Material sorting system and method

Abstract

The invention relates to the field of material handling systems, in particular to a material sorting system comprising a route engine, first and second sized vehicles, and a grid comprising a plurality of grid cells, each grid cell having a grid cell length X. The first sized vehicle has a first vehicle length greater than the grid cell length X, and the second sized vehicle has a second vehicle length greater than the first vehicle length. The system is configured to: receive item information for the first and second items; distributing a first item transported by the first size vehicle and a second item transported by the second size vehicle; a first route for the first size vehicle is determined such that the first route has a first width equal to A * X, and a second route for the second size vehicle is determined such that the second route has a second width equal to B * X. A material sorting system based on an automatic transport vehicle generally assumes that a sorting site can be gridded. The size of the grid cell is just suitable for an automatic transport vehicle. Based on this hypothesis, the path of the automated transport vehicle can be efficiently planned. However, in the actual situation, a part of large objects always exceed the size of the grid unit, so that the large objects cannot be sorted and transported by an automatic transport vehicle. This may introduce additional labor costs, delays and inefficiencies in the originally fully automated sorting system. The technical effect of full-automatic material sorting is achieved through the grids of different sizes, the vehicles matched with the grids and path planning.

Description

Technical Field

[0001] The present invention relates to the field of material handling systems, and in particular to an improved automatic material sorting system using an automatic mobile robot. Background Art

[0002] Item sorting includes distributing items, such as packages, individual items (e.g., units), and other packages in an order fulfillment center or shipping facility to be shipped to different destinations. Item sorting can include distributing items from multiple warehouse locations for unified consolidation at a single exit or destination point. E-commerce is becoming ubiquitous, with third-party logistics (3PL) providers, online e-tailers, and even physical store operators filling online orders at sorting locations and then shipping the sorted items to their respective destinations. These sorting locations typically include automated sorting equipment, including computer-controlled automated transport vehicles. Automated transport vehicle navigation systems typically navigate automated transport vehicles by referencing fiducial markers on a floor or platform surface, the fiducial markers being arranged in a grid pattern, where the distance between the fiducial markers in the x-direction can be set to be the same as the distance in the y-direction, thereby forming square grid cells, where the fiducial markers are located at the center of each grid cell. The size of the grid cells is typically such that all automated transport vehicles of the same standard size fit into these grid cells. Automated transport vehicle navigation controllers and their associated software are used to plan the travel path of each of these automated transport vehicles so that no two automated transport vehicles are in the same grid cell at the same time.

[0003] A pile of items (e.g., packages and individual items) that need to be sorted to their final locations may inevitably include a small number of items whose physical size makes them unable to be transported by one of the standard-sized automated transport vehicles provided in the automated transport vehicle sorting system. For example, large items that account for less than 1% of the total number of items may not fit into a standard automated transport vehicle and therefore need to be manually sorted into their destination containers; in other words, personnel may have to manually physically transfer the large items to their destination containers. Therefore, handling (e.g., sorting or allocating) such large items that cannot fit into a standard-sized automated transport vehicle requires manual labor to physically carry / transport these large items to their respective designated destination containers. However, this procedure may introduce additional labor costs, delays, and inefficiencies in an otherwise fully automated sorting system.

[0004] Therefore, an opportunity exists for an improved sorting system for warehouses and other material handling facilities that overcomes the above-mentioned shortcomings. Summary of the invention

[0005] The object of the present invention is to provide a material sorting method and system to solve the problems raised by the background technology.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] The present invention provides a material sorting system. The system may include: a server including a memory, a processor and a routing engine; and a grid including a plurality of grid cells for a plurality of computer-controlled vehicles to travel thereon, each grid cell having a grid cell length X. The plurality of computer-controlled vehicles include a first-size vehicle having a first vehicle length greater than the grid cell length X and a second-size vehicle having a second vehicle length greater than the first vehicle length. The system may also include: a target container; and a plurality of items to be sorted into the target container, the plurality of items including a first item and a second item. The system is configured to: receive item information corresponding to the first item and the second item at the server; assign the first item to be transported by the first-size vehicle to the target container by the server, and assign the second item to be transported by the second-size vehicle to the target container; determine the first route of the first-size vehicle by the routing engine, so that the first route has a first width equal to A*X, where A is an integer; and determine the second route of the second-size vehicle by the routing engine, so that the second route has a second width equal to B*X, where B is an integer greater than A.

[0008] The present invention provides a material sorting method. The method may include: receiving item information corresponding to a first item and a second item at a server; allocating the first item to be transported by a first-size vehicle to a destination container through the server, and allocating the second item to be transported by a second-size vehicle to a destination container; determining a first route for the first-size vehicle through a routing engine communicating with the server, so that the first route has a first width equal to A*X, where A is an integer; and determining a second route for the second-size vehicle through a routing engine, so that the second route has a second width equal to B*X, where B is an integer greater than A.

[0009] Compared with the prior art, the beneficial effects of the present invention are as follows: the material sorting system based on automatic transport vehicles generally assumes that the sorting site can be gridded. The size of the grid unit is just right for the automatic transport vehicle. Based on this assumption, the path of the automatic transport vehicle can be efficiently planned. However, in actual situations, there is always a part of large items that exceed the size of the grid unit, so they cannot be sorted and transported by automatic transport vehicles. This situation may introduce additional labor costs, delays and inefficiencies in the originally fully automated sorting system. The present invention achieves the technical effect of fully automatic sorting of materials through grids of different sizes, matching vehicles, and path planning. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1A block diagram illustrating an exemplary process for an improved sortation system for use with computer-controlled mixed-size automated transport vehicles to sort items into destination containers in accordance with one or more embodiments of the present invention.

[0011] Figure 2 An example embodiment of a platform of one or more embodiments of the present invention is shown, the platform comprising a grid of cells for computer-controlled automated transport vehicles to travel thereon to a destination container.

[0012] Figure 3 An example embodiment of a computer-controlled automated transport vehicle carrying items to be sorted into destination containers in accordance with one or more embodiments of the present invention is shown.

