Material carrying method and device

Abstract

Methods and apparatus are provided for classifying items into a plurality of classification bins. After the items are classified into the classification box, the classification box can be automatically emptied into a separate container. Alternatively, the classification box can be detached from the device for processing at a remote destination. The apparatus may include a plurality of delivery vehicles for delivering items to the classification bin. The apparatus may also include a plurality of retrieval carriers for retrieving the sorted bins after all the items of the group are sorted into the bins. The retrieval carrier may be configured to move retrieved bins to one or more discharge stations where items in the sorted bins may be emptied into separate containers, such as cassettes for transporting the items.

Description

[0001] Citation of Related Applications This application claims priority to PCT Application No. PCT / US24 / 16389, filed February 19, 2024, which claims priority to U.S. Provisional Application No. 63 / 590,647, filed October 16, 2023, which claims priority to U.S. Provisional Application No. 63 / 446,575, filed February 17, 2023. The entire disclosure of each of the foregoing applications is incorporated herein by reference. Technical Field

[0002] The present invention relates generally to a material handling system and, more particularly, to a system operable to receive and sort articles into a plurality of bins or other displaceable containers. The system may include a retrieval mechanism for retrieving the bins after the articles have been sorted into the bins. Background Art

[0003] The inventors herein have observed that accumulating inventory items to form corresponding groups for purposes such as fulfilling corresponding orders to be shipped to customers or retail locations and / or processing returns of inventory items can be laborious, time-consuming, inefficient, and prone to error. These and other disadvantages are most acutely felt when items must be retrieved from inventory (or returned to inventory) in large quantities from dispersed locations within a warehouse or other large facility. By way of illustration, a single order fulfillment center may receive thousands or more orders per day, each of which requires one, several, or many different items to be retrieved from inventory and assembled into one or more containers for shipment to customers. The least efficient method currently in use requires processing inventory items in a single step by manually retrieving the items from a storage area (e.g., via batch or wave picking) and placing them directly into containers for shipment. Slightly less efficient methods involve, in a first step, placing the items into a temporary item accumulation area or compartment called a "drop wall," and then, in a second step, transferring the accumulated groups of items into shipping packages or cartons. After all items for an order have been accumulated in the manner described above, the packing process is complete and the package, carton or other container can be shipped directly to the customer.

[0004] A more complex system than the prior art systems described above is disclosed in U.S. Patent No. 11,607,713, which is commonly owned by OPEX Corporation, the assignee of the present invention, and was issued to McVaugh et al. on March 21, 2023. McVaugh et al. disclose sorting articles by using movable carriers arranged in aisles between rows and / or columns of sorting bins. The articles are delivered one by one by the carriers in the order in which they arrive at the input station. In the embodiment disclosed by McVaugh et al., the delivery system is implemented as a plurality of independently movable carriers, and indicators are provided to alert operators to events (such as when a sorting bin is ready to be transferred to a container that can be moved to another destination).

[0005] While the system of McVaugh et al. represents a significant advance in the art, the inventors herein have observed that once the items have been sorted into the array of sorting bins, a significant amount of manual handling is still required, with the potential for damage to the sorted items during the necessary handling. With continued pressure to increase processing speeds and reduce the manual handling required for sorting systems, it would be desirable to reduce the manual handling required to handle orders after the items have been sorted. 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] In accordance with embodiments of the present disclosure, the shortcomings and problems associated with conventional warehouse automation methods of sorting inventory items into groups and the subsequent operations associated with sorted item groups have been significantly reduced or eliminated by a sorting system that can be configured to perform various tasks associated with inventory management, distribution center and / or order fulfillment operations.

[0008] The present invention provides various aspects that may form part of a material handling system. The system may include one or more of the various aspects of the present invention, as further described below.

[0009] According to one aspect of the present invention, a device for sorting a plurality of articles is provided. In one embodiment, the device includes: a plurality of sorting boxes, each sorting box defining an internal volume and having an entrance; a rack configured to hold each sorting box at a corresponding position spatially separated from other positions. The sorting boxes held by the rack are organized into rows and / or columns and maintained in a configuration and orientation that enables accumulation of articles in each sorting box. The sorting boxes are arranged along one or both sides of an aisle within which (1) an article sorting system is movable, which receives articles arriving at an input station of the device, transports the articles within the aisle, and operates a first transfer mechanism to deliver the articles one at a time to one or more sorting boxes; and (2) a sorting box retrieval mechanism operable to retrieve a sorting box containing a group of accumulated articles and transport the sorting box to a transfer position arranged within the aisle and proximate to a discharge station of the device.

[0010] According to one aspect, the assortment bin retrieval mechanism extends a second transfer mechanism at the transfer location to initiate unloading of a group of accumulated items from the assortment bin at the unloading station into a container displaced from the aisle. Alternatively or additionally, the assortment bin retrieval mechanism extends the second transfer mechanism to move the assortment bin, along with the group of accumulated items contained therein, away from the aisle. In such an embodiment, the departing assortment bin is replaced by an empty assortment bin.

[0011] According to an embodiment of the present invention, a sorting system movable within an aisle includes a plurality of independently movable carriers, each of which is movable along a path segment of a vertical loop extending within the aisle. Each of at least a first group of independently movable carriers is movable along a corresponding item delivery path, the item delivery path comprising: an input station at which items are transferred to one of the plurality of carriers; and a delivery location adjacent to a shelf's sorting bin holding location. Each item delivery path may comprise a continuous horizontal and / or vertical segment of the vertical loop within the aisle.

[0012] Additionally or alternatively, each of the at least second group of independently movable carriers can be respectively movable along a segment of a vertical loop extending within the aisle. Each of the at least second group of independently movable carriers can be movable along a path segment of a corresponding assortment bin retrieval path, the assortment bin retrieval path comprising: a location within the aisle from which the assortment bin is retrieved onto the carrier; and a location within the aisle from which the assortment bin is transferred from the carrier and away from the aisle into an assortment bin discharge station, which can be an area for emptying accumulated items into a container displaced from the aisle. The assortment bin retrieval path can include continuous horizontal and / or vertical segments of the vertical loop within the aisle.

[0013] According to another aspect of the invention, the unloading station defines one or more unloading areas that are sized and arranged to receive an assortment box after accumulating items in one of a plurality of assortment boxes, wherein carriers of at least a second group of the plurality of carriers are capable of moving along horizontal and / or vertical sections of an assortment box retrieval path that extends from a retrieval position adjacent to an assortment box holding position of the rack structure to a position adjacent to at least one unloading area of ​​the unloading station.

[0014] According to one aspect of the present invention, an apparatus for sorting a plurality of articles is provided. The apparatus includes a plurality of sorting bins and a rack defining an aisle and configured to support the plurality of sorting bins at spatially separated locations along at least a first side or a second side of the aisle. The apparatus also includes a delivery mechanism operable within the aisle to deliver articles to the sorting bins and a retrieval mechanism operable within the aisle to retrieve the sorting bins after the articles have been sorted into the sorting bins.

[0015] According to one aspect, a first set of assortment bins of the apparatus is supported by a shelf along a first side of an aisle, and a second set of assortment bins are positioned along a second side of the aisle, and a retrieval mechanism is operable to move the assortment bins from a storage location within the shelf into the aisle. According to another aspect, the retrieval mechanism is movable vertically and / or horizontally within the aisle.

[0016] In some embodiments, the delivery mechanism and / or the retrieval mechanism are implemented by multiple independently operable carriers. All carriers or a subset of carriers can perform the delivery function, and all carriers or a subset of carriers can perform the retrieval function. In one embodiment, the carrier that performs the delivery function (delivery carrier) includes a transfer mechanism that is operable in a first direction to transfer items from the delivery carrier to one of the sorting boxes along the first side of the aisle, and is operable in a second direction to transfer items from the delivery carrier to one of the sorting boxes along the second side of the aisle. The delivery carrier can be controlled within the aisle to move along a segment of a vertical loop that includes an input station for receiving items from outside the aisle and one or more of the sorting boxes.

[0017] According to one aspect of an embodiment in which the delivery mechanism and / or retrieval mechanism includes vehicles, each vehicle includes an energy storage device for providing power for operation of the vehicle, and wherein charging elements are provided within the aisle for charging the vehicles as they move within the aisle.

[0018] According to any of the foregoing embodiments utilizing a carrier as a delivery and / or retrieval mechanism, the apparatus may include a track for guiding the carrier to the assortment bin. In some such embodiments, both the retrieval mechanism and the delivery mechanism are implemented as a plurality of carriers capable of moving within an aisle, the aisle being arranged between a first group of assortment bins and a second group of assortment bins, and each carrier incorporating either or both of the following mechanisms: a first transfer mechanism operable to unload items into an assortment bin outside the aisle; and a second transfer mechanism capable of extending in a first direction to hold the assortment bin and retracting the assortment bin from its support position along the rack into the aisle for movement within the aisle. In such an embodiment, the second transfer mechanism is further configured to extend from the aisle into a discharge position.

[0019] According to another aspect of the present invention, the apparatus includes one or more unloading stations configured to receive one of the sorting bins after the articles have been sorted into the sorting bin. In one embodiment, the sorting bin includes a movable wall, and the unloading station is configured to facilitate movement of the movable wall when one of the sorting bins is transferred to the unloading station so that the articles can be unloaded from the sorting bin.

[0020] A method for sorting items into groups, comprising: loading a plurality of items one at a time onto a delivery mechanism capable of moving within an aisle at a loading station; operating the delivery mechanism within the aisle to deliver the items to corresponding assortment boxes among a plurality of assortment boxes arranged along the aisle, the operation comprising transporting each loaded item along a vertical loop within the aisle, the vertical loop comprising a loading position and a corresponding destination adjacent to one of the assortment boxes, and operating a transfer mechanism of the delivery mechanism to deposit the items into the assortment boxes respectively so as to accumulate the item groups in the assortment boxes; determining that the item groups assigned to the assortment boxes have been accumulated in a first assortment box; and retrieving the first assortment box, the retrieval comprising moving the retrieval mechanism to a position close to the first assortment box within the aisle; shifting the first assortment box and the accumulated item positions into the aisle while maintaining the first assortment box; transporting the first assortment box to a first unloading station within the aisle; unloading the accumulated items from the first assortment box into a first container separated from the aisle at the first unloading station; and removing the first container from the first unloading station. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The foregoing summary and the following detailed description of 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: Figure 1 is a plan view of a material handling device incorporating aspects of the present invention.

[0022] Figure 2 yes Figure 1 A partial perspective view of an illustrated material handling device.

[0023] Figure 3 yes Figure 1 A side view of an illustrated material handling device.

[0024] Figure 4 yes Figure 1 An end view of the illustrated material handling device.

[0025] Figure 5 It shows Figure 1 A partial side view of a portion of a track of an illustrated material handling device.

[0026] Figure 6 yes Figure 1 A plan view of a delivery vehicle of an illustrated material handling device.

[0027] Figure 7 yes Figure 6 End view of the illustrated delivery vehicle.

[0028] Figure 8 yes Figure 1 A perspective view of a retrieval carrier of an illustrated material handling system.

[0029] Figure 9 yes Figure 8 A perspective view of the illustrated retrieval carrier is shown illustrating the retrieval assembly in an extended position.

[0030] Figure 10 yes Figure 9 A perspective view of the illustrated retrieval carrier illustrating the retrieval latch in the extended position.

[0031] Figure 11A yes Figure 8 A perspective view of an illustrated retrieval carrier positioned with Figure 1 The material handling devices are shown with their classification positions adjacent to each other.

[0032] Figure 11B yes Figure 11A A perspective view of the illustrated retrieval carrier illustrating the box holder in a retracted position.

[0033] Figure 11C yes Figure 11A A perspective view of an illustrated retrieval carrier with a case partially retrieved from a sorting location.

[0034] Figure 11D yes Figure 11A A perspective view of an illustrated retrieval vehicle with boxes loaded onto the retrieval vehicle.

[0035] Figure 12A yes Figure 11A A perspective view of an illustrated retrieval vehicle at a discharge station, with the discharge station partially broken away.

[0036] Figure 12B yes Figure 12A A perspective view of an illustrated retrieval vehicle at a discharge station.

[0037] Figure 12C yes Figure 12A A bottom perspective view of the illustrated retrieval vehicle showing the bin extended above the unloading station.

[0038] Figure 13A is located in Figure 1 An enlarged end view of a bin in the sorting position of the illustrated material handling device.

[0039] Figure 13B yes Figure 13A An enlarged end view of the illustrated bin with the bin retainer shown in a retracted position.

[0040] Figure 14 yes Figure 13A An enlarged perspective view of an alternative embodiment of the tank is illustrated.

[0041] Figure 15 yes Figure 1 An enlarged perspective view of an illustrated unloading station of a material handling system.

[0042] Figure 16 yes Figure 15 An enlarged perspective view of a conveyor of an illustrated unloading station.

[0043] Figure 17 yes Figure 16 A plan view of the illustrated conveyor.

[0044] Figure 18 yes Figure 17 End view of the illustrated conveyor.

[0045] Figure 19 yes Figure 15 Side view of the illustrated unloading station.

[0046] Figure 20 yes Figure 19 Side view of the illustrated unloading station with the carton holders illustrated in the actuated position.

[0047] Figure 21 yes Figure 19 End view of the illustrated unloading station.

[0048] Figure 22A is a perspective view of an alternative unloading station.

[0049] Figure 22B yes Figure 22A A perspective view of the illustrated unloading station showing the bins in position above the empty cartons.

[0050] Figure 22C yes Figure 22A A perspective view of the illustrated unloading station showing the boxes in position after items have been unloaded into the empty cartons.

[0051] Figure 23A is a perspective view of the second alternative unloading station.

[0052] Figure 23B yes Figure 23A A perspective view of the illustrated unloading station showing the bins in position above the empty cartons.

[0053] Figure 23C yes Figure 23A A perspective view of the illustrated unloading station showing the boxes in position after items have been unloaded into the empty cartons.

[0054] Figure 24A is a block diagram depicting aspects of a warehouse operation or distribution center utilizing a warehouse management system and integrating aspects of material handling devices constructed in accordance with exemplary embodiments consistent with the present disclosure.

[0055] Figure 24B is a block diagram depicting in greater detail a warehouse management system utilizing a material handling device configured to integrate the functionality of sorting items into assortment bins and assortment bin retrieval, unloading, and / or exchange according to one or more embodiments of the present disclosure.

[0056] Figure 25A is a block diagram depicting in greater detail a sort and bin retrieval / discharge / exchange (SBRE) system constructed in accordance with an exemplary embodiment of the present disclosure.

[0057] Figure 25B is a block diagram depicting the functional components of an exemplary article inlet station that may form a basis for a process consistent with one or more embodiments of the present disclosure. Figure 25A Part of an exemplary system.

[0058] Figure 25C is a diagram depicting a method according to one or more embodiments consistent with the present disclosure. Figure 25B A top plan view of components of an exemplary article input station; Figure 26 is a graphical representation depicting the exchange of messages and / or instructions between logical control elements of a sort and bin retrieval / discharge / exchange (SBRE) system according to an embodiment; Figure 27is a flow chart depicting an automated process for performing sorting of accumulated groups of items into assortment bins, operating a carrier to retrieve an assortment bin containing the accumulated groups, and operating a carrier within an aisle to transfer the contents of the assortment bin to another container and / or exchange an assortment bin containing the accumulated group for an empty container that is used to hold a partial group of items for combination with other items.

[0059] Figure 28 is a flow chart depicting an exemplary process for assigning groups or subgroups of items to sorting bin locations in accordance with one or more embodiments.

[0060] Figure 29 is a flow chart depicting an exemplary article delivery vehicle traffic control process for coordinating the movement of delivery vehicles during article sorting in accordance with one or more embodiments.

[0061] Figure 30 is a flow chart depicting an exemplary sort retrieval vehicle traffic control process that coordinates the movement of a sort box retrieval vehicle while simultaneously performing sorting and sort box retrieval operations within an aisle.

[0062] Figure 31A is a flow chart depicting an assortment bin sorting process for combining the contents of multiple assortment bins in the same container according to one or more embodiments consistent with the present disclosure.

[0063] Figure 31B is a flow chart depicting a sort bin unloading and / or exchange process according to one or more embodiments consistent with the present disclosure.

[0064] Figure 32 is a flow chart depicting a modified assortment bin sorting process consistent with one or more embodiments of the present disclosure that utilizes determined information about characteristics of one or more items or groups of items to determine the order in which the contents of multiple assortment bins are to be combined in the same container.

[0065] Figure 33 is a detailed block diagram of a computer system according to one or more embodiments, which may be used in various embodiments of the present invention to implement a computer and / or display device according to one or more embodiments.

