method includes the step of displacing the delivery mechanism within an aisle between the first plurality of destinations and the second plurality of destinations. Optionally, the step of moving the delivery mechanism within the aisle includes moving the delivery mechanism horizontally and vertically within the aisle.

[0152] Optionally, the step of moving the delivery mechanism includes moving the delivery mechanism within the aisle along a vertical loop extending from the loading position to the determined destination and back to the loading position to pick up another item.

[0153] During the step of transmitting RF signals toward RFID tags on the items, it may be desirable to support the items on a non-conductive conveyor belt supported by a generally planar non-conductive support engaging an underside of the conveyor belt. Optionally, during the step of transmitting RF signals toward the items, it may be desirable to simultaneously support a second item having a second RFID tag in the input section and a third RFID tag on a third item in the loading section. Optionally, during the step of transmitting RF signals, it may be desirable to simultaneously operate a delivery mechanism to deliver a fourth item having a fourth RFID tag.

[0154] In different embodiments, the systems and methods described herein may be implemented in software, hardware, or a combination thereof. In addition, the order of the methods may be changed, and various elements may be added, reordered, combined, omitted, or otherwise modified. All examples described herein are presented in a non-limiting manner. For those skilled in the art who benefit from the present disclosure, it is apparent that various modifications and changes may be made. The implementation according to the embodiments has been described in the context of a specific embodiment. These embodiments are illustrative and non-restrictive. Many changes, modifications, additions, and improvements are possible. Therefore, multiple instances may be provided for the components described herein as a single instance. The boundaries between various components, operations, and data storage devices are arbitrary to some extent, and specific operations are illustrated in the context of a specific illustrative configuration. Other allocations of functions are foreseeable and may fall within the scope of the appended claims. Finally, the structures and functions presented as discrete components in the example configuration may be implemented as combined structures or components. These and other changes, modifications, additions, and improvements may fall within the scope of the embodiments as defined by the appended claims.

[0155] Therefore, it should be understood that the invention is not limited to the particular embodiments described herein, but is intended to include all changes and modifications within the scope and spirit of the present invention as set forth in the appended claims.

Claims

1. A material handling device, comprising: Input station, which includes: a conveyor having an input section for receiving articles, a scanning section for receiving articles from the input section, and an output section for receiving articles from the scanning section, wherein the scanning section includes a non-conductive element for supporting articles on the scanning section; A scanning station for scanning items on the scanning section of the conveyor, comprising: a housing having one or more conductive walls adjacent the scanning section; an RFID scanner comprising a transmitter for transmitting radio frequency signals toward one or more walls of the housing and toward the scanning section of the conveyor and a receiver for receiving signals transmitted from the transmitter; a delivery mechanism for receiving articles from the output section of the conveyor and delivering the articles to a plurality of storage locations; A central controller is operable to receive information regarding the identification of each item from the scanning station and determine a storage location to which each of the items is to be delivered, wherein the delivery mechanism is configured to deliver each item to the storage location determined for each item.

2. The apparatus of claim 1, comprising a first plurality of storage locations separated from a second plurality of storage locations by an aisle, wherein: The delivery mechanism is configured to move within the aisle.

3. The device according to claim 2, wherein: The delivery mechanism includes a carrier, a shuttle carrier or a crane that can be displaced within the aisle to deliver items.

4. The device according to claim 3, wherein: The delivery mechanism includes a delivery vehicle that is displaceable vertically and horizontally within the aisle.

5. The device according to claim 4, wherein: The delivery mechanism includes a plurality of delivery vehicles that are displaceable within the passageway.

6. The device according to claim 1, wherein: The housing includes a plurality of conductive walls adjacent a scanning area along the scanning section.

7. The device according to claim 6, wherein: The plurality of conductive walls includes a first conductive wall extending across substantially the entire width of the conveyor.

8. The apparatus of claim 7, comprising an opening in the first wall configured to allow items on the conveyor to move from the input conveyor to the scanning area.

9. The device according to claim 7, wherein: The plurality of conductive walls includes a second conductive wall extending across substantially an entire width of the conveyor adjacent the output segment.

10. The apparatus of claim 9, comprising an opening in the second wall configured to allow items on the conveyor to move from the scanning area to the delivery mechanism.

11. The device according to claim 1, wherein: The scanning section includes a first conveyor belt, and the non-conductive element includes one or more generally flat horizontal elements beneath the conveyor belt.