[0013] Figure 4 An example embodiment of a square node grid is shown in accordance with one or more embodiments of the present invention, wherein one large item and two regular sized items are shown.

[0014] Figure 5 An exemplary flow chart illustrating an exemplary embodiment of an improved sorting system for mixed-size automated transport vehicles for sorting items into destination containers in accordance with one or more embodiments of the present invention is shown. DETAILED DESCRIPTION

[0015] Below, the technical solutions in the embodiments of the present invention will be clearly and comprehensively described in conjunction with the drawings in the embodiments of the present invention. Obviously, the examples described here are only some examples of the present invention, not all examples of the present invention. In general, the components in the embodiments of the present invention shown in this article can be arranged and designed according to different configurations. Therefore, the detailed description of the embodiments of the present invention provided in the drawings below is not intended to limit the scope of protection claimed by the present invention, but only represents selected examples of the present invention. On the basis of the embodiments of the present invention, all other embodiments that can be obtained by those skilled in the art without creative work belong to the protection scope of the present invention. The present invention will be further described below in conjunction with the drawings. The embodiment described herein provides an improved sorting system for use with an automatic transport vehicle (e.g., an automatic transport vehicle of mixed sizes) to solve the problem of inefficiency and sort items into destination containers.

[0016] As previously described, the material sorting system may include an automatic sorting device, which includes an automatic transport vehicle navigation system, which navigates automatic transport vehicles of the same / standard size by referring to reference marks set on grid cells, and the size of these grid cells makes the standard-sized automatic transport vehicles fit into these grid cells. It should be understood that for ease of reference and understanding, the embodiments and embodiments described herein with reference to the accompanying drawings are described in the context of mixing automatic transport vehicles of various sizes. In the following description, the automatic transport vehicle is alternately referred to as a computer-controlled vehicle, an AMR (automatic mobile robot), a transport vehicle, a first-size vehicle, a second-size vehicle, and a third-size vehicle, and the items carried thereon are referred to as first items, second items, and third items. In some embodiments, the automatic transport vehicle can take the form of an AMR. In order to solve the problems associated with the classification of large items that cannot be carried by standard-sized automatic transport vehicles, the embodiments of the currently disclosed subject matter provide an improved sorting system and method, which allows automatic transport vehicles of different sizes to run simultaneously on the same grid platform, and the related improved system and method are used to plan the travel path of each of these different-sized automatic transport vehicles so that they do not collide with each other when the automatic transport vehicle navigates the grid platform. The disclosed improved sorting system and method also provides an automated transport vehicle navigation controller and associated software for planning the travel path of each of the automated transport vehicles of different sizes so that no two automated transport vehicles or parts thereof occupy the same grid cell at the same time.

[0017] In an exemplary embodiment, for example, in a grocery store replenishment application, while several products can be loaded on a 500 mm size automated transporter, some products (such as a bag of dog food or a box of bottled water) may not fit on a 500 mm size automated transporter, and therefore require a 750 mm size automated transporter. On the other hand, some products (such as candy, medicine, or cosmetics) can be easily loaded on a 250 mm size automated transporter. Since larger automated transporters are more expensive and take up more space, in the embodiments described herein, it is best to use the best combination of appropriately sized automated transporters to minimize the cost and size of the overall improved automated transporter system. Although it is possible to operate 750 mm, 500 mm, and 250 mm automated transporters on the same grid consisting of 750 mm grid cells (grid cell size suitable for the largest size automated transporter) at the same time without any significant modifications to the navigation method, this arrangement does not have the advantage of saving space because the smallest 250 mm automated transporter will be allocated a path consisting of entire 750 mm grid cells throughout its entire driving route. Additionally, a problem that may arise with a 250mm automated transporter operating on a 750mm grid is that the edge of the 250mm automated transporter must be at the edge of a grid cell in order to transfer the items it is carrying to the destination container; however, when the 250mm automated transporter is located at the center of the 750mm grid, it will be too far from any edge.

[0018] Therefore, to avoid the above-mentioned inefficiencies and limitations, in various embodiments, the sorting system as described herein, i.e., system 501, advantageously provides for large automated transport vehicles (e.g., 750 mm automated transport vehicles) to travel on grid cells that are the size of small automated transport vehicles (e.g., 250 mm automated transport vehicles) in the system, so that automated transport vehicles of various sizes can avoid collisions when traveling on the grid to perform sorting operations. For example, in one embodiment, a large (e.g., 750 mm size) automated transport vehicle is able to travel on a path shared with a 250 mm grid cell, where a large (e.g., 750 mm size) automated transport vehicle will occupy multiple grid cells at any given time, where the system as a whole, and the advanced navigation and collision avoidance algorithms that form part of the system specifically apply a navigation algorithm that always tracks all grid cells occupied by large (e.g., 750 mm size) automated transport vehicles so that no collisions or accidental contact occur during sorting operations.

[0019] refer to Figure 1-5, a system 501 for directing item sorting operations is provided. In various embodiments, the system 501 includes a server 502, which includes a routing engine 508, a memory, a processor, etc. In some implementations, the routing engine 508 can be located outside the server 502, but still integrated with the server 502.