[0066] Certain portions of the following detailed description are presented in terms of operations on binary digital signals stored within the memory of a specific device or special-purpose computing device or platform. In the context of this particular specification, the term "specific device" and the like include a general-purpose computer that is programmed to perform specific functions according to instructions from program software. In this context, operations or processing involve the physical manipulation of physical quantities. Typically, although not necessarily, such quantities can take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, or otherwise manipulated. Primarily for reasons of common usage, it has proven convenient at times to refer to such signals as bits, data, values, elements, symbols, characters, terms, numbers, etc. However, it should be understood that all of these or similar terms are associated with the 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 utilizing terms such as "process," "calculate," "calculate," "determine," etc., refer to actions or processes of a specific device (such as a special-purpose computer or similar special-purpose electronic computing device). 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, registers or other information storage devices, transmission devices or display devices of the special purpose computer or similar special purpose electronic computing device. DETAILED DESCRIPTION

[0067] Systems and techniques are described for automating the accumulation of one or more items at respective sorting destinations to form corresponding groups of items (e.g., for shipment to customers in order fulfillment, or in the case of a distribution center, to destinations such as stores, or in the reverse direction for bulk replenishment of returned items to inventory). In some embodiments, items are automatically identified at a scanning station as they are conveyed along or passed between conveyor stages of an intake module. In other embodiments, items are individually scanned and transferred to a delivery mechanism. Optionally, one or more characteristics (e.g., weight, length, height, or width) are determined by reference to data associated with the identification. Additionally or alternatively, one or more sensors of the intake module may be operated to determine the one or more characteristics. In embodiments, the individual items so identified and / or characterized are transferred from the intake module's transfer conveyor to an item delivery system, e.g., a separately movable delivery vehicle movable along horizontal and / or vertical segments of an item delivery path.

[0068] In some embodiments, the elements of the delivery system are movable within an aisle extending parallel to a horizontal or vertical array of storage locations. Each delivery vehicle is self-propelled and includes a discharge mechanism for transferring items received from an ingestion module and carried to a sorting location to a sorting location aligned therewith. In some embodiments, the discharge mechanism is a conveyor configured to move the items along a discharge path oriented transverse to the aisle within which the vehicle moves.

[0069] According to one aspect, there is provided an apparatus for sorting a plurality of articles into individually displaceable positions such as assortment bins. In one embodiment, the apparatus comprises: a plurality of assortment bins, each of which defines an interior volume and has an entrance; a rack structure comprising a support frame configured to hold each assortment bin at a respective position spatially separated from other positions, whereby the assortment bins are organized into rows and / or columns and maintained in a configuration that enables accumulation of articles; a plurality of independently movable carriers movable along horizontal and / or vertical segments of an article delivery path extending from an input station where the articles are transferred to a carrier of the plurality of carriers to a terminal adjacent to a assortment bin holding position of the rack structure; a point position, wherein carriers of at least a first group of the plurality of carriers are configured to deliver articles received at the input station to a sorting bin temporarily associated with the group of articles to be sorted; and a discharge station defining at least one discharge area sized and arranged to receive a sorting bin from the plurality of sorting bins after accumulating articles in the sorting bin, wherein carriers of at least a second group of the plurality of carriers are movable along horizontal and / or vertical sections of a sorting bin retrieval path extending from a retrieval position adjacent to a sorting bin holding position of the rack structure to a terminal position adjacent to at least one discharge area of ​​the discharge station.

[0070] The carriers in the second group of carriers are constituent elements of the retrieval system, and each carrier in the second group includes a first transfer mechanism, which is configured to remove the assortment box containing the item group from the assortment box holding position of the rack structure and reinsert the assortment box from which the item group has been removed into the assortment box holding position of the rack structure, whereby the reinserted assortment box can be temporarily associated with another item group to be sorted.

[0071] In an embodiment, carriers of the first group of carriers are constituent elements of a sorting system, wherein each carrier of the first group includes a second transfer mechanism configured to transfer items received at the input station to a sorting bin of the plurality of sorting bins.

[0072] In some embodiments, the support frame of the rack structure includes two sections separated by an aisle through which the first group of carriers and the second group of carriers are freely movable vertically and / or horizontally. In one embodiment, the assortment bins are arranged in first and second groups, wherein the groups are arranged in rows and columns, and wherein each of the first and second groups of carriers is movable along horizontal and vertical path segments within the aisle.

[0073] In one embodiment, the sorting bin includes a gravity-operated trapdoor mechanism, wherein opening of the trapdoor mechanism is initiated by extending a retrieved sorting bin containing the sorted articles in a first direction, the first direction being away from an end position and into a first position above a discharge area of ​​the discharge station. Closing of the trapdoor mechanism is initiated by retracting the sorting bin from the position above the discharge area of ​​the discharge station onto a carrier in the second group of carriers.

[0074] In some embodiments, the unloading station further comprises a chute defining an article receiving surface portion, which is arranged directly below the first unloading area of ​​the unloading station, whereby articles discharged from the sorting bin and landing on the chute slide downwardly toward a displaceable container arranged at the second unloading area of ​​the unloading station. Alternatively or additionally, the unloading station further comprises an unloading auxiliary conveying system comprising a first conveyor. The article receiving surface portion of the first conveyor is arranged directly below the first (or third, as the case may be) unloading area, whereby the first conveyor is configured to guide articles discharged from the sorting bin in a conveying direction toward and / or away from the displaceable container arranged at the second (or fourth, as the case may be) unloading area of ​​the unloading station.

[0075] In one embodiment, the discharge-assisted conveyor system further comprises: a second conveyor defining an article-engaging surface sized and arranged to apply friction to discharged articles moving in a conveying direction on the first conveyor, the second conveyor being sized and arranged along a first side of a transfer-receiving surface of the first conveyor; and a third conveyor defining an article-engaging surface sized and arranged to apply friction to discharged articles moving in a conveying direction on the first conveyor, the third conveyor being sized and arranged along a second side of the transfer-receiving surface of the first conveyor. The article-engaging surfaces of the second and third conveyors are offset relative to each other, wherein a surface of each of the second and third conveyors forms an obtuse angle relative to the transfer-receiving surface of the first conveyor.

[0076] The unloading assisted conveying system also includes one or more sensors that are sized and arranged to determine that the unloading assisted conveying system cannot cause the article to advance in the conveying direction toward the destination container; and a controller that is operably associated with the second conveyor and the third conveyor and is responsive to the one or more sensors to cause the second conveyor and the third conveyor to apply frictional forces in opposite directions on the blocked article that cannot advance toward the destination container to facilitate resolution of the blockage.

[0077] In an embodiment, the controller is further responsive to the one or more sensors to cause the first conveyor, the second conveyor, and the third conveyor to apply frictional forces to the articles in a common conveying direction when the articles are able to advance toward the destination container (i.e., in the absence of articles in a jammed state).

[0078] In addition to or as an alternative to incorporating a chute and / or discharge conveyor system according to the aforementioned embodiments, an apparatus according to embodiments of the present invention may further comprise an outfeed conveyor configured to direct displaceable containers received from a discharge area of ​​the discharge station to another destination.

[0079] In addition to or as an alternative to incorporating a chute and / or a discharge portion according to the aforementioned embodiments, the discharge station of an apparatus according to an embodiment of the present invention defines an input / output (I / O) staging area that is sized and arranged to receive an assortment bin from a plurality of assortment bins after accumulating articles therein, wherein carriers of at least a second group of the plurality of carriers are movable along horizontal and / or vertical segments of an assortment bin retrieval path that extends from a retrieval position adjacent an assortment bin holding position of the rack structure to a terminus position adjacent the I / O staging area; and wherein the discharge station further It includes an I / O conveying system, which is configured to accept the retrieved assortment boxes delivered to the I / O staging area by the carrier of the second group, transport the received assortment boxes to the remote destination, receive the assortment boxes arriving from the remote destination, and transfer the assortment boxes arriving from the remote destination to the I / O staging area, whereby the assortment boxes containing items retrieved from the assortment box position of the rack structure can leave the I / O staging area via the I / O conveying system and empty assortment boxes and / or assortment boxes containing less than all items required for the order group can be restored to the assortment box position of the rack structure via the I / O staging area.

[0080] In some embodiments, the segments of the item delivery path along which the carriers of the plurality of carriers move form a vertical loop within an aisle defined by the rack structure. Each delivery carrier may include an energy storage device for providing power for the operation of the delivery carrier. The system may also include a charging element within the aisle for charging the delivery carrier as it moves within the aisle. In one embodiment, a track is positioned within the aisle for guiding the first group of carriers to the sorting bin. Additionally, the track may also be configured to guide the retrieval carrier to the sorting bin.

[0081] 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.

[0082] Now refer to Figures 1 to 4 , a material handling system is generally indicated at 10. The system includes a sorting system 15 that sorts items into a plurality of sorting locations, such as sorting bins 20. After the items are sorted into the sorting bins 20, the bins are retrieved and delivered to a discharge location 400. At the discharge location, the items are discharged from the bins into containers, or the entire bin is discharged from the sorting system onto an output conveyor 700 so that the bins can be transported to another area.

[0083] The sorting system 15 may include a plurality of bins arranged in a series of rows or columns forming a first group of bins 30. A second group of bins 35 may be spaced apart from the first group of bins such that an aisle 100 is formed between the groups of bins. A plurality of delivery vehicles 200 may travel within the aisle 100 to deliver items to different bins 20.

[0084] A group of items can be delivered to one of the bins. Once the last item in the group has been delivered to the bin, the item is retrieved and sent out for delivery. For example, after the group of items has been delivered to the bin, a retrieval vehicle can retrieve the bin. The vehicles can be configured so that the vehicle can deliver items to the bin and, once the group of items has been delivered to the bin, the vehicle can also retrieve the bin. In addition, as described below, the system may include a first type of vehicle, referred to as a delivery vehicle 200, for delivering items to the bin; and a second type of vehicle, referred to as a retrieval vehicle 300, for retrieving items once the group of items has been delivered to the sorting bin.

[0085] The delivery vehicles 200 can be configured so that multiple delivery vehicles 200 can be operated simultaneously and independently to deliver multiple items. In addition, the delivery vehicles 200 can travel within the aisle 100 to deliver items to the sorting bins 30, 35. Alternatively, the delivery vehicle 200 can be moved from the loading station 145 to one of the delivery vehicles and then returned to the loading station so that another item can be delivered to one of the bins.

[0086] As described above, multiple delivery vehicles can deliver a group of items to one of the bins. A bin is considered full when it has received a certain volume of items or when all items in a group (such as an order) have been sorted into the bin. Once the bin is full, the system can automatically retrieve the bin so that the items can be emptied from the bin. In one embodiment, the system automatically retrieves the bin using a retrieval vehicle 300 operating within aisle 100.

[0087] The retrieval vehicle 300 can be moved within the aisle 100 to a position adjacent to the filled box 20. The retrieval vehicle can then transfer the filled box onto the retrieval vehicle. The retrieval vehicle can then move within the aisle while carrying the filled box to a position where the group of items within the box can be transferred out of the aisle.

[0088] For example, the groups of articles in a full case can be unloaded at unloading station 400. Specifically, the articles can be emptied from the full case onto a conveyor operating outside the aisle. Alternatively, the groups of articles can be emptied into boxes or other containers arranged outside the aisle and away from the front and rear shelves 30, 35 of the case.

[0089] Additionally, rather than emptying the full bins at the discharge location, the full bins can be transferred to a conveyor or other transportable item outside the aisle. For example, a retrieval vehicle can move the full bins to an output location. At the output location, the retrieval vehicle can transfer the full bins out of the aisle and onto a conveyor or other transport operating outside the aisle. For example, referring to Figure 22A , the retrieval carrier 300 can transfer the full box 20 to the output conveyor 700, which transfers the full box out of the sorting system 15.

[0090] The system 10 may also incorporate means for supplying empty containers for receiving contents from a filled tank. For example, the system may include means for producing a container (such as in Figure 1 The apparatus is configured to produce a plurality of boxes (cardboard boxes, represented as 600-1 through 600-4). Box erectors 600-1, 2, 3, and 4 are configured to produce a plurality of boxes. Each erector can be configured to erect containers or boxes of different sizes. Empty containers are automatically transported to a discharge station 400, so that the contents of a filled box can be emptied into an empty box. The box can then optionally be transported away from the discharge station, such as by a conveyor 660.

[0091] exist Figure 1In the illustrated configuration, each erector 600-1, 2, 3, 4 produces boxes of different sizes, and each erector supplies the boxes to a different unloading station 400 of the sorting system 15. In this way, the system can determine the appropriate unloading station based on the volume of the items sorted into the sorting bin and the volume of the empty boxes at each unloading station. Once the appropriate unloading station is identified, the retrieval vehicle transports the filled boxes to the appropriate unloading station, and the items are emptied from the filled boxes into the boxes at the unloading station.

[0092] As further described below, instead of a series of erectors 600-1, 2, 3, 4 supplying empty containers to a single sorting system 15, the system 10 may include a series of sorting systems similar to the sorting system 15, and the erectors may supply a series of empty containers from the erectors to each sorting system 15.

[0093] System 10 may include a central controller 800 to control various aspects of the system and provide control signals to various components of the system. The central controller may include one or more microprocessors. Furthermore, the central controller 800 may be connected to a warehouse management system (WMS), which may provide signals to the system 10 regarding the groups into which items are to be sorted. For example, the WMS may indicate which items are to be grouped together to form an order. The WMS can then provide information regarding the item groupings to the central controller, and the central controller 800 controls the operation of various devices (such as delivery vehicles, doors, scanners, etc.) to sort the items based on the information received from the WMS.

[0094] Classification system refer to Figures 1 to 5 , the details of the sorting system 15 of the material handling device 10 will be described in more detail. The material handling system 10 may incorporate any of a variety of systems for sorting items into a series of bins. Figures 1 to 5 In the illustrated embodiment, the sorting system utilizes an aisle-based system, wherein the sorting equipment operates within an aisle 100 disposed between opposing racks 30, 35 of bins 20. Any of a variety of aisle-based sorting systems may be used. In this example, the sorting system 15 incorporates a plurality of delivery carriers 200 that operate independently within the aisle 100.

[0095] Figure 1 The illustrated sorting system 15 includes a front rack 30 positioned at a sorting location on one side of an aisle 100 and a rear rack 35 positioned at a sorting location on a second side of the aisle. The sorting bins 20 in the racks 30, 35 may be arranged as a series of columns or a series of rows. It should be understood that the term rack simply refers to any structure that supports a plurality of sorting bins.

[0096] As described above, the sorting system 15 may include a plurality of carriers 200 that operate in the aisle 100 to sort items into sorting boxes 20. The delivery carrier 200 can be configured to move horizontally and / or vertically in the aisle to deliver items to the sorting position. For example, the system can include a plurality of rows vertically spaced apart from each other, and the delivery carrier can move independently along the horizontal guides or tracks on each row in the aisle. In addition, the system can include a mechanism for vertically moving the delivery carrier in the aisle. For example, a lift or a hoisting mechanism can be used to raise or lower the delivery carrier between rows. The lift / elevator can be positioned at various points in the aisle. An example is the following embodiment, wherein a first lift or elevator is positioned at one end of the aisle to lift the delivery carrier from a downward direction to an upward direction, and a second lift or elevator is positioned at the second end of the aisle to lower the delivery carrier from an upward direction to a downward direction.

[0097] exist Figures 1 to 5 In the illustrated sorting system 15 , the system utilizes a plurality of independently operable vehicles that are operable to climb vertically within a rack without the assistance of a lift or elevator.

[0098] The sorting system may use a guide system such as rails 105 to guide the delivery vehicle as it moves within the aisle. It should be understood that the term rail refers to any structure that is configured to support or guide the vehicle as it moves. For example, the guide system 105 may include a front rail 110 that extends along the aisle adjacent to the front rack 30 and a rear rail 120 that extends along the aisle adjacent to the rear rack 35. In this way, the front rail 110 supports and / or guides a first side of the delivery vehicle 200, while the rear rail supports and / or guides a second side of the delivery vehicle. For example, Figures 6 and 7 As shown, delivery vehicle 200 may include a drive system comprising two pairs of wheels: a pair of front wheels, generally designated 220a and 220c, and a pair of rear wheels, generally designated 220b and 220d. Wheels 220a and 220b are coupled to axle 215 for rotation therewith, while wheels 220c and 220d are coupled to axle 216 for rotation therewith. Front wheels 220a and 220c travel on front track 110, while rear wheels 220b and 220d travel on rear track 120.

[0099] At the loading station 145, items are loaded onto delivery vehicles 200. Each vehicle can carry multiple items. Alternatively, each delivery vehicle 200 can carry a single item, as described further below. After an item is loaded onto one of the delivery vehicles, the delivery vehicle follows a path to one of the sorting bins 20. The delivery vehicle transfers the item into the sorting bin and follows the path back to the loading station to receive another item.

[0100] Each delivery vehicle may follow a different path from the loading station to one of the sorting locations. Track 105 may include a plurality of vertical and horizontal track segments that guide the delivery vehicle as it moves from the loading station to the sorting bin and then back to the loading station.

[0101] Vertical and horizontal track segments can form a vertical loop-shaped path in the aisle. For example, refer to Figure 1 and Figure 5 , the track 105 may include a front track 125 and a rear track. Figure 5 , the front track is illustrated, and it should be understood that the rear track is substantially similar to the front track, such that the rear track is a mirror image of the front track.