12. The device according to claim 11, wherein The one or more generally flat horizontal elements include a generally planar support that supports an underside of the conveyor belt.

13. The device according to claim 12, wherein: The non-conductive element is formed from plastic.

14. The device according to claim 1, wherein: The non-conductive element is formed of a material having an electrical conductivity of less than 10,000 Siemens per meter.

15. The device according to claim 1, wherein: The non-conductive element is formed of a material having an electrical conductivity of less than 1,000 Siemens per meter.

16. The device according to claim 1, wherein The non-conductive element is formed of a material having an electrical conductivity of less than 1 Siemens per meter.

17. The device according to claim 1, wherein: The input section includes a second conveyor belt and a conductive support below the second conveyor belt for supporting articles on the input section.

18. The device according to claim 1, wherein: The output section includes a third conveyor belt and a conductive support member below the third conveyor belt for supporting articles on the output section.

19. The apparatus of claim 1, comprising a first sensor for detecting the presence of an item on the input segment.

20. The device according to claim 19, wherein The central controller is configured to receive a signal from the first sensor and to control the input section in response to the signal from the first sensor.

21. The apparatus of claim 1, comprising a second sensor for detecting the presence of an item on the scanning segment.

22. The device according to claim 21, wherein The central controller is configured to receive a signal from the second sensor and to control the input segment in response to the signal from the second sensor.

23. The device according to claim 22, wherein: The central controller is configured to control operation of the input section and the scanning section to stow a first one of the articles outside of the scanning area while a second article is in the scanning area.

24. The device according to claim 23, wherein: The central controller is configured to control operations of the input section and the scanning section in response to signals from the first sensor and the second sensor to gather the first object such that at least a portion of the first object is positioned outside the housing.

25. Apparatus according to claim 24, comprising a third sensor for detecting the presence of an article on the output section.

26. The device according to claim 25, wherein The central controller is configured to receive a signal from the third sensor and to control the operation of the scanning section and the output section in response to the signal from the third sensor so that the entire length of the first article is positioned outside the scanning area before a portion of another article enters the scanning area.

27. The device according to claim 21, wherein The central controller controls operation of the RFID scanner to scan the scanning area during a time window in response to a signal received from the second sensor.

28. The device according to claim 27, wherein The start of the time window is determined based on a signal from the second sensor.

29. The device according to claim 28, wherein The end of the time window is determined based on a signal from a third sensor.

30. A material handling device for delivering a plurality of articles to a plurality of storage locations, comprising: a conveyor operable to convey a first one of said articles from an input location to a scanning area and then to a loading location; a delivery mechanism operable to receive a first article from the conveyor at the loading location and deliver the first article to one of the storage locations; an RFID scanner positioned adjacent to the scanning area to scan items for RFID tags having identification information; A housing, positioned along the conveyor, comprising: a first wall extending across a width of the conveyor and configured to allow items on the conveyor to pass from the input location to the scanning area, wherein the first wall is formed of a conductive material; a second wall extending across the width of the conveyor and spaced from the first wall such that the scanning area is between the first wall and the second wall, wherein the second wall is configured to allow items on the conveyor to pass from the scanning area to the loading position, wherein the second wall is formed of a conductive material, wherein the conveyor includes a movable surface for moving the first item through the scanning area and a fixed support surface supporting the movable surface, wherein the movable surface and the fixed support surface are formed of a non-conductive material.

31. The device according to claim 30, wherein The conveyor includes a second movable surface configured to move an article from the input region toward the scanning region and a second fixed support surface supporting the second movable surface, wherein the second fixed support surface is formed of a conductive material.

32. The device according to claim 31, wherein The conveyor includes a third movable surface configured to move an article from the scanning area toward the loading position and a third fixed support surface supporting the third movable surface, wherein the third fixed support surface is formed of a conductive material.

33. The device according to claim 30, wherein: A first plurality of said storage locations is separated from a second plurality of said storage locations by an aisle, wherein said delivery mechanism is configured to move within said aisle.

34. The device according to claim 33, wherein: The delivery mechanism includes a carrier, a shuttle carrier or a crane that is displaceable within the aisle to deliver the first item.

35. The device according to claim 34, wherein The delivery mechanism includes a delivery vehicle that is displaceable vertically and horizontally within the aisle.

36. The device according to claim 33, wherein The delivery mechanism includes a plurality of delivery vehicles that are displaceable within the passageway.