[0020] The system 501 also includes or communicates with a vehicle dimension database 512 and one or more destination containers 510. The system 501 includes additional components, such as an item information acquisition device 506 (e.g., a scanner, image capture device, and other similar devices) and a wireless access point 514. The system 501 also includes Figure 2 The grid 15 shown. Figure 2 As shown, the grid 15 includes a plurality of grid cells 18. In one embodiment, the grid 15 can be positioned on a platform 32 having a platform edge. The grid 15 is configured for a plurality of computer-controlled vehicles (e.g., automated transport vehicles or AMRs) to travel thereon, the AMRs including a first-size vehicle 112, a second-size vehicle 212, and a third-size vehicle 312 (e.g., Figure 3As shown). Each grid cell 18 includes a grid cell length X and a grid width Y; in at least one embodiment, the grid cell 18 is a square, where X is the length of the four sides of the grid cell 18. In other embodiments, the grid cell 18 may be a triangle, a rectangle, or other similar polygon; in some embodiments, the lengths of the sides of the grid cell 18 are equal. In various embodiments, the grid cell 18 may be provided with a reference mark at or near its geometric center. A plurality of automated transport vehicles include a first size vehicle, whose first vehicle length P is greater than the grid cell length X, and a second size vehicle 212, whose second vehicle length Q is greater than the first vehicle length. The system 501 also includes one or more target containers 510, wherein the system 501 is used to classify a plurality of items into the target container 510, the plurality of items including a first item 107 (e.g., 250 mm size) and a second item 207 (e.g., 500 mm size). In various embodiments, the system 501 is configured to receive item information corresponding to the first item 107 and the second item 207 at the server 502. In one embodiment, the item information acquisition device 506 interacts with the item to be classified (e.g., the first item 107 or the second item 207) to obtain item information present on the item, for example, the item information is carried on an identifier or tag coupled to the item. The server 502 receives the item information from the item information acquisition device 506. The system 501 is also configured to allocate the first item 107 to be transported by the first size vehicle 112 to the destination container, and the second item to be transported by the second size vehicle 212 to the destination container by the server 502. The system 501 is also configured to determine the first route of the first size vehicle by the routing engine 508, so that the first route has a first width equal to A*X, where a is an integer. The system 501 is also configured to determine the 50-second route of the second size vehicle by the routing engine 508, so that the second route has a second width equal to B*X, where B is an integer greater than A. To optimize efficiency, in various embodiments, system 501 ensures that only those grid cells 18 that have been occupied by an automated transport vehicle or are about to be occupied by an automated transport vehicle are cleared to prevent collision or contact between the automated transport vehicle, the items carried thereon, or the automated transport vehicle and the items; in other words, system 501 operates to allow grid cells 18 to be occupied by other vehicles further "along the way" along the path 60 determined for the second-sized vehicle 212 until the second-sized vehicle 212 is only a few seconds away from entering such "along the way" grid cell 18.

[0021] In various embodiments, the routing engine 508 is further configured to determine a turning center for each of the first sized vehicle 112 and the second sized vehicle 212 so that the vehicle stops and transfers the first item 107 and the second item 207 carried thereon to the target container, respectively. In at least one embodiment, the routing engine 508 is further configured to calculate that the distance between the turning center of the first sized vehicle 112 and the edge of the grid 15 is equal to or approximately 0.5 times the length P of the first sized vehicle. The routing engine 508 is further configured to calculate that the distance between the turning center of the second sized vehicle 212 and the edge of the grid is approximately 0.5 times the length Q of the second sized vehicle. In at least one embodiment, the system 501 is configured to direct each of the first sized vehicle 112 and the second sized vehicle 212 to stop at or near the turning center to begin depositing the first item 107 and the second item 207 into the target container 510

[0022] In at least one embodiment, the system 501 is further configured to calculate the number of first grid cells 18 that remain free at any time along a first route of a first-sized vehicle traveling from the inbound location to the destination container. In addition, in at least one embodiment, the system 501 does not keep the entire route of the vehicle from the inbound location to the destination container free; rather, the system 501 only keeps a portion of the route that the vehicle is on or about to enter free at any given time.

[0023] In at least one embodiment, the routing engine 508 is configured to calculate the first and second routes so that there is no physical contact between the items and the automated transport vehicle, between the items, and between the automated transport vehicles. In at least one embodiment, each grid cell 18 includes a reference marker 16. In at least one embodiment, the system 501 calculates the first number of grid cells so that is the square of a positive integer. As an illustrative example, the first number of grid cells can take values ​​of 1, 4, 9, 16, 25, 36, etc. In at least one embodiment, the second dimension vehicle length Q is an integer multiple of the first dimension vehicle length P. In at least one embodiment, the first dimension vehicle length P and the second dimension vehicle length Q are integer multiples of the grid cell length X.

[0024] In at least one embodiment, the system 501 includes a third-sized vehicle 312 (e.g., 750 mm size) having a third-sized vehicle length R greater than the second-sized vehicle length Q. In at least one embodiment, the third-sized vehicle length R is an integer multiple of the first-sized vehicle length P. In at least one embodiment, the third-sized vehicle length R is an integer multiple of the grid unit length X. In at least one embodiment, the system is further configured to determine, via the routing engine 508, a third travel route of the third-sized vehicle 312 such that the third travel route has a second width equal to C*X, where C is greater than B.

[0025] System 501 also provides an advanced article placement technology that advantageously overcomes the challenges of operating automated transport vehicles of various sizes on the same grid. In various embodiments, each automated transport vehicle is equipped with a transfer mechanism, such as a cross belt or a tilted tray, for transferring the items carried thereon to a target container located near a grid area, wherein the grid area (e.g., grid 15) can take the form of a platform or floor area, and a plurality of reference marks are arranged within the grid area. In order to successfully transfer the items transported by the automated transport vehicle to a position near the grid area, in one embodiment, the edge row of the reference mark is fixedly positioned at a distance from the edge of the grid area equal to half the width of the automated transport vehicle. For example, for a 500 mm automated transport vehicle, the reference mark is located at a distance of 250 mm from the edge, and for a 250 mm automated transport vehicle, the reference mark is located at a distance of 125 mm from the edge. In such an example, grid 15 is composed of 125 mm grid cells, and the distance from the edge of the platform to the edge of the grid cell is set to 62.5 mm. System 501 is also configured to calculate the specific center point at which the automated transport vehicle stops and starts to deposit the items it carries (e.g., by tilting a pallet or rotating a transverse conveyor) into a proximal target container. System 501 allows larger automated transport vehicle sizes to operate on the same grid in increments of the size of the smallest automated transport vehicle (e.g., 250 mm); for example, 750 mm automated transport vehicles, 500 mm automated transport vehicles, and 250 mm automated transport vehicles (i.e., multiples of 250 mm) can be mixed in a grid consisting of 125 mm grid cells. For a 750 mm automated transport vehicle, the system sets the specific center point at which the automated transport vehicle stops and starts to be deposited at 375 mm from the edge of the platform. For a 500 mm automated transport vehicle, the system sets the specific center point at which the automated transport vehicle stops and starts to be deposited at 250 mm from the edge of the platform. For a 250 mm automated transport vehicle, the system sets the specific center point at which the automated transport vehicle stops and starts to be deposited at 125 mm from the edge of the platform.