[0102] The front track may have an upper track segment 125 and a parallel lower track segment 130. A plurality of vertical tracks 132 may connect the upper track to the lower track. Figure 5 As shown, vertical rails 132 can divide the track into a series of columns along which the carrier can move up or down to one of the sorting bins. Alternatively, as previously described, the track can include multiple horizontal rails that divide the track into a series of rows along which the carrier can move to one of the sorting bins 20.

[0103] exist Figure 5 In the illustrated track, the track includes multiple vertical columns. Each column is defined by a pair of vertical rails. Delivery vehicles can move vertically upward or downward within the column. For example, vertical rails 132a and 132b define a first column for guiding delivery vehicles. This first column may be a loading column 140 having a loading station 145, at which each vehicle receives an item to be delivered to one of the sorting bins 20.

[0104] Tracks 105 may include columns that share vertical tracks and columns that have separate vertical tracks. Figure 5 As shown, the second column is defined by vertical rails 132c and 132d, and the delivery vehicle can move vertically up or down within this second column. The second column does not share any vertical rails with the first column. In contrast, the third column is formed by vertical rails 132e and 132f, and the fourth column is formed by vertical rails 132f and 132g. Thus, the third and fourth columns share vertical rails.

[0105] A plurality of doors 135 can be positioned along a track to guide a delivery vehicle along the track. For example, a delivery vehicle can move horizontally along the upper track 125 until it reaches a row of assortment boxes 20 to which the delivery vehicle will deliver items. Once the delivery vehicle arrives at the appropriate row, the door opens, guiding the delivery vehicle to move downward along the row from the upper track. The delivery vehicle may have an actuator for selectively actuating the door. Alternatively, each door may have an actuator for automatically actuating the door from a first position to a second position, in which the delivery vehicle is guided horizontally and in which the delivery vehicle is guided from a horizontal direction to a vertical direction. For example, each door may be controlled by a solenoid or other element configured to move the door in response to a signal from a controller.

[0106] The flow of delivery vehicles 200 along the track can move along any of a variety of paths. According to one embodiment, the delivery vehicles move along a path that forms a vertical loop, and the vehicles generally move in a forward direction along the vertical loop.

[0107] For example, from Figure 5 , the delivery vehicle can follow a vertical loop in a clockwise direction as shown by arrow T1. Specifically, from the loading station 145, the delivery vehicle moves upward in the first column until the delivery vehicle reaches the upper track 125. At the upper track, the vehicle transitions from vertical movement to horizontal movement. The delivery vehicle moves along the upper track 125 in the direction of T1 until the vehicle reaches the column with the classification box to which the delivery vehicle will deliver the item. For example, if the destination box 20 is in the fourth column, the delivery vehicle moves along the upper track until it reaches the vertical tracks 132f and 132g. The door 135 is actuated so that the delivery vehicle is guided downward along the fourth column. The delivery vehicle continues to move downward until it reaches the destination box 20.

[0108] At the destination box, the delivery vehicle unloads the item into the destination box. The delivery vehicle then continues down the column until it reaches the lower track 130. Upon reaching the lower track, the delivery vehicle transitions from vertical travel to horizontal travel. The delivery vehicle then travels to the left (from the Figure 5 perspective) to return to the loading column 140.

[0109] As described above, the delivery vehicles travel along a path that forms a vertical loop in the aisle. Specifically, the delivery vehicles travel in a clockwise direction from the loading area to the upper track to one of the columns, and then down to the lower track, where they return to the loading column along the lower track. Each vehicle travels along a path that forms a vertical loop, but the path of each vehicle may differ depending on which assortment box 20 the delivery vehicle is directed to.

[0110] The delivery vehicles can be controlled to continue to flow in a common direction, such as a clockwise direction as described above. However, it should be understood that although the vehicles can generally flow in a common direction (such as clockwise), there may be situations where one of the vehicles can move in the opposite direction as the vehicle moves around the vertical loop. For example, after moving down along the fourth column, it may be desirable to move the vehicle up within the fourth column before driving the vehicle down to the lower track 130. In this case, the overall flow of the delivery vehicles is the same: following the clockwise path of the vertical loop, the vertical loop moves forward from the loading station 145 to one of the sorting boxes, and then returns to the loading station along a separate return loop path.

[0111] The track 105 is generally configured to cooperate with the delivery vehicle. Specifically, the delivery vehicle 200 may include a drive element having teeth. In such an embodiment, the track may include teeth that mesh with the teeth of the vehicle drive element. Similarly, the delivery vehicle may include a drive element, such as a drive wheel, that frictionally engages the track. In such an embodiment, the track need not have teeth. Therefore, it should be understood that the delivery vehicle may include various known drive mechanisms. The track 105 is configured to cooperate with the drive mechanism of the delivery vehicle to guide the delivery vehicle within the aisle.

[0112] As described above, the configuration of the track can vary depending on the configuration of the delivery vehicle. An exemplary track can be similar to the track in U.S. Patent No. 7,861,844. The entire disclosure of U.S. Patent No. 7,861,844 is incorporated herein by reference.

[0113] Input Station The system can be configured so that items are loaded directly onto the delivery vehicle at a loading station. For example, an operator can place the item directly onto the vehicle at loading station 145. Additionally, a scanner can be provided to scan the item before it is loaded onto the delivery vehicle. It should be understood that the term operator can include a human operator or a mechanical operator, such as a robotic arm or similar element.

[0114] Alternatively, the system may include an input station for loading items onto the delivery vehicle. The input station may include a conveyor 55 for conveying the items toward a loading station 145. The conveyor may include a first end defining a drop zone where the items may be dropped or placed onto the conveyor. A second end of the conveyor may be adjacent to the loading station such that the conveyor conveys the items from the drop zone to the loading station. At the loading station, the items are loaded onto the delivery vehicle.

[0115] Various factors can be detected to assess how the item will be handled. For example, the item typically needs to be identified so that the system can determine the location or box to which the item is to be delivered. This is typically accomplished by determining the item's unique product code. The system may include a scanning element for scanning product identification markings on the product. By way of example, the item may be marked with one or more of a variety of markings, including but not limited to machine-readable optical labels such as barcodes (e.g., QR or UPC codes), printed alphanumeric characters, or unique graphic identifiers. The scanning station 60 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 markings.

[0116] Thus, the input station 50 may include a scanner 60 for scanning items before they are placed onto the conveyor. Alternatively, the input station may include a scanner 60 that scans items as they move along the input conveyor.

[0117] Once the product identification mark has been 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 a central database.

[0118] At the input station 50, items are introduced into the system by continuously loading them onto carriers 200. In one embodiment, each item is manually scanned at the input station to detect one or more characteristics of the item. These characteristics are used to determine the item's identity. Once the item is identified, various characteristics of the item can be retrieved from a central database, and the item can then be processed based on the known characteristics. For example, the input station 50 may include a scanning station 60 that scans a product code, such as a barcode. 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 item.

[0119] The input conveyor 55 can be configured so that an operator can select items from a supply of items located adjacent to the input conveyor. For example, a separate supply conveyor can deliver a steady stream of items to the induction station 50. The operator can continuously select items from the supply conveyor and place them onto the input conveyor 55. Alternatively, a large container of items, such as a box or other container, can be placed adjacent to the input conveyor 55. The operator can select items one at a time from the supply box and place each item onto the input conveyor. Furthermore, the input conveyor 55 can cooperate with a supply assembly that continuously feeds items to the input conveyor. For example, the supply conveyor can convey a continuous stream of items toward the input conveyor 55. The input conveyor can include a sensor that detects when an item is conveyed away from the input conveyor. In response, the system can control the operation of both the supply conveyor and the input conveyor 55 to drive items from the supply conveyor to the input conveyor. In this way, items can be fed to the input conveyor manually by an operator or automatically by a separate feed mechanism that is operable to feed items to the input conveyor.

[0120] Additionally, in the foregoing description, the system is described as having a single input 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 can be increased. Additionally, the inlet stations can be configured to handle different types of items.

[0121] refer to Figure 1 and Figure 5 The input station 50 includes a conveyor 55 that continuously transports items to a loading station 145. The loading station is a location along the track 105 that provides an entry point for loading items onto a carrier 200. At the loading station 145, the carrier is aligned with the conveyor 55 so that the items unloaded from the conveyor are received by a delivery carrier 200 positioned at the loading station. After the items are loaded onto the delivery carrier, the delivery carrier moves away from the loading station 145. Another carrier then moves to the location at the loading station to receive the next item.

[0122] The system may include an optional return conveyor 70 to return items to the input conveyor 55. The return conveyor can facilitate rescanning of items that could not be delivered for some reason. For example, if the system does not recognize a product code scanned for an item, the system will not be able to identify the sorting bin to which the item should be delivered.

[0123] The return conveyor extends rearward from the track 105 toward the drop zone of the input conveyor 55. If a delivery carrier is unable to deliver an item, the delivery carrier can drive along the track 105 to the return conveyor and deposit the item onto the return conveyor 70, rather than delivering the item to one of the bins. The return conveyor then returns the item to the input conveyor so that the item can be re-scanned and loaded onto one of the delivery carriers again.

[0124] delivery vehicle As described above, the sorting system can include multiple independently operable delivery vehicles 200. Each delivery vehicle is configured to deliver one or more items to one of the sorting bins. The following description provides details of an exemplary delivery vehicle. However, it should be understood that the sorting system is not necessarily limited to a sorting system that utilizes multiple delivery vehicles. In addition, the configuration of the delivery vehicles can vary depending on a variety of factors. Therefore, it should be understood that the following discussion provides details of an exemplary vehicle, and the sorting system is not limited to use with delivery vehicles having the details described below.

[0125] refer to Figures 6 and 7 , illustrates a semi-automatic delivery vehicle 200. The delivery vehicle has an onboard drive system including an onboard power source. The delivery vehicle 200 includes mechanisms for loading and unloading items for delivery. An example of a vehicle that can operate with the sorting system 15 is illustrated and described in U.S. Patent No. 7,861,844.

[0126] The carrier 200 may incorporate any of a variety of mechanisms for loading items onto the carrier and unloading items from the carrier into one of the bins. Furthermore, the loading / unloading (or transfer) mechanism 210 may be customized for a particular application. However, in this example, the loading / unloading mechanism 210 comprises 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.

[0127] One or more transfer motors (such as motors 240a and 240b ( Figure 6 )) drives the conveyor belt. Specifically, the conveyor belt is driven around a front roller at the leading edge of the carrier and a rear roller at the trailing edge of the carrier. One or more conveyor motors 240a and / or 240b are connected to the front roller to drive the front roller, thereby operating the conveyor belt.

[0128] The vehicle includes four wheels for transporting the vehicle along the track 105. The wheels are mounted to two parallel spaced axles 215 and 216 so that two of the wheels are arranged along the leading edge of the vehicle and two of the wheels are arranged along the trailing edge of the vehicle.

[0129] In one embodiment, each wheel (e.g., wheels 220a, 220b, 220c, and 220d) includes a corresponding external gear, indicated at 222a, 222b, 222c, and 222d, respectively, that cooperates with the track's drive surface. The external gears are fixed relative to the axle to which they are mounted. Thus, rotating axle 215 or 216, as appropriate, operates to rotate the corresponding gear. Therefore, when the vehicle moves vertically, the gears cooperate with the track's drive surface to propel the vehicle along the track.

[0130] The vehicle includes an onboard drive motor 250 for driving the wheels. More specifically, the onboard drive motor 250 is operatively connected to the wheel axles 215 and 216 to rotate the wheel axles, which in turn rotate the wheel gears 222a to 222d.

[0131] The vehicle 200 can 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. While the power source could include a power source such as a rechargeable battery, in this example, the power source is comprised of one or more supercapacitors.

[0132] 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 800. Additionally, 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.

[0133] If the system 10 includes multiple delivery vehicles 200, the positioning of the vehicles is controlled to ensure that different vehicles do not collide with each other. In one embodiment, the central controller 800 tracks the position of each vehicle 200 and provides control signals to each vehicle to control the vehicle's progress along the track. The central controller 800 can also control the operation of various elements along the track, such as the gate 135 that redirects the vehicle from a horizontal direction of travel to a vertical direction of travel or vice versa.

[0134] Retrieve the vehicle The system 10 may include one or more vehicles for retrieving the box 20. The vehicle used to deliver items to the box may also be configured to retrieve the box. Alternatively, as discussed further below, the system 10 may include one or more retrieval vehicles 300 that are configured differently than the delivery vehicle 200.

[0135] The retrieval vehicle 300 is configured to be movable vertically and horizontally. For example, the retrieval vehicle can be configured to be movable to align the retrieval vehicle with the box.

[0136] exist Figures 8 to 10 In the illustrated embodiment, the retrieval vehicle 300 is configured to travel within the aisle 100. Although the retrieval vehicle can move along a separate track or guide, in this example, the retrieval vehicle can operate within the track 105. In particular, the retrieval vehicle 300 can have a drive system 310 that is generally similar to the drive system 220 of the delivery vehicle 200.

[0137] refer to Figures 8 to 10 The retrieval vehicle 300 may include a plurality of drive wheels 310 for driving the vehicle within the aisle. The drive wheels 310 may include teeth that mesh with the track 105. Similarly, if the track 105 is configured to cooperate with friction wheels, the drive wheels may include friction wheels.

[0138] The retrieval vehicle 300 may include two pairs of synchronously driven drive wheels 310. For example, a first pair may be mounted on a first axle and a second pair may be mounted on a second axle. Alternatively, the axles may be driven independently. However, in this example, the axles are interconnected so that the two axles are driven synchronously.

[0139] The retrieval carrier 300 includes a support surface 320 for supporting one or more items. For example, the support surface may include a generally horizontal surface for supporting a large bag 20.

[0140] The retrieval carrier 300 may include one or more walls for holding items on the carrier. Figure 8 As shown, the retrieval carrier 300 may include a pair of side walls 330 spaced apart from each other. Figure 8 As shown, side walls 33 may span the support surface to prevent items from being unloaded from the leading edge of the carrier or the trailing edge of the carrier.

[0141] The retrieval carrier 300 is also configured to facilitate loading and unloading of items onto and from the carrier. For example, the carrier can have a front opening between the sidewalls 330 adjacent to the front edge of the carrier and a rear opening between the sidewalls 330 adjacent to the rear edge of the carrier. The front and rear openings provide paths for loading items onto and unloading items from a support surface.

[0142] The system includes one or more mechanisms for transferring assortment bins 20 between racks 30, 35 and retrieval carrier 300. In one embodiment, the storage locations may be configured to transfer assortment bins to the retrieval carrier. For example, each sorting location may include a transfer mechanism, such as a conveyor or other element. Alternatively, as Figures 8 to 10As shown, the retrieval carrier may include a transfer mechanism for transferring items between the carrier and a storage location.

[0143] Figures 8 to 10 A transfer mechanism is illustrated extending outwardly from the retrieval carrier 300 to engage an assortment bin in one of the assortment racks 30, 35. Figure 8 , the retrieval mechanism 350 is illustrated in a retracted position. Figure 9 , the retrieval mechanism 350 is illustrated in an extended position. Figure 10 , a plurality of optional latch elements 355, 357 are illustrated in an extended position.

[0144] The retrieval mechanism 350 may include one or more telescopic arms. For example, the retrieval mechanism may include a pair of telescopic arms 352 that are adapted to span the box 20, such as Figure 10 and 11A to 11D Alternatively, the telescopic arm may be formed from a plurality of segments so that the arm is telescopically extendable from the vehicle.

[0145] The telescoping arms 352 may include latches or other features for positive engagement with the bin 20. For example, each arm may include a front bin latch 355 and a rear bin latch 357 spaced apart from the front bin latch. The front bin latch 355 is positioned to engage the front edge of the assortment bin 20, while the rear bin latch 357 is positioned to engage the rear edge of the assortment bin. Additionally, the latches 357 may be positioned such as Figure 9 The retracted position shown and Figure 10 352. In the retracted position, the latches 355, 357 are not engaged with the assortment bin. In the extended position, the latches 355, 357 engage the bin so that displacement of the arm 352 displaces the assortment bin. Optionally, the latches 355, 357 are positioned around the bin as shown. Figures 9 and 10 The pivot axis is shown pivoting from a retracted position to an extended position.

[0146] An actuator on the retrieval vehicle, such as a solenoid or motor, is operable to drive the retrieval mechanism 350 between the extended position and the retracted position. Figures 9 and 10 As shown, the telescoping arm is connected to one or more drive elements, such as gears, that cooperate to extend the arm. Similarly, latches 355, 357 are connected to one or more drive elements to move the latches between an extended position and a retracted position. Both the telescoping arm 352 and the latches 355, 357 can be connected to a common actuator, such as a motor.

[0147] The retrieval vehicle 300 may include an internal power source similar to the delivery vehicle 200 described above. For example, the retrieval vehicle 330 may include a rechargeable power source that can be recharged while the vehicle is moving within the aisle. Specifically, the vehicle may include one or more contacts that establish electrical contact with a power source located within or adjacent to the aisle 100.

[0148] The retrieval vehicle 300 may also include a controller for controlling the operation of the vehicle similar to the delivery vehicle 200. For example, the vehicle 300 may include a controller configured to receive signals from the central controller 800 to control the operation of various functions of the vehicle. The control signals may include signals for controlling the drive wheels 310 to control the movement of the vehicle within the aisle. The control signals may also include signals for controlling the operation of the retrieval mechanism 350.