37. The device according to claim 30, wherein: The movable surface comprises a conveyor belt and the non-conductive fixed support surface comprises one or more generally flat horizontal elements beneath the conveyor belt.

38. The device according to claim 37, wherein The one or more generally flat horizontal elements include a generally planar support that supports an underside of the conveyor belt.

39. The device according to claim 30, wherein: The non-conductive fixed support surface is formed from plastic.

40. The device according to claim 30, wherein: The non-conductive fixed support surface is formed from a material having an electrical conductivity of less than 10,000 Siemens per meter.

41. The apparatus of claim 30, wherein: The non-conductive fixed support surface is formed of a material having an electrical conductivity of less than 1,000 Siemens per meter.

42. The apparatus of claim 30, wherein: The non-conductive fixed support surface is formed from a material having an electrical conductivity of less than 1 Siemens per meter.

43. The apparatus of claim 30, comprising a central controller configured to control operation of the conveyor to prevent a first article from moving past the first wall while a second article is between the first wall and the second wall.

44. The device according to claim 43, wherein The central controller is configured to operate the RFID scanner to scan the second item while the second item is between the first conductive wall and the second conductive wall and the second item is on the non-conductive fixed support.

45. The apparatus of claim 30 including a first sensor for detecting a leading edge of each said article before a trailing edge of said article moves past said first wall.

46. ​​The device according to claim 45, wherein The central controller is configured to receive a signal from the first sensor and to control the transmitter in response to the signal from the first sensor.

47. The apparatus of claim 30 including a second sensor for detecting the presence of each article on the conveyor while the article is supported on the non-conductive fixed support.

48. The apparatus of claim 47, wherein: The central controller is configured to receive a signal from the second sensor and control the conveyor in response to the signal from the second sensor to prevent the conveyor from conveying a trailing edge of a second article past the first wall before a leading edge of a first article is conveyed past the second wall.

49. The apparatus of claim 44, wherein: The central controller controls operation of the RFID scanner to scan the scanning area during a time window in response to a signal received from the first sensor.

50. The apparatus of claim 49, wherein: The start of the time window is determined based on a signal from the first sensor.

51. The apparatus of claim 50, wherein: An end of the time window is determined based on a signal from the second sensor.

52. A method for delivering an item to one or more destinations, comprising the steps of: conveying a first object along a first conveying section; conveying the first article under a first conductive wall and onto a second conveying section, wherein the first conductive wall separates the first conveying section from the second conveying section; transmitting an RF signal toward an RFID tag on the first article on the second conveying section while the first article is supported on a non-conductive support; receiving an RF signal from the RFID tag on the first item while the first item is supported on the non-conductive support; determining a destination of the first item based on the step of receiving the RF signal from the RFID tag; conveying the first article beneath a second conductive wall separating the second conveying section from a third conveying section; loading the first article from the third conveying section onto a delivery mechanism; displacing the delivery mechanism to deliver the first item to the determined destination; and The article is unloaded from the delivery mechanism to the determined destination.

53. The method of claim 52, wherein: The step of conveying the first article along a first conveying section includes supporting the first article with a conductive support.

54. The method of claim 52, wherein: An aisle separates the first plurality of destinations from the second plurality of destinations, and the step of displacing the delivery mechanism includes moving the delivery mechanism within the aisle.

55. The method of claim 54, wherein: The step of moving the delivery mechanism within the aisle includes moving the delivery mechanism horizontally and vertically within the aisle.

56. The method of claim 54, wherein: The step of moving the delivery mechanism includes moving the delivery mechanism within the aisle along a vertical loop extending from the third conveying section to the determined destination and back to the third conveying section to pick up another article.

57. The method of claim 52, wherein: The step of transmitting an RF signal toward an RFID tag on the first article on the second conveying section while the first article is supported on a non-conductive support includes the step of transmitting the RF signal while the first article is on a non-conductive conveyor belt supported by a generally planar non-conductive support engaging an underside of the conveyor belt.

58. The method of claim 52, wherein: Receiving the RF signal from the RFID tag includes receiving the RF signal while a second item having a second RFID tag is positioned on the input section and a third item having a third RFID tag is positioned on the loading section.

59. The method of claim 58, wherein: The step of receiving the RF signal includes receiving the RF signal while the delivery mechanism delivers a fourth item having a fourth RFID tag.