[0026] In another embodiment, a 600mm automatic transporter, a 400mm automatic transporter, and a 200mm automatic transporter (i.e., a multiple of 200mm) can be mixed in a grid consisting of 100mm grid cells. In such an example, the embodiment described herein provides a grid consisting of 100mm grid cells 50mm away from the edge of the platform. For the 600mm automatic transporter, the system sets the specific center point of the automatic transporter to stop and start storage at 300mm away from the edge of the platform. For the 400mm automatic transporter, the system sets the specific center point of the automatic transporter to stop and start storage at 200mm away from the edge of the platform. For the 200mm automatic transporter, the system sets the specific center point of the automatic transporter to stop and start storage at 100mm away from the edge of the platform.

[0027] In another embodiment, 300 mm automatic transporters, 200 mm automatic transporters, and 100 mm automatic transporters (i.e., multiples of 100 mm) can be mixed in a grid consisting of 50 mm grid cells. In such an example, the embodiments described herein provide a grid consisting of 50 mm grid cells, which is 25 mm away from the edge of the platform. For the 300 mm automatic transporter, the system sets the specific center point of the automatic transporter to stop and start storage at 150 mm away from the edge of the platform. For the 200 mm automatic transporter, the system sets the specific center point of the automatic transporter to stop and start storage at 100 mm away from the edge of the platform. For the 100 mm automatic transport vehicle, the system sets a specific center point so that the automatic transport vehicle stops and starts storage at 50 mm away from the edge of the platform.

[0028] System 501 includes an improved server collision avoidance protocol that ensures that all grid cells 18 occupied or about to be occupied by an automated transport vehicle are cleared. Depending on the size of the items carried by the transport vehicle, server 502 of system 501 operates to clear a predetermined number of grids along the route of the automated transport vehicle carrying the items (optionally on both sides of the route). In at least one embodiment, server 502 of system 501 operates to clear an odd number of grid cells 18 along the route of the transport vehicle so that the transport vehicle passes through the route without colliding with other vehicles or the items carried by these other vehicles. In at least one embodiment, the smallest transport vehicle is a first size vehicle 112, whose length is twice the length of a grid cell 18.

[0029] An autonomous transport vehicle (e.g., first dimensional vehicle 112, second dimensional vehicle 212, and third dimensional vehicle 312 (e.g., see Figure 3)) Turning is typically performed by stopping on the reference mark 16 and rotating approximately 90 degrees or 180 degrees to change the direction of travel. In at least one embodiment, the position of the reference mark 16 can be roughly coincident or superimposed with the center of rotation of the turning radius. In various embodiments, the automatic transport vehicle transports the items to be sorted from the sensing position to the target container position. In at least one embodiment, the item information acquisition device interacts with the items to be sorted to obtain the item information. The system 501 receives the item information (for example, from the item information acquisition device) and determines a target container among multiple target containers based on the item information to store the items therein. Each automatic transport vehicle may include a central processing unit ("CPU") or processor configured to control the movement and action of the automatic transport vehicle. The server 502 of the system 501 includes its own CPU or processor for communicating with the automatic transport vehicle and / or for controlling and directing the movement of each automatic transport vehicle. Each automatic transport vehicle may also be equipped with a wireless communication system configured to communicate with the wireless communication systems of other automatic transport vehicles and the wireless communication system of a centralized controller that constitutes part of the server 502. These wireless communication systems can communicate with each other via any available wireless communication technology, such as Wi-Fi communication (802.11 networks), radio frequency (RF) communication (e.g., in the 425 to 900 MHz frequency range), infrared (IR) communication, Bluetooth Communications or cellular communications (3G, 4G, 5G, etc.).

[0030] In at least one embodiment, each automatic transport vehicle includes a propulsion or motion mechanism, for example, in the form of wheels or tracks, and at least one motor for driving wheels or tracks to move and manipulate the automatic transport vehicle. In one embodiment, the movement of the automatic transport vehicle occurs on a controlled grid 15, wherein each automatic transport vehicle can only move in two vertical directions. For example, the automatic transport vehicle can be configured to move only between reference marks in the grid 15, each of which defines a node. The grid 15 can cover the area between the sensing position and multiple destination positions. However, other mobile modes of the automatic transport vehicle, such as optical navigation, radio frequency-based navigation, visible light navigation, invisible light navigation, electromagnetic signal-based navigation, SLAM, VSLAM (visual SLAM) and similar other navigation technologies are also within the scope of the currently disclosed subject matter. In some embodiments, the constraints on the movement of the automatic transport vehicle along the plane in two vertical directions can be realized by any one of (i) server 502, (ii) a separate controller of each automatic transport vehicle and (iii) a centralized controller or a combination thereof. In some embodiments, the automated transport vehicle is configured to move along the ground or along a flat surface in any direction, and the server 502 operates to avoid collisions 10 by any of a variety of traffic control methods known in the art, including, for example, optical navigation, radio frequency-based navigation, visible light navigation, invisible light navigation, electromagnetic signal-based navigation, and similar other collision avoidance protocols.