[0149] refer to 11A to 11D The retrieval vehicle 300 is configured to retrieve a case 20 from one of the storage locations in one of the shelves 30, 35 after one or more items have been sorted into the case. In particular, the retrieval vehicle 300 can be configured to pull a case 20 from one of the storage locations onto the carrier while the carrier is positioned in the aisle 100.

[0150] The system can be configured so that the bin 20 can be releasably held in the storage location while one or more items are sorted into the bin. When the retrieval vehicle 300 retrieves the bin, the retrieval vehicle actuates a release to release the bin from the storage location. After releasing the bin, the retrieval vehicle retrieves the bin from the storage location.

[0151] Any of a variety of retainers may be used to engage the bins to hold them in the storage position. 11A to 11D and 13A to 13B An exemplary retainer 42 is illustrated. The bin retainer 42 is a displaceable latch that operates as a stopper operable to prevent displacement of the bin from the storage position toward the aisle 100. In a first position, the retainer 42 abuts the bin, thereby preventing displacement of the bin toward the aisle 100 (see FIG. Figure 13A In the second position, the retainer 42 is displaced out of engagement with the bin 20 so that the bin can be displaced toward the aisle.

[0152] The system can include components for automatically actuating the retainer from the first position to the second position in response to a control signal. For example, the retainer 42 can be coupled to a solenoid or other linear or rotary actuator that displaces the retainer in response to the control signal. Alternatively, in this example, the system includes an actuator 44 coupled to the retainer 42 that can be operated by the retrieval vehicle to release the retainer.

[0153] The actuator 44 has an actuating surface configured to cooperate with the retrieval vehicle. In this example, the actuator is vertically displaceable. In particular, the actuator 44 comprises a roller rotatable about a horizontal axis, and the roller is vertically displaceable between an upper position and a lower position.

[0154] The actuator 44 may be directly connected to the retaining member 42, however, 11A to 11DAs shown, a linkage mechanism, such as a pivotable link 45, connects the actuator 44 to the retaining member 42. Thus, displacement of the actuator 44 causes displacement of the retaining member 42.

[0155] The system may also include an element for automatically returning the retainer 42 from the retracted position to the actuated position. For example, the system may include a biasing element that biases the actuator and / or the linkage 45 so that the retainer is moved from the retracted position to the actuated position. Figure 13B The released position shown is offset to Figure 13A The biasing element may include a spring that pushes the actuator 44 upward or in a clockwise direction (from Figure 11B angle) pushes the spring of the connecting rod.

[0156] The retrieval vehicle 300 can have a separate actuation element configured to engage the actuator 44 to release the retainer 42. However, in the present example, the retrieval mechanism 350 is configured to engage the actuator 44. For example, the telescoping arm 352 can engage the actuator 44 to displace the actuator 44 downward when the arm 352 is extended into the storage position.

[0157] The actuator 44 can be configured to limit the impedance on the arm when the telescopic arm 352 engages the actuator. For example, the actuator can be angled or tapered in a wedge or similar configuration. However, in this example, the actuator is a roller 44 having a surface along which the telescopic arm can roll while maintaining the actuator in an actuated position, such as Figure 13B shown.

[0158] Actuator 44 can be configured such that retainer 42 is maintained in the released position until the entire length of the box has been displaced past the retainer. In this way, the retainer does not exert force on the box when it is transferred from the storage location to the retrieval vehicle. For example, in this example, actuator 44 is positioned and configured such that telescopic arm 352 remains engaged with the actuator during all or substantially all of the box transfer process. Specifically, telescopic arm 352 can engage actuator 44 to hold actuator 44 downward while the box is transferred to the vehicle. Once arm 352 is retracted from engagement with the actuator, the entire length (or substantially the entire length) of the box is displaced onto the retrieval vehicle. Therefore, when actuator 44 is released, retainer 42 does not move toward the upward position until at least substantially the entire length of the box has been transferred to the retrieval vehicle 300. In this way, retainer 42 does not potentially engage or block the box when it is transferred to the retrieval vehicle.

[0159] like Figure 11D As shown, the box 20 can be supported by a shelf 40 that supports the box in a storage position in the rack. A retainer 42 can protrude upwardly through the shelf 40, as shown. Figure 13A In addition, Figure 11DAs shown, the shelf may also include a retaining element, such as a flange or wall 43, that prevents the boxes from being displaced outwardly, away from the aisle. This external stop 43 prevents or blocks the boxes from being inadvertently removed from the shelf. For example, when the transfer mechanism moves the boxes into a storage position (e.g., onto one of the box supports 40), the external stop prevents the transfer mechanism 350 from pushing the boxes out of the shelves 30, 35.

[0160] In one embodiment, Figure 11A As shown, the track can be arranged in multiple columns so that when the box is displaced onto the carrier, the retrieval vehicle 300 displaces the box between a pair of vertical track segments 132. When the retrieval mechanism 350 pulls the box onto the carrier, the drive system 310 of the retrieval vehicle 300 engages the vertical track segments 132. However, as previously described, the track 105 can be formed from multiple horizontal rows rather than multiple vertical columns. If the track is formed into multiple rows, then when the box is pulled onto the carrier, the box may not necessarily be displaced between the vertical track segments.

[0161] As described above, the system is configured to sort items into bins and then retrieve the bins after they are full or once all items in a particular group (such as an order) have been sorted into the bins. In one embodiment, a carrier such as the retrieval carrier 300 retrieves the bins 20. After retrieving the bins, the bins are transferred to a discharge location.

[0162] At the discharge location, items are discharged from the bin or the bin is transferred out of the sorting system 15. For example, the items in the bin may be discharged from the bin 20 into separate containers external to the sorting system 15, or the bin may be discharged onto a conveyor mechanism that operates separately from the sorting system 15. Examples of such a conveyor mechanism include, but are not limited to, a conveyor or a carrier such as an autonomous carrier.

[0163] By moving the box from the storage position to the unloading position in the aisle, the box can be transported to the unloading position. For example, the box can be pulled into the aisle from the storage position and moved vertically and / or horizontally to align the box with the unloading position.

[0164] In this example, the boxes are moved within the aisle by a retrieval carrier 300. After the carrier retrieves the box 20, the carrier can be moved along the track 105 to a discharge position. For example, the carrier can move vertically and / or horizontally along the track. The carrier can move along the track with the box while one or more delivery carriers deliver items to the box in the rack 30, 35.

[0165] The retrieval vehicle 300 can be controlled to flow in a common direction. For example, the retrieval vehicle can flow in the same general direction as the delivery vehicle 200 as described above. In one embodiment, the delivery vehicle and the retrieval vehicle can flow generally in a clockwise direction, as discussed above in conjunction with the delivery vehicle 200.

[0166] It should be understood that while carriers may generally flow in a common direction (such as clockwise), there may be situations where one of the carriers may move in the opposite direction as the carrier moves around the vertical loop. For example, after moving down the fourth column, it may be desirable to move the carrier up within the fourth column before driving the carrier down to the lower track 130. In this case, the overall flow of retrieving or delivering the carrier is the same: following a clockwise path of the vertical loop moving forward from a starting position.

[0167] While the retrieval vehicle 300 can generally follow the same direction as the delivery vehicle 200, it may be desirable to reverse the direction of travel of the retrieval vehicle. For example, it may be desirable to move the retrieval vehicle along a first path when moving from a bin location to a dump station. After delivering a bin to the dump station, the retrieval vehicle may follow a route that moves in a direction similar to the first path (e.g., generally clockwise). Alternatively, it may be desirable to reverse the direction of travel of the retrieval vehicle when returning to a bin location. For example, the retrieval vehicle may move in a second direction that follows the same path as the first path but in the opposite direction.

[0168] The unloading position can be one of various transition positions, and it is used for unloading articles from the sorting system after the article group has been sorted in the box. Specifically, the group of sorted articles can be poured out from the box 20 into which the article is sorted.

[0169] The bin 20 may include one or more openings through which sorted items may be unloaded at a discharge location. For example, each bin may include a movable wall that selectively covers an opening in the bin. In a first position, the movable wall covers the opening to prevent items from moving through the opening; in a second position, the wall opens the opening, thereby facilitating unloading of the items from the bin.

[0170] Figure 12C An example of a box with a movable wall for unloading items is illustrated in FIG. The bottom wall or floor of the box 20 is formed by a trap door or bomb bay door that opens to allow items to fall from the box. The trap door can be formed by one or more segments. For example, Figure 12C As shown, the trapdoor is formed from two sections 25. However, in this example, each section can be opened separately, with both sections 25 opening substantially simultaneously so that all items in the box can be unloaded substantially simultaneously.

[0171] It may be desirable to configure the movable wall so that the items are unloaded sequentially rather than all at once. By unloading the items sequentially, the items in the box are unloaded in a series of one or more groups of one or more items rather than in a single group.

[0172] Figure 14Illustrated is a box that is constructed to facilitate the sequential release of items from the box. Box 20 can have a trapdoor formed by a plurality of segments formed along the length of the box. The door segments can be opened sequentially to sequentially unload the items in the box. For example, the first door segment 25A can be opened first, so that the items supported on segment 25A are released or unloaded from the box. After opening segment 25A, segment 25B can be opened, so that the items supported on segment 25B are released or unloaded from the box. Finally, segment 25C can be opened, so that the remaining items in the box are released or unloaded from the box. It should be understood that the number of door segments can vary depending on the application. In addition, it should be understood that Figure 14 This is just one example of a structure that allows the items in a box to be released sequentially.

[0173] refer to 12A to 12C The unloading location may include a structure that supports the box 20 when the contents are unloaded at the unloading location. For example, rails 420 may support the box at the unloading station. The guide rails 420 may project outwardly away from the aisle 100 to support the box 20 as it is transferred off the carrier 300.

[0174] In this example, the rails may be flanges or U-shaped channels that engage the box to support it as it is removed from the retrieval carrier 300. The rails 420 may be sized to cooperate with the flange or lip 27 at the top edge of the box (see FIG. Figure 12C ).

[0175] Optionally, the track may include one or more elements for improving the displacement of the bin 20 along the guide track 420. Figure 12B As shown, a plurality of rotatable elements, such as rollers, in the guide track may provide a rolling surface for the lip 27 of the bin to travel along as the bin 20 is extended away from the carrier at the unloading station.

[0176] The unloading location 400 may also include one or more elements for guiding the items unloaded from the bin 20. Figure 12C , when the items are unloaded from the box, the angled wall 425 can guide the items away from the aisle. The angled wall can also bend to facilitate closing the trap door 25 when the box is pulled back onto the retrieval carrier 300.

[0177] The unloading location may also include a wall 415 that forms a chute to guide the items in a desired direction as they are unloaded from the carrier. The guide wall 415 may extend outwardly from the vertical support or vertical track 132, as shown in FIG. FIG. 12A to FIG. 12B Optionally, the guide rail 420 may be fixedly connected to the side wall 415 .

[0178] At the unloading position, the items in the 400 bin can be unloaded from the bin as described above. The items can be dumped directly into a container, such as a box or another bin. For example, refer to Figure 2, the articles are unloaded from the box 20-1 onto the guide 430 which guides the articles into the container. If the box 20-1 includes a wall that can be moved (such as Figure 12C If the box 20-1 is supported above the guide 430 with a trapdoor 25 as shown, the box can be supported above the guide 430 to provide a gap between the bottom of the box and the upper surface of the guide. In this way, the trapdoor 25 can be opened when the box 20-1 is extended away from the aisle above the guide.

[0179] The guide 430 may be formed in various configurations. Figure 2 , where the guide is a ramp or slide that angles downward and away from the aisle 100. The guide 430 may also include a housing 435 or shell that operates as a funnel to guide items into the open container. The housing may have side walls and an end wall opposite the angled slide 430. The bottom edge of the housing 435 may be spaced above the conveyor 650 that conveys the containers above, so that an empty conveyor can travel below the housing 435.

[0180] As described above, the items can be discharged directly into the container via a guide such as a hopper or chute. Alternatively, the items can be discharged onto a movable element that is used to guide or transfer the items from the bin to the empty container. Such movable elements may include one or more conveyors or delivery vehicles that operate externally to the sorting system 15.

[0181] Figures 15 to 21 A discharge conveyor 450 is illustrated that directs or transfers items from a bin to an empty container, such as an empty box 500. The discharge conveyor 450 includes a generally horizontal conveyor 460 configured to receive items discharged from a bin retrieved by a retrieval vehicle. For example, the bin 20 may be supported above the horizontal conveyor 460 such that items discharged from the bin are deposited on the horizontal surface of the horizontal conveyor.

[0182] The horizontal conveyor 460 has a first end adjacent the aisle and a second end positioned above a loading position 475. An empty container, such as a box, can be positioned at the loading position so that items are unloaded from the conveyor 460 into the container.

[0183] One or more guide elements may surround loading location 475 to guide items from the second end of conveyor 460 into a container at the loading location. Preferably, the guide elements form an opening that is smaller than the opening of the container into which the items are loaded. In this way, the guide elements may operate like a funnel to guide items into the container at loading location 475.

[0184] For example, an angled guide or ramp adjacent the second end of the conveyor can guide the articles into the cassette and prevent the articles from falling under the conveyor. A stop or end wall 470 can be positioned opposite the second end of the conveyor. The end wall is configured so that articles driven off the conveyor 460 do not displace outward beyond the sides of the empty cassette at the loading position 475.

[0185] Discharge conveyor 450 may include sidewalls or guides that prevent items from falling off the sides of the horizontal conveyor. For example, the sidewalls may extend along the sides of the horizontal conveyor, extending vertically upward from a first end to a second end of the horizontal conveyor. The sidewalls may be generally vertical. Alternatively, the sidewalls may be angled to form a groove. In this configuration, the sidewalls guide items downward toward horizontal conveyor 460.

[0186] like Figures 15 to 18 As shown, the discharge conveyor 450 optionally includes side walls to prevent items from falling off the sides of the horizontal conveyor 460. Additionally, the side walls may include conveyors 462, 464 to help move items along the length of the discharge conveyor. The side conveyors span the horizontal conveyor and extend along at least a portion of the horizontal conveyor. Figure 16 As shown, the side conveyors 462 , 464 optionally extend beyond the second end of the horizontal conveyor and into a loading position 475 .

[0187] The side conveyors 462, 464 may be a series of rollers to form a roller conveyor. However, in this example, the side conveyors are formed by a continuous belt that is driven around rollers. The rollers for the side conveyors may rotate about a vertical axis so that the conveyor belt has a generally vertical contact surface. However, as Figures 16 to 18 As shown, the side conveyors are formed so that the conveyor belt has a surface that forms an obtuse angle with the surface of the horizontal belt.

[0188] The side conveyors 462, 464 are operable in a first, or forward, direction to move articles toward the loading location 475. Additionally, the side conveyors are operable in a second, or reverse, direction to move articles away from the loading location. During normal operation, the side conveyors operate in a forward direction. However, the side conveyors can selectively reverse direction to loosen or release articles that may be stuck or jammed in the discharge conveyor 450.

[0189] Additionally, the side conveyors 462, 464 can be independently operated such that one of the side conveyors operates in a first direction while the second side conveyor operates in a second direction. The opposing operation of the side conveyors can create a twisting motion or torque on items in the discharge conveyor, which can release or loosen items that may be stuck or jammed in the discharge conveyor.

[0190] The side walls and / or side conveyors 462, 464 can be fixedly positioned. In the fixed position, the distance between the side walls and / or side conveyors is fixed. Alternatively, the side walls and / or side conveyors can be flexibly connected relative to each other so that the distance between the side walls and / or side conveyors is variable.

[0191] A variety of mechanisms can be utilized to allow the side walls and / or side conveyors 462, 464 to move relative to one another. For example, rollers supporting the side conveyors 462, 464 can be displaced outwardly, away from the horizontal conveyor. Biasing elements can bias the side conveyors inwardly, toward the horizontal conveyor. However, if one or more items become jammed between the side walls or side conveyors, the lateral force from the jammed items can overcome the biasing force, causing one or both of the side walls and / or side conveyors to move outwardly, which in turn can release or unblock the jam.

[0192] The discharge conveyor assembly 450 may include one or more sensors for detecting whether one or more items are blocked or otherwise restricted from advancing from the discharge conveyor into one of the containers 500. For example, the discharge conveyor assembly 450 may include a plurality of beam interruption sensors positioned along the length of the conveyor assembly to monitor the movement of items along the conveyor. Alternatively, the conveyor assembly 450 may include one or more light curtains that detect the presence of items at locations along the length of the conveyor. Thus, the conveyor assembly includes one or more elements for detecting the presence of items at one or more points along the length of the conveyor assembly 450.

[0193] Optionally, the conveyor assembly 450 may include one or more sensors for detecting the presence of items along the length of the horizontal conveyor 460. Optionally, the conveyor assembly 450 may include one or more sensors for detecting the presence of items along the length of the first side conveyor 462. Optionally, the conveyor assembly 450 may include one or more sensors for detecting the presence of items along the length of the second side conveyor 464. Additionally, the conveyor assembly may include one or more sensors along each of the three conveyors 460, 462, 464 so that the system can detect the presence of items on each conveyor.