60. A material handling device for delivering a plurality of articles to a plurality of storage locations, comprising: means for conveying a first one of said articles from an input position to a scanning area and then to a loading position; means for receiving the first article from the conveyor at the loading location and delivering the first article to one of the storage locations; an RFID scanner positioned adjacent to the scanning area to scan items for RFID tags having identification information; means for shielding items in the input location and the loading location from radio frequency signals from the RFID scanner; Wherein, the device for conveying comprises a movable surface for moving the first object through the scanning area and a fixed support surface supporting the movable surface, wherein the movable surface and the fixed support surface are formed of a non-conductive material.

61. The material handling device of claim 60, wherein: The means for shielding includes a first conductive shield extending across a width of the means for conveying and configured to allow items on the means for conveying to pass from the input location to the scanning area.

62. The material handling device of claim 61, wherein: The means for shielding includes a second conductive shield configured to shield items at the loading position from radio frequency signals from the RFID scanner, wherein the second conductive shield extends across a width of the means for conveying and is configured to allow items on the means for conveying to pass from the scanning area to the loading position.

63. The material handling device of claim 60, wherein: The means for conveying comprises: a second movable surface configured to move an article from the input region toward the scanning region; and a second fixed support surface supporting the second movable surface, wherein the second fixed support surface is formed of a conductive material.

64. The material handling device of claim 63, wherein: The means for conveying includes a third movable surface configured to move an article from the scanning area toward the loading position and a third fixed support surface supporting the third movable surface, wherein the third fixed support surface is formed of a conductive material.

65. The material handling device of claim 60, wherein: A first plurality of said storage locations are separated from a second plurality of said storage locations by an aisle, wherein the means for receiving is configured to move within said aisle.

66. The material handling device of claim 65, wherein: The means for receiving comprises a carrier, a shuttle carrier or a crane which is displaceable within the aisle to deliver the first item.

67. The material handling device of claim 66, wherein: The means for receiving comprises a delivery vehicle displaceable vertically and horizontally within the aisle.

68. The material handling device of claim 65, wherein: The means for receiving includes a plurality of delivery carriers displaceable within the aisle.

69. The material handling device of claim 60, wherein: The movable surface comprises a conveyor belt and the non-conductive fixed support surface comprises one or more generally flat horizontal elements beneath the conveyor belt.

70. The material handling device of claim 69, wherein: The one or more generally flat horizontal elements include a horizontal planar support that supports an underside of the conveyor belt.

71. The material handling device of claim 60, wherein: The non-conductive fixed support surface is formed from plastic.

72. The material handling device of claim 60, wherein: The non-conductive fixed support surface is formed from a material having an electrical conductivity of less than 10,000 Siemens per meter.

73. The material handling device of claim 60, wherein: The non-conductive fixed support surface is formed of a material having an electrical conductivity of less than 1,000 Siemens per meter.

74. The material handling device of claim 60, wherein: The non-conductive fixed support surface is formed from a material having an electrical conductivity of less than 1 Siemens per meter.

75. The material handling device of claim 62, comprising a central controller configured to control operation of the device for conveying to prevent a first article from moving past the first shield while a second article is between the first shield and the second shield.

76. The material handling apparatus of claim 75, wherein: The central controller is controlled to operate the RFID scanner to scan the second item while the second item is between the first conductive shield and the second conductive shield and the second item is on the non-conductive fixed support.

77. The material handling device of claim 75 including a first sensor for detecting a leading edge of each said article before a trailing edge of said article moves past said first shield.

78. The material handling device of claim 77, wherein: The central controller is configured to receive a signal from the first sensor and to control the transmitter in response to the signal from the first sensor.

79. The material handling apparatus of claim 75 including a second sensor for detecting the presence of each said article on said means for conveying while said articles are supported on said non-conductive fixed support.

80. The material handling device of claim 79, wherein: The central controller is configured to receive a signal from the second sensor and control the device for conveying in response to the signal from the second sensor to prevent the device for conveying from conveying a trailing edge of a second article through the first shield before a leading edge of a first article is conveyed through the second shield.

81. The material handling device of claim 77, wherein: The central controller controls operation of the RFID scanner to scan the scanning area during a time window in response to a signal received from the first sensor.

82. The material handling device of claim 81, wherein: The start of the time window is determined based on a signal from the first sensor.

83. The material handling device of claim 82, wherein: An end of the time window is determined based on a signal from the second sensor.

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