[0031] like Figure 2 As shown, in some embodiments, the automated transport vehicle is configured to move along the grid cells 18 formed by the grid 15, wherein the server 502 provides a "wide lane" for the automated transport vehicle that transports large items from the sensing location to the target container. For example, in one embodiment, large automated transport vehicles (e.g., second size vehicle 212 and third size vehicle 312) are provided to transport large items (e.g., second item 207 and third item 307) that are difficult or impossible to transport by conventional size automated transport vehicles (e.g., first size vehicle 112), which are sized to transport conventional size items (e.g., first item 107). In order to complete the transportation of large items, in the example Figure 2In one embodiment shown, the server 502 allocates: a first area 10 with a first area center 10a (equal to four grid cells 18; 2x2 node square) for a first size vehicle 112; a second area 20 (equal to nine grid cells 18; 3x3 node square) with a second area center 20a for a second size vehicle 212; a third area 30 (equal to 16 grid cells 18; 4x4 node square) with a third area center 30a for a third size vehicle 312. In this embodiment, the first size vehicle 112 has a first vehicle length P, the second size vehicle 212 has a second vehicle length Q, the third size vehicle 312 has a third vehicle length R, and the grid cell 18 has a grid cell length X. In this embodiment, the system 501 provides the following relationships: the second vehicle length Q is an integer multiple of the first vehicle length P; the first and second vehicle lengths P, Q are integer multiples of the grid cell length X; the third vehicle length R is greater than the second vehicle length Q; the third vehicle length R is an integer multiple of the first vehicle length P; the third vehicle length R is an integer multiple of the grid cell length X.

[0032] In at least one embodiment, the grid 15 is modified to provide a wide transverse lane and a wide longitudinal lane along which the second dimension vehicle 212 or the third dimension vehicle 312 travels to (or away from) the large item location. In one embodiment, this is accomplished, for example, by a control server (e.g., Figure 1 A centralized controller running on a server 502 (shown in FIG. 5 ) or in the form of a control server determines that a given automated transport vehicle carrying or configured to carry large items requires a predetermined number of grid cells 18 or nodes during parking and driving. This is achieved, for example, by a large item automated transport vehicle (e.g., second size vehicle 212 or third size vehicle 312) indicating that it will occupy one or more grid cells 18 (each grid cell 18 can be considered equivalent to a node) that are adjacent to and can be centered on it. For example, as directed or arranged by system 501, a large item automated transporter may appear to occupy an area equal to four grid cells 18 (2x2 node squares), nine grid cells 18 (3x3 node squares), 16 grid cells 18 (4x4 node squares), or 25 grid cells 18 (5x5 node squares), as well as other similar grid areas representing simple integer squares, with other automated transporters being directed by server 502 (or routing engine 508 forming part of server 502) to leave ample space for the large item automated transporter at any given time.

[0033] In one embodiment, a large-item automated transport vehicle (e.g., second-size vehicle 212 or third-size vehicle 312) can utilize a "large-item grid" (whose nodes do not necessarily correspond to nodes of an existing "conventional" grid), and the large-item automated transport vehicle moves along this dedicated large-item grid rather than a conventional grid. The server 502 (or, the routing engine 508 or the automated transport vehicle's own controller) can then indicate to other automated transport vehicles that a specified grid cell or node within a certain distance of the currently occupied large-item grid cell or node has been occupied. In one embodiment, the system 501 can effectively design a large-item grid so that the footprint of an automated transport vehicle carrying large items is reduced to a minimum area, such as a square of 2x2 nodes, thereby minimizing the footprint of the large-item grid and its impact on the movement of other automated transport vehicles.

[0034] By providing one or more large-scale automated transport vehicles (e.g., second-size vehicle 212 or third-size vehicle 312) that are larger than conventional (or small) automated transport vehicles (e.g., first-size vehicle 112) to transfer large items from sensing locations to destination containers, the available square footage of grid 15 can be effectively utilized. In some embodiments, server 502 configures the path or route of travel of the large-scale automated transport vehicle so that the large-scale automated transport vehicle always moves along the dedicated large-item grid determined by server 502 to further reduce the chance of a large-scale automated transport vehicle (or a large-item carried thereon) colliding with a conventional automated transport vehicle (or a conventional item carried thereon). In some embodiments, server 502 configures the path or route of travel of the large-scale automated transport vehicle so that the large-scale automated transport vehicle always moves along the dynamically determined large-item grid determined by server 502 to reduce the chance of a large-scale automated transport vehicle (or a large-item carried thereon) colliding with a conventional automated transport vehicle (or a conventional item carried thereon). In one embodiment, all sensing locations and all destination containers are set to be large enough to handle the largest item that system 501 allows to be sorted.

[0035] In one embodiment, the grid 15 includes square grid cells 18, for example, spaced as a 1x1 foot grid, a 2x2 foot grid, a 3x3 foot grid, a 4x4 foot grid, a 5x5 foot grid, or a 6x6 foot grid. However, grids of other shapes, such as rectangular, L-shaped, and all other shapes specified by the current application, are also within the scope of the presently disclosed subject matter. By limiting the automated transport vehicles in this manner, collisions can be avoided by each automated transport vehicle communicating with the server 502 or central controller to ensure that it moves to a grid cell that is unoccupied upon arrival. In one embodiment, the grid 15 includes nodes corresponding to, for example, the grid cells 18, each of which includes a fiducial marker 16.

[0036] In one embodiment, each item introduced onto the automated transport vehicle includes item information provided on an identification tag, such as an RFID tag, a barcode, a QR code, etc., wherein the item information may be unique to each item introduced for classification by the system 501. In order to track the classified items, one or more item information acquisition devices 506 provided at each stripping location are used to read or acquire the item information and transmit the acquired item information to the server 502 through their respective communicators. After receiving the item information, the server 502 may associate the item information with the corresponding automated transport vehicle 10 into which the corresponding item is introduced or placed, which is determined by the item information acquisition device 506 (e.g., in the form of a scanner) at the introduction location.

[0037] In one embodiment, the sensing location includes an item information acquisition device 506 that acquires item information from the second item 207 that is sensed to be sorted into the target container 510. The item information acquisition device 506 communicates with the server 502. When the item information received by the server 502 indicates that the second item 207 is a large item and therefore requires a larger automatic transport vehicle (e.g., the second sized vehicle 212) to transport the second item 207 from the sensing location to the target container, the server 502 coordinates with the routing engine 508 and the vehicle size database 512 to determine and execute a travel path for the second sized vehicle 212 to transfer or transport the second item 207 to the target container. The server 502 then instructs the second sized vehicle 212 to collect the second item 207, travel along the route determined by the second item 207, and place the second item 207 into the target container designated to receive the second item 207. In at least one embodiment, the routing engine 508 is configured to calculate the route or path of the second size vehicle 212 so that there is no physical contact between items and the automated transport vehicle, between items, and between automated transport vehicles throughout the entire route or path of the second size vehicle 212. In at least one embodiment, the second size vehicle length Q (i.e., the length of the second size vehicle 212) is an integer multiple of the first size vehicle length P (i.e., the length of the first size vehicle 112). In at least one embodiment, the first size vehicle length P and the second size vehicle length Q are integer multiples of the grid unit length X.