[0194] Sensors on the conveyor assembly can provide signals indicating whether items are jammed at a certain point in the conveyor assembly 450. The system can control the operation of the conveyors 460, 462, 464 based on the signals received from the sensors. For example, if the sensors provide signals indicating that there is no jam, the central controller can control the conveyors so that the horizontal conveyor 460, the first side conveyor 462, and the second side conveyor 464 are all operated in a forward direction to drive the items toward the discharge location 475. Alternatively, if one or more sensors provide signals indicating a jam, the central controller can control the conveyors to change the movement of the conveyors. For example, as described above, the system can reverse the direction of one side conveyor while driving another side conveyor in a forward direction to produce a twisting motion, thereby rotating the items and potentially clearing any jammed items.

[0195] In addition to controlling the operation of the conveyors in response to signals from sensors, the central controller can control the conveyors based on steps already taken to clear a jam. For example, as described above, the system may declare a jam in response to signals received by one or more sensors, and as a result, the central controller may reverse the direction of one of the side conveyors. After one of the side conveyors is reversed, if the sensors continue to detect a jam, the central controller may change the operation of conveyors 460, 462, and 464. For example, if the first side conveyor is reversed and the second side conveyor is driven forward, but a jam is still detected, the central controller may reverse the direction of both side conveyors, causing the first side conveyor to be driven forward and the second side conveyor to be reversed. Alternatively, both side conveyors may be reversed. Alternatively, if the sensors continue to detect a jam, one side conveyor and the horizontal conveyor may be reversed.

[0196] Thus, the central controller can make multiple changes in the direction of one or more conveyors in response to signals received from sensors along the length of the discharge conveyor assembly 450.

[0197] refer to Figure 15 and Figures 19 to 21 It may be desirable to include a holder for holding the container while the items are transferred into the container at the discharge station 400. An exemplary assembly for holding empty containers (such as boxes) is illustrated in conjunction with the discharge conveyor 450 described above. However, it should be understood that the container holder can be incorporated into a structure at the discharge station that does not include a discharge conveyor (such as the chute 430 described above). Furthermore, it should be noted that in various applications, the system can function adequately without the container holder.

[0198] The container holder 520 can be configured to hold a container to be loaded at the loading position 475. The container holder 520 can include a movable holder 530 that can be displaced between an engaged position and a retracted position. In the first position, the holder holds the container in a fixed position at the loading position 475. In the second position, the holder releases the container so that the container is free to be transferred away from the loading position.

[0199] The movable retainer 530 may be in the form of a generally flat plate operable to press against the side of the container. Alternatively, a fixed wall or plate 550 may be disposed opposite the movable retainer (see FIG. Figure 19 and Figure 21 ). Thus, in the first position, the movable retainer presses the container against the fixed wall 550 to clamp or hold the container in place.

[0200] The movable holder 530 may also include an end wall 532 that projects transversely to the planar surface of the movable holder. The end wall may operate as a stop to stop the container in the loading position 475 as the container moves along the conveyor. In particular, the end wall 532 may project into the path of the container as it moves into the loading position 475.

[0201] Various mechanisms may be utilized to position the movable retainer in the first position (see Figure 19 ) and the second position (see Figure 20 In this example, the container holder includes an actuator 540 such as a solenoid, and a link mechanism 545 connects the movable holder 530 with the solenoid.

[0202] The system 10 may include a conveyor for conveying containers away from the sorter after the sorter bin is emptied at a discharge station 400. Additionally, the system may include a conveyor for conveying empty containers to a discharge station for receiving items from the sorter bin.

[0203] Figure 2 One type of conveyor is illustrated for conveying containers away from a sorter after items from a sorting bin have been transferred into the containers. The conveyor may include a transfer conveyor 660 that moves the containers along a path parallel to the aisles 100 of the sorter 15. The transfer conveyor may include one or more conveyor belts or one or more rollers or similar mechanisms for moving the containers along a generally horizontal path. Alternatively, the transfer conveyor may include a shuttle or other mobile carrier onto which the containers may be loaded after the items from the sorting bin have been transferred into the containers.

[0204] The transfer conveyor 660 can move the filled container 510 from the unloading station 400 toward the output conveyor 675, which moves the filled container 510 away from the sorter 15. The output conveyor can include one or more conveyor belts or one or more rollers or similar mechanisms for moving the container along a horizontal path in a generally horizontal orientation. Alternatively, the output conveyor can include a shuttle carrier or other mobile carrier onto which the container can be loaded.

[0205] The output conveyor 675 can be arranged at an angle to the transfer container 660, such as Figure 2 Thus, the transfer conveyor moves the filled container from the unloading station 400 along the path to the output conveyor 675. When the container reaches the end of the transfer conveyor 660, the container is transferred to the output conveyor 675.

[0206] The system 10 may include one or more conveyors for providing a supply of empty containers to the unloading station 400 for receiving items from the sorting bins, as described above. Figures 1 to 2 As shown, the system may include container input conveyors 650-1, 650-2, 650-3, and 650-4. Each of the four conveyor lines provides a supply of empty containers 500 to the unloading station 400. Figures 1 to 2 In the embodiment shown, each input conveyor 650-1, 650-2, 650-3 and 650-4 reaches a separate unloading station 400. Thus, each input conveyor 650 independently provides a supply of empty containers to a unloading station. Therefore, each input conveyor 650 can be controlled individually.

[0207] Alternatively, input conveyor 650 can be configured to transmit containers with different physical properties. The physical property can be the size of the container, such as length, width and height, or the physical property can be the type of container, such as a large bag, box or cardboard box. For example, input conveyor 650-1 can transmit an extra-large cardboard box to unloading station 400-1, input conveyor 650-2 can transmit a large cardboard box to unloading station 400-2, input conveyor 650-3 can transmit a medium cardboard box to unloading station 400-3, and input conveyor 650-4 can transmit a small cardboard box to unloading station 400-4.

[0208] In some applications, it may not be desirable to automatically convey the supply of containers to the discharge stations. Alternatively, the system may have a single input conveyor that supplies empty containers to each discharge station. Therefore, it should be understood that the number of input conveyors may vary depending on the application. Similarly, the direction and orientation of the input conveyor 650 may vary depending on the application.

[0209] For example, Figure 15 and Figures 19 to 21An alternative input conveyor 650' is illustrated in FIG. The alternative input conveyor has an input path that moves empty containers 500 parallel to the aisles of the sorter. The empty containers 500 move along the path toward a loading position of the unloading station 450. At the loading position, the container is filled with items from one of the sorting bins 20. Figure 15 , a container filled in the loading position is designated as 505.

[0210] From the discharge location, the container moves toward a right-angle diverter 655, which moves the filled container transverse to the input conveyor and toward a transfer conveyor 660'. The transfer conveyor 660' is configured to transport the filled container along a path parallel to the aisle and opposite to the direction of travel of the input conveyor. As can be seen above, it should be understood that the number and layout of the container input conveyor, the container transfer conveyor, and the container output conveyor can vary depending on various factors, including but not limited to the size and shape of the available floor space, the number of sorting systems used, and the type of items being sorted.

[0211] In the foregoing description, the system is discussed as having a single sorter 15 that sorts items and then transfers the sorted items into containers that are conveyed away by an output conveyor 675. However, the system may include multiple sorters linked together by one or more common input conveyors for providing empty containers to the sorter and / or one or more common output conveyors for conveying full containers away from the sorter.

[0212] In the foregoing description, after a group of articles has been sorted into a bin, the bin is transferred to a discharge station 400, where the articles from the bin are discharged into another container. However, rather than transferring articles from one container to another at the discharge station, the entire bin can be discharged at the discharge station. For example, the discharge station can include a conveyor or other movable object onto which the bin can be placed. The retrieval carrier can transfer the filled bin to a conveyor at the discharge station by similarly actuating the transfer mechanism 350 to move the filled bin away from the carrier.

[0213] Once the full case is transferred to the conveyor at the unloading station, the full case can be transferred to a transfer conveyor and / or an output conveyor similar to the conveyors described above to move the full box 510 away from the sorter 15.

[0214] In an arrangement where full cases are unloaded from the sorter rather than being emptied, the system may also include a mechanism for providing a supply of empty cases to restock the sorter after the full cases are unloaded. For example, a conveyor may convey the empty cases toward a discharge station so that after a retrieval carrier unloads a full case, the carrier may then retrieve the empty case and deliver the case to a sorting location that does not have an empty case.

[0215] Thus, as described above, the system can sort items into bins and then unload the sorted items by transferring the sorted items from the bin to another container or by transferring the entire bin out of the sorter. Alternatively, the system can combine these two features by unloading a full bin from the sorter and then transferring the items to a separate container.

[0216] refer to Figures 22A to 22C , illustrates an alternative embodiment in which the bins 20 into which the items have been sorted are transferred to a bin output conveyor. For example, the bins 20 may be retrieved by a retrieval vehicle as described above and transferred to a discharge station 400'. At the discharge station, the retrieval vehicle may transfer the filled bins to a bin output conveyor 700.

[0217] The case output conveyor 700 conveys filled cases 20 along a path above the container conveyor 650 which conveys empty containers. Figure 22B As shown, a gap in the box conveyor 700 can be arranged above the container conveyor 650 to allow items to be unloaded from the box 20 into the empty box 505 at the loading position. The box can be supported above the gap by the unloading station via supports and / or guides similar to the above-described rails 420. In this way, the bottom trapdoor 25 of the box can be opened so that the items in the box can fall into the container 505 below the box.

[0218] After the items are unloaded from the case, the empty case is conveyed along the output conveyor 700. The door 25 of the case is closed as the case is conveyed out of the gap in the output conveyor 700. The empty case can then be conveyed back toward the sorter so that it can be transferred back into the sorter by one of the retrieval carriers.

[0219] Figures 23A to 23C Yet another embodiment is illustrated in , where the system transfers full cases out of a sorter along a conveyor and then transfers items from the full cases to empty containers, such as boxes. In this second alternative embodiment, an output conveyor 700 for full cases 20 selectively discharges items onto empty boxes 505A, 505B on separate container conveyors 650A, 650B.

[0220] The output conveyor 700 may include one or more movable sections that are selectively opened to unload items from the box. For example, the output conveyor 700 may include a first movable section 725A above the first container conveyor 650A and a second movable section 725B above the second container conveyor 650B.

[0221] Each movable section 725A, 725B is configured so that in a first position, the movable section provides a surface for supporting the box so that the trap door of the box remains closed. In a second position, each movable section is displaced away from the path of the output conveyor to provide a gap or opening so that the trap door 25 of the box can be opened. For example, Figure 23C As shown, the movable sections 725 can pivot similar to a trapdoor. Similar to the above embodiments, box supports 730 can be provided above the movable sections so that when one movable section is open, the box is supported over a gap in the output conveyor 700.

[0222] When one of the movable sections is moved to the open position, the box support 730 supports the box to prevent it from falling through the opening in the output conveyor. When the box is supported and the pivotable section 725B is opened, the trapdoor of the box opens, allowing items to fall into the container 505B on the output conveyor 650B. Similarly, when the box is positioned above the first output conveyor, the first pivotable section can be pivoted open so that items can be unloaded from the box into the empty container 505A.

[0223] refer to Figures 1 to 4 The system 10 may also include one or more box erectors 600. The box erectors automatically manufacture cardboard boxes from a cardboard supply. The box erectors 600 are operable to cut a certain length of cardboard from the cardboard supply and then cut and fold the cardboard segments to produce empty boxes 500. Figure 1 As shown, the system can include multiple box erectors 600-1, 600-2, 600-3, and 600-4. The box erectors can all produce boxes of the same size. Alternatively, the box erectors can produce boxes of different sizes and configurations. For example, a first erector 600-1 can produce boxes of a first size, a second erector 600-2 can produce boxes of a second size, a third erector 600-3 can produce boxes of a third size, and a fourth erector 600-4 can produce boxes of a fourth size.

[0224] The system may also include a plurality of conveyors 650 for conveying empty boxes 500 from the box erectors to the unloading station 400. The conveyors may be configured so that boxes from any erector can be conveyed to any unloading station. Alternatively, as Figure 1 As shown, the conveyors from the erectors to the discharge stations may be separate so that each erector only supplies empty boxes to a single discharge station.

[0225] operate The system is operable to sort a plurality of items into bins 20 and then automatically retrieve the bins after the items have been sorted into the bins. The system may empty the retrieved bins. Alternatively, the system is operable to remove the bins from the system so that they can be processed at a location remote from the system.

[0226] The process of sorting items into a plurality of bins may optionally include the step of loading the items onto a plurality of independently operable delivery vehicles 200 operating within the aisle 100. To deliver an item, one of the delivery vehicles 200 may travel along a vertical loop within the aisle from a loading position to one of the bins. At the bin, the delivery vehicle may actuate a transfer mechanism to deliver the item into the bin. After delivering the item, the delivery vehicle may travel along a vertical loop within the aisle to return to the loading position to receive another item to be delivered. This process may be repeated with the delivery vehicle to sort the items into the sorting bins.

[0227] As described above, the process of sorting items may optionally include scanning the items to identify their characteristics before they are loaded onto one of the delivery vehicles. For example, the characteristic may be a unique identifier such as a product identification code. Alternatively, the process may include manually entering information about the characteristic (such as typing in the product identification code). The central controller 800 may then use this characteristic to determine the bin to which the item is to be delivered.

[0228] The process of sorting items may also include conveying the items along a conveyor and scanning the items as they are conveyed. As the items are conveyed along the conveyor, a scanner (such as a barcode scanner or a line scan camera) positioned along the conveyor may scan the items. The conveyor may transport the items to one of the delivery vehicles at a loading location so that the items can be loaded onto the delivery vehicle 200. Alternatively, the sorting process may include scanning the items and placing them directly onto one of the delivery vehicles. For example, an operator may manually place the items onto the delivery vehicles, or an automated device (such as a robotic arm) may place the items directly onto the delivery vehicles.

[0229] The process for sorting items may also include moving a delivery vehicle along a vertical loop within the aisle, the vertical loop comprising one or more vertical segments and one or more horizontal segments. The bins 20 may be positioned on either side of the aisle so that the delivery vehicle can transfer items forward to a bin on one side of the aisle or backward to a bin on a second side of the aisle.

[0230] The step of moving the delivery vehicle may include moving the delivery vehicle along the track 105 in the aisle 100. The step of moving the delivery vehicle may include vertically driving the vehicle or lifting the vehicle. The step of driving the delivery vehicle may include actuating doors at intersections along the track to control the direction of travel of each vehicle.

[0231] The central controller 800 can control the delivery of items to accumulate them in bins. Specifically, the central controller 800 can store the identification of a group of items to be accumulated in one of the bins. For example, the central controller can receive information about a group of items required for a particular order. The central controller will provide a control signal to a delivery vehicle to deliver the items for the order to one of the bins. Once all items for an order have been accumulated in a bin, the central controller identifies the bin as ready for retrieval.

[0232] The central controller 800 can individually control each delivery carrier so that each carrier follows a vertical loop within the aisle, but each carrier can follow a separate path depending on the box the carrier is delivering the item to. For example, a first carrier can follow a first path to a first box, while a second carrier follows a second path to a second box.

[0233] The process of sorting items may include a step of determining a carrier route based on the bin to which the items are to be sorted. Specifically, the central controller 800 may determine the route of the carrier and transmit information about the bin to which the items are to be delivered to the carrier.

[0234] After determining the vehicle's route, the central controller can provide signals that control doors along the track to guide the vehicle to the appropriate column. The doors can be directly actuated by actuators such as solenoids, allowing the central controller to provide signals to the door solenoids. Alternatively, the delivery vehicle can include actuators for actuating doors along the track. The central controller can provide signals to the delivery vehicle to selectively actuate the actuators, thereby selectively actuating the doors to guide the delivery vehicle along the appropriate path.

[0235] The process for sorting items may include the step of stopping the carrier so that it is aligned with the gap above the bin to which the item is to be delivered. For example, the top of the carrier may be aligned with the gap between the appropriate bin 20 and the bottom edge of the bin directly above the appropriate bin.

[0236] When the carrier stops, a controller on the carrier can send appropriate signals to the conveyor motor to drive the conveyor belt, which drives the items forward to discharge the items into the bin.

[0237] The process of retrieving a box may include identifying box 20 among the multiple boxes. In particular, the central controller 800 may determine that all items in the group of items have been delivered to the box. Once the items in the group are delivered to the box, the central controller 800 may identify the box as a box to be retrieved.

[0238] The process of retrieving the box may also include driving a carrier to the box to be retrieved within aisle 100. The carrier may be the same carrier as the delivery carrier, or the retrieval carrier may be configured differently from the delivery carrier. The retrieval carrier may move vertically and / or horizontally within the aisle.

[0239] Alternatively, when retrieving a box, the retrieval vehicle can be moved from the staging location to a storage location where the box will be received. For example, the system can include one or more retrieval vehicles 300 that are not used to deliver items. Thus, when the retrieval vehicle is not operating, the retrieval vehicle can be staging at a location outside the delivery path of the delivery vehicle 200.