[0038] In at least one embodiment, the system 501 includes a third-sized vehicle 312, whose third-sized vehicle length R is greater than the second-sized vehicle length Q, wherein the third-sized vehicle length R is an integer multiple of the first-sized vehicle length P, and wherein the third-sized vehicle length R is an integer multiple of the grid unit length X; in this implementation, the server 502 coordinates with the routing engine 508 and the vehicle size database 512 to determine and execute a driving path of the third-sized vehicle 312 based on the item information of the third item 307 received at the server 502. The routing engine 508 or the server 502 determines a third driving route of the third-sized vehicle 312 so that the third driving route has a second width equal to C*X, where C is an integer greater than B.

[0039] In at least one implementation, system 501 provides an improved article storage technique for storing a third article 307 transported by a third size vehicle 312 and a second article 207 transported by a second size vehicle 212. In order to successfully transfer the articles transported by the automated transport vehicle to a location adjacent to the grid area, the edge row of the fiducial markers is fixedly positioned next to the edge of the grid area, with a distance equal to half the width of the automated transport vehicle. For example, for a 500 mm automated transport vehicle, the fiducial markers are 250 mm from the edge, while for a 250 mm automated transport vehicle, the fiducial markers are 125 mm from the edge. In an example consisting of 250 mm, 500 mm, and 750 mm automated transport vehicles, the embodiments described herein provide a grid consisting of 125 mm grid cells, the fiducial markers are 125 mm from the edge, and the distance from the edge of the platform to the edge of the grid cell is set to 62.5 mm for the 250 mm automated transport vehicle, 125 mm for the 500 mm automated transport vehicle, and 250 mm for the 750 mm automated transport vehicle. The system 501 is accordingly configured to calculate specific center points at which the automated transport vehicle stops and begins storage (eg, by tilting a pallet or rotating a transverse conveyor).

[0040] The computer-controlled vehicle, such as the first dimension vehicle 112, the second dimension vehicle 212, or the third dimension vehicle 312, may be an autonomous mobile robot (automatic transport vehicle). In some embodiments, the automatic transport vehicle may include a cross belt for engaging and collecting the first object 107, the second object 207, or the third object 307 to be sorted. The identifier on the object (e.g., the first object 107, the second object 207, or the third object 307) may be scanned by an object information acquisition device located at or near the sensing location to associate the automatic transport vehicle with the specific object (e.g., the first object 107, the second object 207, or the third object 307) carried thereon. The server 502 determines a specific target container 510 in which to store the object (e.g., the first object 107, the second object 207, or the third object 307) from among the plurality of target containers 510 based on the object information received from the object information acquisition device, and instructs the automatic transport vehicle to transport the object (e.g., the first object 107, the second object 207, or the third object 307) to the designated target container 510.

[0041] In one embodiment, system 501 includes two or more vertically separated layers, wherein grid 15 can be set on the top layer, and the bottom layer can be used for unloaded automatic transport vehicles to travel and return to the designated sensing location, thereby improving the efficiency of automatic transport vehicles by reducing traffic. In some embodiments, according to embodiments of the present invention, additional layers can be provided between the top layer and the bottom layer. System 501 may also include an elevator (not shown) for automatic transport vehicles to move between layers. An automatic transport vehicle parking area may also be provided, where the automatic transport vehicle can rest or park during idle periods, or can be parked while waiting in line during busy periods, and a charging location may also be provided, where the automatic transport vehicle can be charged.

[0042] Figure 3 An example of an automated transport vehicle for transporting items is shown as part of the system 501 described herein. Figure 3 , an automatic transport vehicle (e.g., in the form of a first-dimensional vehicle 112, a second-dimensional vehicle 212, or a third-dimensional vehicle 312) transports items (e.g., a first item 107, a second item 207, or a third item), wherein the items include item information in the form of an identifier or a tag that can be read by a scanner, such as an RFID tag, a barcode, or a QR code.

[0043] Figure 4 A square node grid for autonomous transport vehicle movement is shown in accordance with at least one embodiment of the present invention. Figure 4Also shown is an example of how collisions can be prevented when large items (e.g., the second item 207 or the third item 307) are being transported, where a large (or larger) automated transport vehicle is assigned a large clearance area in the form of a fourth area 306 to avoid collisions. In Fig. 4, each hollow circle represents an unoccupied node 302 in the grid 15, and each solid circle represents an occupied node 304 in the grid 15. In at least one embodiment, each node (whether occupied or unoccupied) is assigned an area equal to the area of ​​one grid cell 18, and each node includes a fiducial marker 16. In at least some embodiments, the fiducial marker 16 serves as a center of rotation for the automated transport vehicle as it turns to change direction or steer items carried thereon (e.g., relative to a fiducial marker 16 along an edge of the grid 15) to a proximal target container 510. Figure 4 The area shown in the figure can be located between the sensing location and the target container 510, although neither is contained within the area shown. As shown, the fiducial marker 16 serves as a rotation center for the automated transport vehicle as it turns to change direction or steer items carried thereon (e.g., relative to the fiducial marker 16 along the edge of the grid 15) to the proximal target container 510. Figure 4 The area shown in FIG. 5 may be located between the sensing location and the target container 510, although neither is included in the area shown. Figure 4 As shown, each node may be unoccupied (e.g., unoccupied node 302 is Figure 4 ), or may be occupied or about to be occupied (for example, occupied nodes 304 may include some nodes about to be occupied, Figure 4 For regular-sized items, a node is occupied if an automated transport vehicle (eg, first-sized vehicle 112) carrying an item (eg, first item 107) is currently located at the node or is moving toward the node. Figure 4 The three blocks in the figure correspond to an automatic transport vehicle respectively, wherein the fourth area 306 corresponds to the area required for the second-size vehicle 212 or the third-size vehicle 312 to pass safely, and the fifth area 308 corresponds to the area required for the first-size vehicle 112 to pass safely, and the arrows indicate the movement direction of each automatic transport vehicle. Figure 4 As shown, the maximum number of nodes that can be simultaneously assigned to an automatic transport vehicle carrying regular-sized items (represented by the fifth area 308 with smaller squares) is two, namely, the first node where the automatic transport vehicle is currently located (or leaving) and the second node that the automatic transport vehicle is about to drive to or enter. On the other hand, the server 502 assigns nodes adjacent to the central node that the large-item automatic transport vehicle travels to and from to the second-size vehicle 212 or the third-size vehicle 312 (represented by larger squares) carrying large-items (e.g., the second item 207 or the third item 307). Therefore, in Figure 4 In the example shown, the second-sized vehicle 212 carrying the second item 207 (or the third-sized vehicle 312 carrying the third item 307) is effectively assigned by the server 502 to between 9 and 12 nodes, thereby advantageously preventing collisions between automated transporters, between items and automated transporters, and between items carried by automated transporters; however, it is understood that the number of additional nodes occupied by larger items (e.g., the third item 307) may be greater than 12. Figure 4 More than that shown in (e.g., 16 or 20 nodes).

[0044] In a given application, Figure 4 Whether the implementation shown in may be better depends on several factors, such as the geometry of the grid 15, the size and shape of the large items, the number of automated transport vehicles on the grid 15, the distances between nodes in the grid 15, and similar other factors. In another exemplary grid implementation, the server 502 may logically alternate between a regular grid and a large item grid as appropriate, where the server 502

[0045] Configured to dynamically determine which is more efficient based on the situation and implement the most effective solution.

[0046] Figure 1 A block diagram of an exemplary implementation of an improved system for mixed-size automated transport vehicles for sorting items into target containers is depicted, the improved system including an improved server collision avoidance protocol as described herein. Referring to FIG. 5 , in one embodiment, system 501 includes server 502, routing engine 508, vehicle size database 512, item information acquisition device 506 (e.g., scanner, image capture device, and similar other devices), computer-controlled vehicle 12 (similar to first size vehicle 112, second size vehicle 212, and third size vehicle 312), destination container 510, and wireless access point 514, etc., which are depicted in a representative manner as blocks representing a general description of the technology. Server 502 is a control server that is configured to communicate with one or more components of system 501, as described herein, and, for example, as described herein. Figure 1As shown. In one embodiment, the server 502 includes a memory, a processor and / or one or more communication interfaces, which are communicatively coupled to each other. The network can constitute a part of the system 501, wherein the network can take any appropriate form, including a wireless network (such as Wi-Fi, cellular or other privately used frequency bands) or a hard-wired network (such as LAN, WAN, Internet, etc.) and a combination thereof. In one embodiment, the server 502 can communicate with the cloud through the network. In some embodiments, one or more components of the server 502 can reside in the cloud. Similarly, multiple components (e.g., item information acquisition device 506, wireless access point 514, computer-controlled vehicle 12 (these are similar to the first size vehicle 112, the second size vehicle 212 and the third size vehicle 312) and server 502) can communicate with the cloud through the network. In some embodiments, one or more components of the system 501 can reside in the cloud. For example, in one embodiment, the server 502 can reside in the cloud. In at least one embodiment, the server 502 can communicate with one or more third-party servers, such as a warehouse management system server and an automatic transport vehicle operation control server.

[0047] As used herein, the term "cloud" refers to multiple servers connected to the Internet that can be rented as part of a software or application service. Cloud-based services can include web hosting, data hosting and sharing, and software or application usage. The term "cloud" also refers to cloud computing, in which multiple servers are linked together to share the load. This means that complex processes can be distributed across multiple smaller computers instead of using one powerful machine. In various embodiments, server 502 can be or can include a server, as the term "server" is understood in its broadest sense. The term "server" as used herein includes any computer that provides data to other computers. It can provide data to systems on a local area network (LAN) or a wide area network (WAN) via the Internet. In various embodiments, server 502 can be or can include a cloud server. The term "cloud server" as used herein includes any centralized, hosted and delivered server resources over a network (usually the Internet) and can be accessed on demand by multiple users. A cloud server can be located at a remote location (e.g., residing in a remote cloud server configuration). A cloud server can be a virtual server (rather than a physical server) running in a cloud computing environment. A cloud server can include all the software required to run and can run as a standalone unit. Cloud servers can perform all the same functions of traditional physical servers, including providing processing power, storage, and applications. One of the advantages of cloud storage is that there are many distributed resources operating as one - often called a federated storage cloud. This makes the cloud highly tolerant to failures because of the distribution of data. Using the cloud can reduce the creation of different versions of files because of shared access to documents, files, and data. Figure 1-5 Each component shown in the figure can communicate with one or more other components through a wired and / or wireless network. For example, the cloud, server 502 can also communicate with routing engine 1508, vehicle size database 512, item information acquisition device 506, computer-controlled vehicle 12, destination container 510, and wireless access point 514 through the network.

[0048] Figure 5 A flow chart of an exemplary process corresponding to system 501 is shown. Figure 5 The exemplary process shown in can be implemented by, for example, server 502. Figure 5 , at step 602, item information corresponding to the first item 107 and the second item 207 is received, for example, at the server 502; in one implementation, the server 502 receives the item information from the item information acquisition device 506. At step 604, the server 502 allocates the first item 107 to be transported by the first size vehicle 112 to the destination container; the server 502 also allocates the second item 207 to the destination container 510 for transportation by the second size vehicle (where the second size vehicle is larger than the first size vehicle, or the second size vehicle has a greater cargo capacity than the first size vehicle). At step 606, the routing engine 508 (or the server 502) determines a first route for the first size vehicle 112, such that the first route has a first width equal to A*X, where A is an integer and X is the length of the grid unit. At step 608, the routing engine 508 (or the server 502) determines a second route for the second size vehicle, such that the second route has a second width equal to B*X, where B is an integer greater than A.