[0240] The staging location for retrieving the carrier 300 is preferably located within the aisle 100. For example, referring to Figure 1 and Figure 5 , the system can include a staging row 150 within aisle 100. Staging row 150 can be positioned anywhere along the length of the aisle. In this example, the staging row is positioned adjacent to loading row 140, where items are loaded onto delivery vehicles. Storage locations or storage bins can be located along staging row 150. However, in this example, the storage bins are not located along the staging row, thereby minimizing the need for delivery vehicles to move through the staging row.

[0241] Rather than marshaling retrieval vehicles when not in use, retrieval vehicles can be moved within aisles. For example, central controller 800 can track the gaps between delivery vehicles moving within an aisle. Central controller 800 can control the movement of retrieval vehicles so that they move within the gaps between delivery vehicles. Specifically, controller 800 can control the path of retrieval vehicle movement to minimize the impact of the retrieval vehicle on the movement of delivery vehicles when the retrieval vehicle is not in use.

[0242] As described above, the process of retrieving the box 20 may include the step of moving the carrier to the box within the aisle. Once the carrier is positioned adjacent to the box, the carrier can transfer the box to the carrier while the carrier is in the aisle. In other words, the box 20 is transferred from the storage location into the aisle 100.

[0243] The box can be transferred to the carrier by a mechanism at the storage location, or the carrier can include a transfer mechanism for transferring the box to the carrier. In this example, the carrier includes a transfer mechanism that is operable to engage the box and transfer the box to the carrier. Alternatively, the process of transferring the box can include extending the transfer mechanism 350 from the carrier 300 to engage the box 20 and then retracting the transfer mechanism to pull the box onto the carrier.

[0244] Extending the transfer mechanism 350 may include extending one or more telescoping arms 352 toward the bin. Optionally, the transfer mechanism 350 may include retractable engagement elements, such as pivotable latch fingers 355, 357. Extending the telescoping arms 352 may include maintaining the latch elements in a retracted position while the arms are extended. After the arms 352 are extended, the engagement elements may engage the bin. For example, after the arms are extended to a storage position where the bin is located, the latch fingers 355, 357 may pivot to an extended position to engage the bin.

[0245] The step of retracting the transfer mechanism may include the step of retracting the arm by collapsing the telescopic arm 352 to the retracted position to pull the box onto the carrier. Additionally, the retracting step may include the step of maintaining the latch elements 355, 357 in the extended position so that the latch elements remain engaged with the box when the arm is retracted.

[0246] refer to Figures 8 to 10 , illustrates the operation of retrieving the carrier 300 when retrieving the box. Figure 8 , the carrier is illustrated with the transfer mechanism 350 in a retracted position. Once the carrier is aligned with the box to be retrieved, the motor on the carrier is actuated to rotate a drive mechanism (such as one or more gears), which in turn extends the transfer mechanism 350 to a position such as Figure 9 In this position, the transfer mechanism is extended to the storage position so that the telescopic arms 352 span the box, as shown. Figure 11B Once the arm is extended, the motor is driven to actuate the latch 355 so that the latch is extended to engage the box. In this example, by pivoting the latches 355, 357 to Figure 10 The box 20 is held between the front latch 355 in contact with the front edge of the box and the rear latch 357 in contact with the rear edge of the box (see Figure 11C ). In this way, the box is forcibly held so that the box moves forward or backward in response to the extension or retraction of the arm 350.

[0247] The step of retrieving the box 20 may optionally include the step of releasing the box from a box retainer. For example, the storage location may include a retainer that engages the box to prevent it from being removed from the storage location. In one example described above, the retainer 42 may engage a surface of the box to retain the box in the storage location. The retainer may be a stopper 42 that abuts against a surface of the box to prevent movement of the box.

[0248] The step of releasing the bin retainer 42 may include the step of actuating the actuator 44 to displace the bin retainer. The step of actuating the actuator may include the step of continuing to engage the actuator so that the retainer remains in the released position during substantially the entire displacement of the bin from the storage position. The step of actuating the actuator 44 to release the bin retainer 42 may include the step of extending the transfer mechanism 350 into the storage position. Optionally, the step of actuating the actuator 44 may include the step of aligning the transfer mechanism with the actuator.

[0249] Optionally, the retrieval carrier 300 may include side walls 330 with a generally horizontal surface 320 therebetween. A front opening may extend between the side walls along a front edge of the carrier, and a rear opening may extend between the side walls along a rear edge. The step of retrieving the box may include the step of displacing the box onto a horizontal surface through the front opening or the rear opening.

[0250] As described above, the process may include the step of emptying the retrieved bin. The method for emptying the retrieved bin 20 may include the step of driving the retrieval vehicle within the aisle to a location where the bin can be emptied. Specifically, the process may include the step of moving the vehicle vertically and / or horizontally along a path extending from the storage location where the bin was retrieved to the unloading station 400 where the bin can be emptied.

[0251] The central controller can determine the path of the retrieval vehicle within the aisle based on one or more of a number of variables. For example, the system can include multiple unloading stations 400. Each unloading station can be configured to receive items or orders with specific characteristics. For example, a unloading station can be configured to receive groups of items with a total weight below a first threshold, and another unloading station can be configured to receive groups of items with a total weight above the first threshold. Similarly, different unloading stations can be configured to receive orders based on characteristics such as the number of items in a box, the estimated volume of the items in the box, the maximum length of the items in the box, etc.

[0252] Alternatively, each unloading station can be configured to receive boxes regardless of the physical characteristics of the items in the box. In other words, each unloading location can be configured to receive any box, regardless of the grouping of items in the box. Thus, the central controller can determine to which unloading station a retrieved box will be directed based on various factors, including but not limited to: the proximity of the retrieved box to the unloading station, the traffic between the retrieved box location and the unloading station (i.e., the travel of the delivery and retrieval vehicles), and the availability of the unloading station (i.e., whether a vehicle is currently at the unloading station or en route to the unloading station).

[0253] The process of moving the retrieval vehicle 300 to the unloading station 400 may include the step of driving the vehicle along the track 105 within the aisle 100. The driving step may include the step of driving a first drive wheel on one side of the aisle and the step of driving a second drive wheel on the other side of the aisle.

[0254] The process of emptying the box may include the step of transferring the box away from the retrieval vehicle. The box may be transferred away from the retrieval vehicle at the unloading station. Alternatively, the box may be transferred by actuating the transfer mechanism 350 to extend the box away from the retrieval vehicle.

[0255] The steps of moving a case off the carrier 300 at the unloading location may be similar to the steps of transferring a case onto the carrier from one of the storage locations, but in reverse. 11A to 11D The step of transferring the items in the bin from one of the storage locations is illustrated when the central controller determines that all items in the predetermined group have been accumulated in the bin. Figure 11A In , align the retrieval carrier with the storage location so that the carrier's support surface 320 is at the same height as or slightly below the bottom surface of the box. Figure 11B , extend the transfer mechanism to the storage position. Figure 11C In , the engagement elements 355, 357 are moved into engagement with the box. Figure 11D In the embodiment of the present invention, the transfer mechanism is retracted while the engagement elements 355, 357 engage the case, thereby transferring the case onto the carrier 300. Conversely, the process of transferring the case off the carrier can be initiated by aligning the carrier with a conveyor or guide at the unloading station 400. The transfer mechanism 350 is then extended while the engagement elements engage the case, thereby moving the case off the carrier.

[0256] The bin 20 may include a movable wall, and the process for unloading items from the bin may include the step of displacing the movable wall. For example, the retrieval vehicle may include an actuator operable to displace the movable wall to unload the item from the bin. Alternatively, the bin may cooperate with a mechanism at the unloading station to displace the movable wall. In this example, the bottom wall of the bin is displaceable, and the process includes the steps of supporting the bin while releasing the bottom wall so that the bottom wall is displaced to an open position, thereby allowing the item to fall through the bottom of the bin.

[0257] The process of unloading items from the bin may include the step of aligning the bin 20 with guides 430 or 435 that direct the items toward the container 500. After the step of aligning the bin with the guides, the bin is opened and the guides direct the items into the container.

[0258] The process of unloading the items may optionally include aligning the empty container with a guide that guides the items being unloaded from the bin. Aligning the empty container may include conveying the empty container along a conveyor to a discharge position 475. The method may also include engaging the empty container 500 at the discharge position to hold the empty container at the discharge position while the items are transferred from the bin into the container. Engaging the empty container may include clamping the empty container in place or engaging the container between one or more stops to restrict movement of the container.

[0259] After the items are transferred into the container 500, Figure 1 、 Figure 2 , a full container is indicated at 510. The full container is conveyed away from the discharge position so that an empty container can be moved to the discharge position to receive items from the next bin. The full container can be conveyed by a horizontal conveyor such as transfer conveyor 660, and the transfer conveyor can convey the container to an output conveyor, which conveys the container with the sorted items away from the sorter 15.

[0260] refer to Figures 15 to 21 The process of unloading the articles from the bin 20 may include the step of dropping the articles onto a generally horizontal conveyor. The horizontal conveyor may convey the articles toward a discharge position aligned with a container below the conveyor.

[0261] The process of conveying the articles toward the discharge position may include driving the side conveyors 462, 464 across the horizontal conveyor and forming a certain angle with the horizontal conveyor. The side conveyors can be driven in a forward direction to push the articles downward toward the horizontal conveyor and toward the discharge position 475.

[0262] The method may optionally include the step of displacing the side conveyors 462, 464 relative to each other to increase the distance between the side conveyors.

[0263] The method of unloading the items may optionally include a step of sensing whether an item has become jammed somewhere in the path between the bin 20 and the empty container 500. Additionally, the system may include a step of displacing items along the path in an attempt to free the jammed item. For example, the method may include the step of driving one of the side conveyors in a forward direction while simultaneously driving a second side conveyor in an opposite direction to deflect items that may be jammed in the path along the horizontal conveyor 460.

[0264] Optionally, the process of unloading the items may include gradually releasing the items from the box. This prevents the items from being released or transferred all at once. Gradually releasing the items can limit or minimize the possibility of items becoming jammed as they are transferred into container 500. The step of gradually releasing the items from the box may include gradually opening a movable wall of the box. For example, the movable wall may include multiple segments, such as door segments 25A, B, and C, and the method may include sequentially opening the door segments. Alternatively, the method may include gradually opening or displacing the movable wall of the box to gradually increase the opening in the box through which the items are unloaded from the box.

[0265] After the items are unloaded from the case, the process may include the step of transferring the case back onto the retrieval vehicle. The process of transferring the case back onto the retrieval vehicle may include the step of closing the movable wall while the case is transferred onto the vehicle.

[0266] After the empty case is transferred back to the carrier, the carrier may then travel vertically or horizontally within the aisle to follow a path to an empty storage location (i.e., a storage location without a case). The empty storage location may be the storage location from which the carrier retrieved the case. Alternatively, the empty storage location may be different from the storage location from which the carrier retrieved the case. Once the retrieval carrier reaches the empty storage location, the carrier is retracted by reversing the aisle. 11A to 11D The illustrated steps transfer the empty boxes into a storage location.

[0267] The step of transferring the empty bin to the empty storage location may include the steps of actuating the retainer to a release position while the bin is transferred to the storage location and then actuating the retainer to a retaining position such that the retainer engages the bin to retain the bin.

[0268] As described above, the method may include the step of unloading full bins from the sorting system rather than emptying the full bins. In such a method, items can be sorted into sorting bins as described above and the sorting bins can be retrieved when they are full. The retrieved bins can then be transferred to one of the unloading stations described above. At the unloading station, rather than transferring the bins off the carrier 300 to empty the bins, the bins are transferred to a conveyor at the unloading location. For example, bin 20 can be transferred to a transfer conveyor 660 so that the full bins can be transferred out of the sorting system.

[0269] The method may also include the step of transferring the empty container to the retrieval vehicle after the vehicle has transferred the full container to a conveyor at the discharge location. For example, the system may include a conveyor for supplying the empty container to the discharge location. The conveyor may be controlled so that after the retrieval vehicle unloads the full container, the empty container is advanced to the discharge location. The vehicle may then transfer the empty container to the carrier in a manner similar to how the vehicle retrieves a full container from the storage location, as described above.

[0270] Once the empty case is loaded onto the carrier, the carrier can be moved to one of the empty storage locations to transfer the empty case into the empty storage location, as described above.

[0271] Additionally, the process of unloading a filled case from the retrieval vehicle may include a process of automatically emptying the case after it is conveyed away from the unloading station 400 .

[0272] refer to Figures 22A to 22C The process of emptying a full box may include the step of operating a conveyor 700 to transport the full box away from the sorter. The conveyor may transport the full box 20 toward an opening above a conveyor 650, which transports an empty container 505 positioned in a discharge position to receive items from the box. While the box is positioned above the empty container, the box may discharge the items into the empty container.

[0273] The method of unloading items from a bin may include the following steps: supporting the bin 20 so that the bottom of the bin is free to open while the bin is positioned above a gap in the conveyor 700. The bottom door 25 of the bin opens, allowing the items in the bin to fall into the cassette 505 below. After the items are unloaded from the bin 20, the bin advances along the conveyor 700 and the filled containers 505 move along the container conveyor 650.

[0274] refer to Figures 23A to 23C , the process of emptying the box may include the step of selectively actuating the movable sections 725A, 725B of the conveyor 700 to selectively create an opening. This process may include the steps of identifying a location for unloading items from the box and conveying a filled box toward that location. The process may also include the step of operating the container conveyors 650A, 650B to align an empty container with the identified location for emptying the box. The method may also include the step of actuating the movable conveyor segments at the identified location to create a gap in the conveyor. In addition, the method may include the step of supporting the box so that the bottom door of the box can be opened so that items can be unloaded from the box into the container.

[0275] Optionally, the process may include the steps of generating empty containers and conveying the empty containers toward a discharge location. Optionally, the process may include the steps of generating empty containers having different physical properties and selecting a discharge station to which the containers are to be delivered based on the physical properties of the empty containers.

[0276] It should be understood that the above method may include the steps of sorting items into bins 20 while the retrieval vehicle 300 operates to retrieve bins from a storage location, move the retrieved bins to a dump station 400, empty the retrieved bins, and / or return the empty bins to an empty storage location.

[0277] In the foregoing discussion, items were sorted into sorting bins before being unloaded at one of the discharge stations. However, it should be understood that the process can also include a step of delivering items directly to the discharge station for unloading into containers. In this way, some items can bypass the sorting bins and be delivered directly to the containers for removal from the sorter.

[0278] In some cases, the items in a group (such as those in an order) may be too large or too numerous to fit into a single sorting bin 20. In this case, the central controller will control the delivery vehicle to deliver the items to two or more separate bins. The bins will be collectively identified as belonging to a single order, so that no bin will be retrieved until all items for that order have been sorted into the sorting bin identified for that order. The system will then retrieve multiple bins and deliver each bin to one of the unloading stations so that all items in each bin can be emptied into a single container. Thus, the method may include the step of maintaining the container at the unloading position after the first bin has been emptied into the container.

[0279] Alternatively, a plurality of assortment bins may be sequentially conveyed to a discharge location and then sequentially emptied into a plurality of empty containers. The central controller may identify each individual container so that the individual containers are identified as belonging to the same order.

[0280] The system can also process a group of items to control how the items are sorted into two or more bins. The system can also control the order in which the retrieval robots 300 retrieve the bins.

[0281] According to one example, the system may sort multiple items for an order into multiple bins. Sorting of items may be accomplished by multiple sorting vehicles 200 operating within the aisles as described above. The system may determine which bins the items for an order will be sorted into based on a first characteristic. For example, the first characteristic may be the weight of the item, and the system may sort items with a weight exceeding a threshold into a first bin, while items with a weight below the threshold may be sorted into a second bin. In this way, the system may sort items for a single order into multiple bins based on the characteristics of each item, such that items sharing common characteristics are sorted into bins together.

[0282] The first characteristic may be any of various characteristics of the item including, but not limited to, length, width, height, weight, fragility, density, volume, or shape.

[0283] The system can also control the order in which the retrieval robots retrieve boxes. One method for controlling the order in which boxes are retrieved is to retrieve them in the order in which they are filled. Specifically, after the last item of an order is sorted into the box, the box can be identified as full or ready for retrieval. The system can prioritize the retrieval of boxes based on the order in which the boxes are identified as full or based on the order in which the boxes are identified as ready for retrieval.

[0284] Rather than controlling the order of box retrieval based on the order in which boxes are identified as full or ready to be retrieved, the system can control the ordering of box retrieval to maintain order cohesion. Specifically, if the items of an order are sorted into multiple boxes, the system can delay the retrieval of any box of the order until all items of the order are sorted. For example, an order may include items A to F, and items A, B, and C will be sorted by the system into the first box, and items D, E, and F will be sorted by the system into the second box. Once items A, B, and C are sorted into the first box, the box can be considered full because all items have been sorted into the box. However, if one of items D, E, or F has not yet been sorted into the second box, the system can delay the retrieval of the first box. Specifically, the first box may not be designated as ready for retrieval until all items of all boxes of the order have been sorted. Once the last item of the order is sorted, all boxes with items of the order can be designated as ready for retrieval.