[0049] According to at least one embodiment, a material sorting method includes: receiving item information corresponding to a first item and a second item at a server; the server allocates the first item to be transported by a first-sized vehicle to a destination container, and allocates the second item to be transported by a second-sized vehicle to a destination container; a routing engine communicating with the server determines a first route for the first-sized vehicle, so that the first route has a first width equal to A*X, where A is an integer; and the routing engine determines a second route for the second-sized vehicle, so that the second route has a second width equal to B*X, where B is an integer greater than A.

[0050] According to one embodiment, the method further includes: the routing engine determining a turning center for the first and second sized vehicles to stop and turn the first and second articles carried thereon toward the destination container.

[0051] According to one embodiment, the method further includes: the routing engine calculates that the distance between the turning center of the first size vehicle and the edge of the grid is approximately 0.5 times the length of the first vehicle; and the routing engine calculates that the distance between the turning center of the second size vehicle and the edge of the grid is approximately 0.5 times the length of the second vehicle; wherein

[0052] The grid includes a plurality of grid cells for a plurality of computer-controlled vehicles to travel thereon, each grid cell having a grid cell length X, a first size vehicle having a first vehicle length greater than the grid cell length X, and a second size vehicle having a second vehicle length greater than the first vehicle length.

[0053] According to one embodiment, the method further includes: calculating, by the routing engine, a first number of grid cells that remain idle at any time when a first-sized vehicle travels from the sensing location to the destination container on the first route, wherein the grid includes a plurality of grid cells for a plurality of computer-controlled vehicles to travel thereon, each grid cell having a grid cell length X.

[0054] According to one embodiment, the method further includes calculating, by a routing engine, the first and second routes so that there is no physical contact between the item and a plurality of computer-controlled vehicles traveling in a grid, the grid comprising a plurality of grid cells, the plurality of computer-controlled vehicles being able to travel on the grid, between the items, and between the plurality of computer-controlled vehicles.

[0055] According to one embodiment, the method further includes: determining, by a routing engine, a third driving route of a vehicle of a third size, wherein a third vehicle length of the vehicle of the third size is greater than the second vehicle length, so that the third driving route has a second width equal to C*X, where X is an integer greater than B.

[0056] Those skilled in the art will appreciate that the embodiments described in this application are examples, and the scope of this application is not limited by these examples or embodiments. For example, although the preferred embodiments relate to sorting robots, the apparatus and methods described herein are equally applicable to any automated transport vehicle for transporting or transferring items of different sizes. For example, the disclosed apparatus and methods are also applicable to pick-assist robot applications. Similarly, the disclosure herein also relates to lifting robots and several other types of robots used in warehouse and material handling facility applications.

Claims

1. A material sorting system, characterized in that: include Server, including memory, processor and routing engine; a grid including a plurality of nodes for a plurality of computer-controlled vehicles to travel thereon, each node being assigned a grid cell area, each node being designated as occupied when a computer-controlled vehicle occupies at least a portion of the grid cell area assigned to the node; a plurality of computer-controlled vehicles including a first sized vehicle having a first vehicle length and a second sized vehicle having a second vehicle length greater than the first vehicle length; Destination container; a plurality of articles to be sorted into a destination container, the plurality of articles comprising a first article and a second article; Wherein, the system is configured as follows: receiving, at a server, item information corresponding to a first item and a second item; The server transports the first item to the destination container by a vehicle of the first size, and transports the second item to the destination container by a vehicle of the second size; Allocating, by a routing engine, a first number of nodes N corresponding to a collision avoidance clearance area occupied by a vehicle of a first size; and A second number of nodes M corresponding to the collision avoidance clearance area occupied by vehicles of the second size is allocated by the routing engine, where M is greater than N.

2. The material sorting system according to claim 1, characterized in that: The system is also configured to designate, by the routing engine, a plurality of nodes that are not designated as occupied as unoccupied nodes, the nodes comprising a fiducial marker that serves as a center of rotation for the first-size vehicle and the second-size vehicle when changing direction or turning a turn.

3. The material sorting system according to claim 2, characterized in that: The system is further configured to direct each of the first sized vehicle and the second sized vehicle to stop at or near the center of rotation to begin depositing the first and second items into the target container.

4. The material sorting system according to claim 1, characterized in that: The system is also configured to designate a node as occupied when a computer-controlled vehicle is about to occupy at least a portion of the grid cell area assigned to the node.

5. The material sorting system according to claim 1, characterized in that: The system is further configured to assign a node as occupied when the computer-controlled vehicle is heading toward at least a portion of the grid cell area assigned to the node.

6. The material sorting system according to claim 1, characterized in that: The system is further configured to assign the node as occupied based on at least one of a shape and a size of the second item.

7. The material sorting system according to claim 1, characterized in that: The system is also configured to assign nodes as occupied based on the number of computer controlled vehicles traveling on the grid.

8. The material sorting system according to claim 1, characterized in that: The system is further configured to assign nodes as occupied based on distances between nodes or to assign nodes as occupied based on a geometry of the grid.

9. The material sorting system according to claim 1, characterized in that: The system is also configured to calculate the first route and the second route such that there is no physical contact between the items and the plurality of computer-controlled vehicles, and between the items and the plurality of computer-controlled vehicles.

10. A material sorting method, characterized in that: Using the system according to any one of claims 1 to 9, comprising: receiving, at a server, item information corresponding to a first item and a second item; allocating, by the server, a first object to be transported by a first-sized vehicle to a destination container and a second object to be transported by a second-sized vehicle to a destination container; allocating, by the routing engine, a first number N of nodes corresponding to a clearance area for avoiding collisions occupied by vehicles of the first size, the nodes forming a portion of a grid on which vehicles of the first size and vehicles of the second size travel, each node being allocated a grid cell area, each node being allocated as occupied when a computer-controlled vehicle occupies at least a portion of the grid cell area allocated to the node; A second number of nodes M corresponding to a clearance area for avoiding collision occupied by a vehicle of a second size is allocated by the routing engine, wherein M is greater than N.

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