[0285] Once all boxes of an order are designated ready for retrieval, the system can control the retrieval of the boxes to keep the items for the order together. For example, in one application, all items from multiple boxes of a single order can be unloaded into a single container at a single unloading station. In this case, the boxes of the order are retrieved serially and transported to a common unloading station 400. The single container remains at the unloading station until all items from all boxes of the order are unloaded into the container. The filled container, containing all items for the order, then moves out of the unloading station 400.

[0286] In an alternative application, rather than unloading items from multiple boxes for an order, the boxes can be electronically tagged as being associated with a single order, and the boxes can be unloaded sequentially from the sortation system 15 to keep the boxes together. For example, the system can control the unloading of other boxes for other orders so that all boxes for a single order are unloaded sequentially, without boxes for other orders being inserted onto the conveyor between boxes for a single order. In this way, multiple boxes for a single order are conveyed along an output conveyor (such as conveyor 700) in an uninterrupted sequence.

[0287] As described above, the items in an order can be sorted into multiple boxes based on the characteristics of the items, so that items with similar characteristics are sorted into the same box. It may be desirable to retrieve the boxes in a specific order based on the characteristics of the items in the box. For example, an order with multiple items can be sorted into multiple boxes, such as two boxes. The first box can be used for items with a weight greater than a certain threshold. The second box can be used for items with a weight below the threshold. After the items in the order have been sorted into the two boxes, the system can first retrieve the first items and transport the first box to a discharge station to unload the heavy items into a container. Subsequently, the system can retrieve the second box and transport the second box to a discharge station to unload the light items into the container. In this way, the system avoids unloading heavy items in the order onto light items, which may damage the light items. Therefore, the system can be operated to retrieve multiple boxes in a sequence so that the items are unloaded into a common container based on the physical characteristics of the items in the order.

[0288] As described above, the system can be operated to sort items into bins and then unload the items from one or more bins into containers. Optionally, the system can also include one or more components for pushing the items into the container after they have been unloaded. For example, after the items have been poured into the container, one or more items may protrude upward above the upper edge of the open container. The system can include a structure configured to push the protruding items downward into the bin. Preferably, the structure pushes the protruding items below the upper edge of the bin.

[0289] Alternatively, the structure for pushing items into the container may include a height-limiting rod extending across the width of the container. The rod extends at a predetermined height (such as the height of the rim of the box). The rod may be positioned adjacent to the unloading station so that when the box is transported from the unloading station, the box passes under the rod. In this way, items in the container that protrude above the rim will engage the height-limiting rod and tend to be pushed downward into the container as the container passes under the rod.

[0290] Alternatively, the structure for pushing items into the container can include a flexible element, such as a curtain, that extends across the width of the conveyor adjacent to the discharge station, such that the container passes beneath the curtain as it is conveyed away from the discharge station. The curtain is suspended above the container and extends below the upper edge of the container. Alternatively, the curtain can be formed from multiple panels, thereby forming a split curtain with separate panels. In this way, if the item in the container protrudes above the edge of the container, the curtain will tend to push the item downward into the container as the container passes beneath the curtain.

[0291] Therefore, the system may optionally include the steps of unloading the items into the container and engaging the items protruding beyond a threshold value so that the items are pushed downwardly into the container. Optionally, the step of engaging the items protruding beyond a threshold value may occur during the step of displacing the container away from the unloading station.

[0292] Another aspect of the system may include the steps of retrieving a bin of items and unloading the items from the bin into a container. Unloading the items into the container may include causing the items to fall into the container. The system may also include the step of shaking or rocking the container to settle the items within the container. For example, the method may include the step of rocking the container back and forth. Similarly, the method may include the step of vibrating the container to settle the items. Alternatively, settling the items within the container may occur while the container is positioned at the unloading station.

[0293] The foregoing describes a system with a sorting system having a single aisle. However, the system may include multiple aisles, each with its own system configured as described above. Optionally, in a multi-aisle system, a feed system may be provided to deliver items to be sorted to each aisle. The feed system may be any of a variety of systems, including, but not limited to, a delivery vehicle or a conveyor.

[0294] The central controller can be configured to control the supply system such that the supply system supplies a first group of items to a first sorting aisle and a second group of items to a second aisle. In this way, the first aisle can be used to process items with a first characteristic, while the second aisle can be used to process items with a second characteristic. The characteristic used to determine the aisle to which the supply system supplies items can be any of a variety of characteristics, such as physical characteristics, including size, weight, shape, etc. However, the characteristic need not be a physical attribute of the item.

[0295] Thus, the system can include a process for feeding items to a plurality of aisles of a sorting device. Each aisle can be configured to sort items into a plurality of sorting locations to accumulate the items in the sorting locations. After the items for an order have been completed, the sorting device can retrieve one or more sorting bins for the completed order using a retrieval device and transfer the bins to a discharge location where the bins are emptied or unloaded and transferred away from the sorting device. Optionally, the system can include a process for detecting characteristics of each item and determining the aisle to which the item is to be directed. The system can also include a process for controlling the feeding system to selectively feed the items based on the step of determining the aisle to which the item is to be directed.

[0296] As described above, the system may operate by accumulating items into a sorting bin, then retrieving the bin when full, and unloading the full bin onto a conveyor, rather than unloading items from the bin into another container (see, for example, Figures 22A to 22C 、 Figures 23A to 23Cand described above). In the foregoing description, the system is described as feeding empty boxes to the retrieval vehicle 300 after the retrieval vehicle unloads a full box onto the output conveyor 700. However, in some applications, it may be desirable to load boxes that already have items in them, rather than loading empty boxes onto the vehicle. Therefore, after the retrieval vehicle unloads a box out of the aisle, the system can feed a replacement box toward the retrieval vehicle. The replacement box can be empty, or it can contain one or more items. The replacement box can then be loaded onto the retrieval vehicle. The retrieval vehicle can then deliver the replacement box to one of the sorting locations so that the items can be sorted into the replacement box.

[0297] According to another aspect, a system for sorting items using multiple aisles is provided. The system may include using multiple aisles to sort items for a single order. For example, as described above, the system may include a process for sorting items into a first sorting aisle and a second sorting aisle based on the item's characteristics. Furthermore, as described above, the system may be configured to supply a replacement bin to the sorting aisle after a sorting bin is removed from the aisle, and the removed sorting bin may be replaced with a replacement bin containing items. Thus, multiple items may be sorted into a first bin in a first storage location adjacent to a first aisle. Alternatively, multiple sorting carriers 200, as described above, may be used to sort the items into the first bin. A first retrieval carrier 300 in the first aisle may retrieve the first bin and remove it from the first aisle. The removed bin may be transferred to a second aisle. A second retrieval carrier 300 in the second aisle may retrieve the first bin at an input / output or unloading location. The second retrieval carrier may then deliver the first bin along the second aisle to a second sorting location. One or more items may then be sorted into the first bin while the first bin is in the second storage location. For example, one or more delivery vehicles may move within the second aisle to sort one or more items into the first bin in the second storage location.

[0298] Optionally, the system can further include the step of retrieving the first box from the second aisle using a retrieval vehicle after the first box has received all required items from the second aisle. Thus, the first box includes items from both the first aisle and the second aisle. The retrieval vehicle can then deliver the first box to a discharge station, where the first box is unloaded from the second aisle.

[0299] like Figures 1 to 2 As an example, the system can include one or more unloading stations 400 positioned along the aisle 100 of the sorting system 15. The system is illustrated as having the unloading station 400 on one side of the aisle 100. However, it should be understood that the unloading station can be on either side of the aisle. In addition, the unloading station 400 can be positioned on both sides of the aisle.

[0300] The system can be operated to reduce the cycle time when a retrieval carrier unloads a case from the sortation system 15. For example, if the sortation system includes unloading stations on both sides of an aisle and the two unloading stations are aligned in the same column, the system can control the flow of replacement totes to the unloading stations to allow the retrieval carrier to load replacement cases onto the retrieval carrier at one station while unloading a full case at a second station.

[0301] For reference Figures 8 to 10 An exemplary process for loading a replacement bin while unloading a full bin is described. Specifically, when a retrieval carrier 300 is positioned in an aisle having a first unloading station 400 on one side and a second unloading station on a second side, a retrieval mechanism 350 on the carrier can extend toward the replacement bin at the first unloading position while the full bin is positioned on the support surface 320. Specifically, the system can control the supply of replacement bins to deliver the replacement bin aligned with the first unloading position. The retrieval mechanism 350 can engage the replacement bin and pull the replacement bin toward the carrier. As the retrieval mechanism pulls the replacement bin toward the support surface 320, the retrieval mechanism pushes the full bin off the support surface and across from the first unloading position to the second unloading station. For example, as Figure 10 For example, the retrieval mechanism may include a front latch 355 and a rear latch 357. The front latch 355 can pull the replacement box onto the carrier 300, while the rear latch 357 pushes the full box off the carrier. By pushing the full box off while loading the replacement box, the system can reduce the time the retrieval robot is positioned at the unloading station.

[0302] Now turn Figure 24A , a block diagram depicting aspects of a warehouse operation or distribution center that utilizes a warehouse management system and integrates aspects of material handling devices constructed in accordance with the aforementioned embodiments and other exemplary embodiments described below.

[0303] Figure 24A 24 is a block diagram depicting one or more sorting and bin retrieval / exchange (SBRE) systems, generally designated 2410-1 through 2410-n, operable to sort items identified to respective item groups into designated sorting bins that have been temporarily associated with the item groups. In an embodiment, the item groups correspond to items required to fulfill an order. Figure 24A In the exemplary embodiment shown, sorting and sort retrieval, unloading (emptying) and / or transfer tasks are managed under the direction of a centralized warehouse management system 2420 that forms part of an order fulfillment arrangement 2400. Figure 24AAs shown, the exemplary order fulfillment arrangement 2400 may also include an order entry and scheduling system, generally indicated at 2435, which illustratively allows an administrator to set minimum inventory thresholds to trigger replenishment alerts and tracking of inventory levels when new orders are received and processed. The arrangement 2400 may optionally include a return material authorization (RMA) processing system 2450, wherein item returns deemed acceptable for return of inventory are processed and may be fed as input items into one or more SBREs (such as SBREs 2410-1 through 2410-n) (depending on the order process) or returned to a storage location of one or more automated storage and retrieval systems (ASRS), generally indicated at 2460-1 through 2460-m.

[0304] Figure 24B is a block diagram that depicts in greater detail one or more sorting and sort bin retrieval / exchange systems (SBRE) (such as SBRE systems 2401-1 through 2410-n), the operation of which is coordinated by a warehouse management system (WMS) 2420, as may be found in a system such as Figure 24A 2400 depicted in FIG. 1. SBRE 2410-1 will be seen to include: a controller 2413; an item input station 2414; a delivery mechanism 2415, which in one embodiment comprises independently movable carriers configured to receive items as they arrive at the input station and transfer them to an arrangement of assortment bins; and an assortment bin retrieval mechanism 2416, which in one embodiment comprises independently movable carriers configured to retrieve assortment bins once they have accumulated, for example, a group of items corresponding to orders processed by an order fulfillment or distribution center, and, as will be described in more detail later, transport these retrieved bins to a transfer station whereby the assortment bins can exit the SBRE (e.g., SBRE 2410-1) en bloc. In this latter aspect, SBRE 2410-1 also includes one or more infeed, outfeed, and cross-feed conveyors consistent with the aforementioned embodiments. Thus, the contents of the assortment bin can be unloaded and transferred to another container (e.g., a carton or other packaging for shipment to a customer, or in the case of a distribution center, to a larger container, such as a Gaylord, for transport to a point-of-sale location). As used herein, the term "exchange" is intended to refer to transferring an assortment bin out of the system without unloading its contents and transferring the contents of the assortment bin to a different container.

[0305] In the latter case, the emptied assortment bin is returned to an available location where a new group of items can be accumulated therein (e.g., for a different customer or distribution destination). The container that received the items discharged from the first assortment bin at the first unloading area can be maintained at the unloading area to receive additional items needed to fulfill the order requirements. Alternatively, the partially filled assortment bin can be transferred by an infeed / outfeed conveyor through the controller of SBRE 2410-1 to another SBRE (such as SBRE 2410-n) and receive additional items at the unloading area of ​​the SBRE. Alternatively, or in addition, the partially filled assortment bin can receive additional items at some other location outside the SBRE, where, for example, items that exceed the handling limit of delivery system 2415 can be combined with the remaining items suitable for the order.

[0306] In the former case, another infeed / outfeed conveyor may be employed at a different type of unloading area to receive the assortment bin without unloading its contents, and the assortment bin may be transported to a destination remote from the SBRE (eg, SBREs 2410-1 to 2410-n).

[0307] exist Figure 24B In the depicted embodiment, the delivery mechanism or system 2415 is implemented by a first group of self-propelled delivery vehicles, generally designated by reference numerals 2415-1 through 2415-j, and the retrieval mechanism or system 2416 is implemented by a second group of self-propelled sort bin retrieval vehicles, generally designated by reference numerals 2416-1 through 2416-m. In an embodiment, the first group of vehicles 2415-1 through 2415j and the second group of vehicles 2416-1 through 2416-m are track-guided along horizontal and / or vertical segments of an item retrieval path that connects an input station of the SBRE (such as item input station 2414) with a discharge station or discharge area of ​​the SBRE. In one embodiment, the delivery vehicles 2415-1 to 2415-j and the retrieval vehicles 2416-1 to 2416-m are directed by the controller 2413 as needed to define corresponding appropriate item retrieval paths that are used to define the routes of each corresponding delivery vehicle as it traverses the paths, the paths extending from the point at which the items are received from the intake module to the point at which the items are unloaded at the sorting bin. In one embodiment, a door mechanism is provided at the intersection of the horizontal and vertical tracks, which is mechanically actuated by the delivery vehicle (such as the delivery vehicle 140-1), and the delivery vehicle is guided along both the horizontal and vertical segments that define the vertical loop.

[0308] In some embodiments, the two groups of carriers 2415 and 2416 are equipped with various types of transfer mechanisms, enabling them to perform both item delivery and assortment bin retrieval functions. In other embodiments, a small number of carriers are employed that are configured solely to provide assortment bin retrieval functions, and these small numbers of carriers are moved between aisles based on the level of sorting activity performed by the item delivery carriers within the corresponding aisles of each SBRE. The number of carriers assigned to assortment bin retrieval functions can be significantly smaller than the number of carriers performing sorting duties, for example, approximately 15% to 35%.

[0309] At the unloading station of the SBRE, unloading aids such as downwardly inclined chutes or unloading conveyors may optionally be included, e.g. Figures 15 to 21 As depicted. Figure 24B In the illustrative example, the unloading auxiliary conveyor system 2419-1 to 2419-p incorporates the aforementioned horizontal conveyor, first side conveyor and second side conveyor and a sensor 2418 as an input for reversibly controlling a conveyor drive motor (not shown), which is used to operate the horizontal conveyor, first side conveyor and second side conveyor of the unloading conveyor.

[0310] exist Figure 24B In the depicted embodiment, WMS 2420 serves as a controller that directs the operation of one or more SBRE systems, such as system 2410-1. To this end, WMS 2420 includes a central processing unit (CPU) 2402, input / output interfaces 2406, support circuits 2408, memory 2404, and one or more network interfaces 2401. CPU 2402 is configured to retrieve and execute instructions stored in memory 2404 to implement sorting and bin retrieval / discharging and exchange equipment (SBRE) control modules, which include an item delivery control module 2430 and a sorting bin retrieval control module 2440. The SBRE control modules include item delivery control module 2430, which includes a sorting bin item group scheduler 2432, an item introduction event monitor 2434, an item group completion alert generator 2438, and a sorting bin availability monitor. These modules perform functions that enable the item delivery control module 2430 to designate assortment bins to which individual items that are the subject of at least one order and / or active RMA replenishment process are to be delivered. Memory 2404 also includes other WMS modules 2455 and an operating system 2457 .

[0311] The assortment bin retrieval control module 2440 includes an assortment bin retrieval sequencer, an assortment bin destination selector 2444, a container infeed conveyor control device 2446 (for replacing containers that have received items from the assortment bin and have left the system via the outfeed conveyor), a container outfeed conveyor control device 2448 (for directing containers and / or assortment bins away from the unloading stations and aisles) and an assortment bin / container cross-feed controller 2449 (for directing containers or assortment bins to other unloading stations so that these bins can receive items from other assortment bins before being directed out of the aisle by the outfeed conveyor).

[0312] Figure 25A System execution and Figure 24B The system performs similar tasks as sorting and bin retrieval, unloading and swapping, but uses Figure 24B The WMS performs some of the control functions of the middleware (Equipment Control System or ECS 2550). ECS 2550 includes the item accumulation, unloading, and group transfer control module 2540, which includes the assortment bin item group association module 2542, the assortment bin position status monitor, the assortment bin retrieval sequencer, and the assortment bin destination selector. The item delivery vehicle status monitor 2550 includes an item delivery vehicle status monitor, an item delivery vehicle position monitor, a retrieval vehicle status monitor, a vehicle traffic control device that manages the relative positions of the delivery and retrieval vehicles to avoid collisions, and an optional gate / path segment control device.

[0313] In an embodiment, traffic control provides messages to vehicles authorizing them to proceed along a segment of a corresponding path leading to the vehicle's assigned destination. When the segment has been completed, the vehicle will stop unless it has received the next message to proceed. Other modules include an input station control device.

[0314] ECS 2550 also includes an input station control module 2530, which includes modules 2534, 2536, 2538, and 2532, and an item group consolidation and I / O control device 2560, which includes submodules 2562, 2564, 2566, 2568, 2563, and 2567. Module 2532, indicated as optional, is used to authenticate the operator (in the case of human input of items) for purposes of product integrity and traceability in highly regulated industries such as the medical field.

[0315] Figure 24B and Figure 25A Other components common to the devices of FIG. 1 and FIG. 2 are denoted by the same or similar reference numerals and are not described here.

[0316] Figure 25B is a block diagram depicting functional components of an exemplary article input station 2514 that may form a basis for a process consistent with one or more embodiments of the present disclosure. Figure 25A 25. Items are introduced into the system at input station 2514 by continuously loading them onto an item delivery system (e.g., a carrier). Because the characteristics of the items can be used to control the operation of the carrier, the system may need to know the characteristics. In one example, the characteristics can be stored in a central database so that the characteristics are known, and the system tracks the progress of the items so that the identity of the items is known when they arrive at the input station. Thus, since the identity of the items is known, system 2514 can retrieve data regarding the characteristics of the items stored in the database. Alternatively, the items are scanned and / or weighed at input 2514 to identify one or more characteristics of each item.

[0317] In one embodiment, each item is manually scanned at the ingestion station to detect one or more characteristics of the item. These characteristics are used to determine the item's identity. Once the item is identified, various characteristics of the item can be retrieved from a central database, and the item can then be processed based on the known characteristics. For example, ingestion station 602 may include a scanning station that scans a product code, such as a barcode. 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 item, as discussed further below.

[0318] In a second embodiment, items are scanned at the inlet station 602 to detect various physical characteristics of the items. For example, the inlet station 602 can measure characteristics such as the item's length, height, and / or width. Similarly, the item's weight or shape can be detected. These characteristics can be detected manually or automatically at the inlet station. For example, a series of sensors can be used to detect the item's length, and a scale can be used to automatically weigh the item. Alternatively, an operator can analyze each item and enter information about it via an input mechanism (such as a mouse, keyboard, or touchscreen). For example, the system can include a touchscreen that presents one or more questions or options. One example is packaging: Is the item in a plastic bag, blister pack, or loose? Is the item flat, cylindrical, or round? The system can include default characteristics so that if an item has characteristics that differ from the default, the operator only needs to identify the characteristics of the item. For example, the default characteristics for an item could be flat or rectangular. If the item is round (e.g., spherical or cylindrical), the operator enters information indicating that the item is round, and the item is then processed accordingly. Based on the detected information, the item is processed accordingly.

[0319] As mentioned above, a variety of configurations are available for the input station, including manual or automated configurations, or a combination of manual and automated features. In manual systems, an operator enters information about each item, and the system delivers the item accordingly. In automated systems, the input system includes components that scan each item and detect information about the item. The system then delivers the item based on the scanned information.

[0320] In an exemplary manual configuration, the input system includes a workstation with a conveyor, an input device such as a keyboard, and a monitor. An operator reads information on an item, such as an ID tag, enters the information from the tag into the system using a keyboard or other input device, and then drops the item onto a conveyor belt. The conveyor then transports the item to the input station. For example, the operator can visually read information marked on the item, or the operator can use an electronic scanner, such as a barcode reader, to read a barcode or other marking on the item. Sensors positioned along the conveyor track the item as it moves toward a loading station.

[0321] Alternatively, as Figure 25C As shown, it is depicted Figure 25B FIG2 is a top plan view of components of an exemplary article input station, illustrating an input station 2514, which may include a scanning station 2570 for automatically detecting characteristics of an article. Specifically, the input station 2514 may include one or more feed conveyors (such as conveyor 2536A) for receiving an article and conveying the article to a scanning station operable to detect one or more physical characteristics of the article. Figure 4 B's transfer conveyor 2536B transports the items from the scanning station to a loading station 2539A where they are loaded onto a receiving surface of an item delivery mechanism or passed through the loading station to a reject bin.

[0322] The input feed conveyor can be any of a variety of conveying devices designed to transport articles. In particular, the input conveyor can be designed to receive articles dropped onto the conveyor. For example, the input feed conveyor 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.

[0323] Figure 25D and Figure 25E An illustrative manner of controlling the discharge conveyor 2650 is depicted, which includes conveyors 2662, 2664, and 266 of the discharge auxiliary conveyor system 2600. A sensor, which is a path blockage sensor 2640, detects whether an article cannot pass through the conveying path of the conveyor. If not, then the following steps are performed: Figure 25E The process includes steps 2621, 2622, 2624, 2625, 2626 and 2629.

[0324] Figure 26 is a graphical representation depicting the exchange of messages and / or instructions between logical control elements of a sort and bin retrieval / discharge / exchange (SBRE) system according to an embodiment.

[0325] Figure 27 is a flow chart depicting an automated process for performing sorting of accumulated groups of items into assortment bins, operating a carrier to retrieve an assortment bin containing the accumulated groups, and operating a carrier within an aisle to transfer the contents of the assortment bin to another container and / or exchange an assortment bin containing the accumulated group for an empty container that is used to hold a partial group of items for combination with other items. Figure 28 is a flow chart depicting an exemplary process for assigning groups or subgroups of items to sorting bin locations in accordance with one or more embodiments. Figure 29 is a flow chart depicting an exemplary article delivery vehicle traffic control process for coordinating the movement of delivery vehicles during article sorting in accordance with one or more embodiments. Figure 30 is a flow chart depicting an exemplary sort retrieval vehicle traffic control process that coordinates the movement of a sort box retrieval vehicle while simultaneously performing sorting and sort box retrieval operations within an aisle. Figure 31A is a flow chart depicting an assortment bin sorting process for combining the contents of multiple assortment bins in the same container according to one or more embodiments consistent with the present disclosure. Figure 31B is a flow chart depicting a sort bin unloading and / or exchange process according to one or more embodiments consistent with the present disclosure. Figure 32 is a flow chart depicting a modified assortment bin sorting process consistent with one or more embodiments of the present disclosure that utilizes determined information about characteristics of one or more items or groups of items to determine the order in which the contents of multiple assortment bins are to be combined in the same container.

[0326] Various embodiments of the methods and apparatus for organizing, enhancing, and presenting message content incorporating one or more media files as described herein may be executed on one or more computer systems that may interact with various other devices. One such computer system is Figure 33 The illustrated computer system 3300 can implement the illustrated elements or functions in various embodiments. In various embodiments, the computer system 3300 can be configured to implement the above-described method. The computer system 3300 can be used to implement any other system, device, element, function, or method of the above-described embodiments. In the illustrated embodiment, the computer system 3300 can be configured to implement the method 2700 ( Figure 27 ), Method 2800 ( Figure 28 ), Method 2900 ( Figure 29 ), Method 3000 ( Figure 30) and / or any other method described and / or depicted herein is implemented as processor-executable program instructions 3322 (e.g., program instructions executable by processor 3310).

[0327] In the illustrated embodiment, computer system 1200 includes one or more processors 3310a-3310n coupled to system memory 3320 via an input / output (I / O) interface 3330. Computer system 3300 also includes a network interface 3340 coupled to I / O interface 3330, as well as one or more input / output devices 3350, such as a cursor control device 3360, a keyboard 3370, and a display 3380. In various embodiments, the system may utilize any means for receiving user input as described above. In various embodiments, a user interface may be generated and displayed on display 3380. In some cases, it is contemplated that embodiments may be implemented using a single instance of computer system 3300, while in other embodiments, multiple such systems or multiple nodes comprising computer system 3300 may be configured to host different portions or instances of various embodiments. For example, in one embodiment, some elements may be implemented via one or more nodes of computer system 3300 that are distinct from the nodes implementing other elements. In another example, multiple nodes may implement computer system 3300 in a distributed manner.

[0328] In different embodiments, computer system 3300 can be any of various types of devices, including but not limited to personal computer systems, desktop computers, laptop computers, notebook or netbook computers, mainframe computer systems, handheld computers, workstations, network computers, application servers, storage devices, peripheral devices such as switches, modems, routers, or generally any type of computing or electronic device.

[0329] In various embodiments, computer system 3300 may be a uniprocessor system including one processor 3310, or a multiprocessor system including several processors 3310 (e.g., two, four, eight, or another suitable number). Processor 3310 may be any suitable processor capable of executing instructions. For example, in various embodiments, processor 3310 may be a general-purpose or embedded processor that implements any of a variety of instruction set architectures (ISAs). In a multiprocessor system, each processor 3310 may, but need not, collectively implement the same ISA.

[0330] System memory 3320 may be configured to store program instructions 3322 and / or data 3324 accessible by processor 3310. In various embodiments, system memory 3320 may be implemented using any suitable memory technology, such as static random access memory (SRAM), synchronous dynamic RAM (SDRAM), non-volatile / flash-type memory, or any other type of memory. In the illustrated embodiment, program instructions and data implementing any of the elements of the above-described embodiments may be stored within system memory 3320. In other embodiments, program instructions and / or data may be received, sent, or stored on different types of computer-accessible media or on similar media separate from system memory 3320 or computer system 1200.

[0331] In one embodiment, I / O interface 3330 can be configured to coordinate I / O traffic between processor 3310, system memory 3320, and any peripheral devices in the device, including network interface 3340 or other peripheral interfaces such as input / output devices 3350. In some embodiments, I / O interface 3330 can perform any necessary protocol, timing, or other data transformations to convert data signals from one component (e.g., system memory 3320) into a format suitable for use by another component (e.g., processor 3310). In some embodiments, I / O interface 3330 can include support for devices attached via various types of peripheral buses, such as variants of the Peripheral Component Interconnect (PCI) bus standard or the Universal Serial Bus (USB) standard. In some embodiments, the functionality of I / O interface 3330 can be split into two or more separate components, such as a northbridge and a southbridge. Furthermore, in some embodiments, some or all of the functionality of I / O interface 3330 (such as the interface to system memory) can be incorporated directly into processor 3310.

[0332] Network interface 3340 can be configured to allow data to be exchanged between computer system 3300 and other devices (such as one or more display devices (not shown)) or one or more external systems attached to a network (e.g., network 3390), or between nodes of computer system 3300. In various embodiments, network 33390 can include one or more networks, including but not limited to a local area network (LAN) (e.g., an Ethernet or enterprise network), a wide area network (WAN) (e.g., the Internet), a wireless data network, some other electronic data network, or some combination thereof. In various embodiments, network interface 3340 can support communication via: a wired or wireless general-purpose data network, such as any suitable type of Ethernet network; a telecommunications / telephone network, such as an analog voice network or a digital fiber-optic communications network; a storage area network, such as a Fibre Channel SAN, or any other suitable type of network and / or protocol.

[0333] In some embodiments, input / output devices 3350 may include one or more communication terminals, keyboards, keypads, touchpads, scanning devices, voice or optical recognition devices, or any other device suitable for entering or accessing data by one or more computer systems 3300. Multiple input / output devices 3350 may be present in computer system 900 or may be distributed across various nodes of computer system 1200. In some embodiments, similar input / output devices may be separate from computer system 1200 and may interact with one or more nodes of computer system 1200 via a wired or wireless connection, such as via network interface 3340.

[0334] Those skilled in the art will recognize that changes or modifications may be made to the above-described embodiments 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, in addition to traveling along tracks, the vehicles may also travel along the ground.

[0335] 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 vehicles can each include one or more contact elements, such as wheels, rollers, guide tabs, pins, or other elements that can engage a guide assembly. The guide assembly can be a linear element, such as a straight rail, or it can be a curved element. The guide assembly can bend in a horizontal plane so that the rail stays in the plane, or the guide can bend vertically so that the rail is in a single plane. The guide assembly can include multiple 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 an elevator for moving the vehicle between the vertically spaced rails.

[0336] As can be seen from the above, the system can be incorporated into various systems that use physical guide mechanisms to guide vehicles along open areas by orienting paths to guide the vehicles to storage locations or transfer locations.

[0337] In various embodiments, the systems and methods described herein may be implemented in software, hardware, or a combination thereof. Furthermore, 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. It will be apparent to those skilled in the art having the benefit of this disclosure that various modifications and variations are possible. Implementations according to the embodiments have been described in the context of specific embodiments. These embodiments are illustrative and not restrictive. Many variations, modifications, additions, and improvements are possible. Therefore, multiple instances may be provided for components described herein as single instances. The boundaries between various components, operations, and data storage devices are somewhat arbitrary, and specific operations are illustrated in the context of specific illustrative configurations. Other allocations of functionality are foreseeable and may fall within the scope of the appended claims. Finally, structures and functions presented as discrete components in the example configurations may be implemented as combined structures or components. These and other variations, modifications, additions, and improvements may fall within the scope of the embodiments as defined in the appended claims.

[0338] It should be understood, therefore, that this 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. An article sorting device comprising: an input station for acquiring information identifying a destination suitable for the items to be sorted; Multiple classification boxes; and a rack defining an aisle and configured to support the plurality of assortment bins at spaced-apart locations along at least a first side or a second side of the aisle, characterized in that a plurality of unloading stations proximate to the aisle; a delivery mechanism operable within the aisle for delivering items to the assortment bins to accumulate groups of items suitable for an order; a retrieval mechanism operable within the aisle and configured to move with the aisle to retrieve respective assortment bins containing sorted articles, transport the respective assortment bins within the aisle to one or more locations adjacent the discharge station, and discharge articles from at least one transported assortment bin into a container displaced from the aisle; and An outfeed conveyor is provided for moving the containers out of the aisle.

2. The device according to claim 1, wherein A first group of assortment bins is supported by the rack along a first side of the aisle, wherein a second group of assortment bins is positioned along a second side of the aisle, and wherein the retrieval mechanism is operable to move the assortment bins into the aisle.

3. The device according to claim 1 or 2, wherein: The retrieval mechanism is movable in a vertical and / or horizontal direction within the aisle.

4. The device according to any one of claims 1 to 3, wherein The delivery mechanism includes a plurality of delivery vehicles capable of operating independently.

5. The device according to claim 4, wherein The delivery vehicle includes a transfer mechanism operable in a first direction to transfer items from the delivery vehicle along a first side of the aisle to one of the assortment bins, and operable in a second direction to transfer items from the delivery vehicle along a second side of the aisle to one of the assortment bins.

6. The device according to claim 4 or 5, wherein: The delivery vehicle is operable to follow a vertical loop within the aisle.

7. The device according to any one of claims 4 to 6, wherein: Each delivery vehicle includes an energy storage device for providing power for operation of the delivery vehicle, and wherein a charging element is disposed within the aisle for charging the delivery vehicle as the delivery vehicle moves within the aisle.

8. Apparatus according to any one of claims 4 to 7, comprising tracks for guiding the delivery vehicle to the sorting bin.

9. The device according to any one of claims 1 to 8, wherein The retrieval mechanism includes a plurality of retrieval carriers.

10. The device according to claim 9, wherein The retrieval carrier includes a transfer mechanism configured to engage the assortment bin.

11. The device according to claim 9 or 10, wherein: Each retrieval vehicle includes an energy storage device for providing power for operation of the retrieval vehicle.

12. Apparatus according to any one of claims 9 to 11, comprising one or more discharge stations configured to receive one of the sorting bins after articles have been sorted into the sorting bins.

13. The device according to claims 1 to 12, wherein The sorting box includes movable walls.

14. The device according to claim 13, wherein The unloading station is configured to facilitate movement of the movable wall when one of the assortment bins is transferred to the unloading station, such that items can be unloaded from the assortment bin.

15. A method for sorting items into groups, comprising: loading a plurality of articles, one at a time, at a loading station onto a delivery mechanism capable of moving within the aisle; Operating the delivery mechanism within the aisle to deliver articles to corresponding assortment bins among a plurality of assortment bins arranged along the aisle, the operation comprising: transporting each loaded item along a vertical loop within the aisle, the vertical loop comprising a loading location and a corresponding destination adjacent to one of the assortment bins, and operating the transfer mechanism of the delivery mechanism to deposit the articles individually into the assortment boxes so as to accumulate groups of articles in the assortment boxes; determining that the group of items assigned to the assortment bin has accumulated in the first assortment bin; and Retrieving the first classification box, wherein the retrieving comprises: moving a retrieval mechanism within the aisle to a position proximate to the first assortment bin; shifting the first assortment bin and the accumulated items into the aisle while retaining the first assortment bin; transporting the first assortment box to a first unloading station within the aisle; unloading the accumulated articles from the first sorting bin into a first container separated from the aisle at the first unloading station; displacing the first container in a direction parallel to the aisle; receiving, at a second unloading station, the accumulated articles from a second sorting bin retrieved by the sorting mechanism into the first container; and The first container is transported away from the second unloading station.

Images