Unloading and sorting system
By using a design of elevated surfaces and suspended barriers on an autonomous carrier device, the forward momentum of the carrier device is used to push items away, solving the platform complexity and weight problems caused by complex mechanical systems in the existing technology, and achieving low-cost, automated item sorting and sorting.
Patent Information
- Application Number
- CN202480013050.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2023-02-18
- Filing Date
- 2024-02-16
- Publication Date
- 2025-09-23
AI Technical Summary
In existing automated item sorting systems, autonomous mobile robots need to be incorporated into complex mechanical item removal systems, which increases the complexity and weight of the platform. In addition, existing technologies fail to effectively sort items of different qualities or characteristics.
The design adopts a raised surface and suspended barrier. The forward momentum of the carrier device is used to push the items away when traveling under the barrier. The items are unloaded and sorted through the sorting outlet. The height and position of the barrier can be adjusted to accommodate different item sizes. Automated sorting is achieved by combining navigation sensors and travel instructions.
It achieves low-cost, automated item sorting, reduces the need for mechanical unloading mechanisms, can effectively sort items according to their height and size, and simplifies system complexity and weight.
Smart Images
Figure CN120693218A_ABST
Abstract
Description
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] This application claims priority to Australian Provisional Patent Application No. 2023900411 filed on February 18, 2023, the disclosure of which is incorporated herein by reference in its entirety. Technical Field
[0003] The present disclosure relates to an unloading and sorting system for articles on one or more carrier devices. Background Art
[0004] In logistics and other industries, there is a need to sort items (e.g., parcels) into groups that share different qualities, characteristics, or a common destination. Examples include, but are not limited to, warehouses, delivery services, and library services. Sorting can be done manually or using automation.
[0005] Current automation technologies typically use robotic arms or autonomous mobile robots, or conveyor-based systems to carry, transport, and deliver items to desired locations. They typically use a mechanical system fixed to a carrier device to lift and transfer the carried objects to their destination.
[0006] An example of an autonomous mobile robot system is a sorting machine, which utilizes a flap or conveyor mounted on an autonomous mobile robot. A problem with known autonomous mobile robot-based object movement, sorting, and unloading technologies is the need for complex mechanical object removal systems, which are often incorporated into the robot itself. These mechanical systems significantly increase the complexity of the platform and the weight of the individual robots. The incorporation of this hardware significantly increases the functionality of the individual robots, thereby increasing the number of tasks each robot can perform.
[0007] It would be desirable to provide a system for unloading and sorting articles transported on autonomous carrier devices having one or more improved features.
[0008] In this specification, unless expressly stated to the contrary, where a document, act or item of knowledge is referred to or discussed, such reference or discussion is not an admission that the document, act or item of knowledge, or any combination thereof, was publicly available, known to the public, part of the common general knowledge, or was known to be relevant to an attempt to solve any problem dealt with in this specification, as at the priority date. Summary of the Invention
[0009] According to one aspect of the present disclosure, there is provided a system for unloading and sorting items transported on an autonomous carrier device, the system comprising:
[0010] a surface on which the carrier device is configured to travel, the surface comprising at least one sorting outlet in the surface, and
[0011] at least one barrier spaced above the surface at a height high enough to allow a carrier device to travel beneath the barrier without being obstructed, and low enough to allow at least one item on the carrier device to be pushed off the carrier device by the barrier as the carrier device travels beneath the barrier,
[0012] Wherein, the at least one sorting outlet is configured to receive the at least one article when the at least one article is pushed away from the carrier device by the barrier.
[0013] The surface may include a plurality of spaced apart sorting outlets, each sorting outlet being positioned adjacent to the barrier.
[0014] The carrier device may have a track width, and the multiple sorting outlets may each include two longitudinal side edges, and the width of each sorting outlet is defined between the two longitudinal side edges, which width may be smaller than the track width of the carrier device, so that the carrier device can cross one of the multiple sorting outlets when approaching the barrier.
[0015] The barrier may be substantially upright and have a flat surface for impact with the article, with one form of the flat surface being arranged substantially perpendicular to the surface.
[0016] Each sorting outlet can be aligned relative to the barrier so that the longitudinal side edge of each sorting outlet is perpendicular to the bottom edge of the plane, and a form of carrier device is configured to: move toward the barrier in general alignment with the longitudinal side edge of one of the sorting outlets so that the items are pushed away from the rear end of the carrier device.
[0017] The surface on which the carrier means travels may be elevated, and each sorting outlet may comprise a ramp formed between longitudinal side edges of the sorting outlet, the ramp descending below the surface for transporting articles pushed off the carrier means.
[0018] The barrier may be at a height above the surface to enable one or more articles to remain on the carrier means and pass under the barrier means, and to enable one or more articles to be struck by the barrier depending on the height of the articles.
[0019] In one form, the system may include a plurality of barriers, each barrier being associated with a corresponding one or more of the plurality of sorting outlets, at least two of the barriers being of different heights from one another, thereby enabling items of a certain height to remain on the carrier device and pass under one barrier device, and enabling items of a certain height to be impacted and pushed off the carrier device by another barrier device, thereby enabling items to be assigned to specific sorting outlets based on their height.
[0020] The barriers may be mounted on one or more upright support members and configured to interlock with adjacent barriers.
[0021] The surface may be arranged substantially horizontally relative to a ground surface and comprise one or more modular surface elements connected together to form the surface.
[0022] In another aspect of the present disclosure, there is provided a system for unloading and sorting items, the system comprising:
[0023] at least one autonomous carrier device for transporting one or more items,
[0024] an elevated surface on which the carrier device is configured to travel, the elevated surface including at least one sorting outlet in the elevated surface, and
[0025] at least one barrier spaced above the elevated surface at a height high enough to allow a carrier device to travel beneath the barrier without being obstructed and low enough to allow at least one item on the carrier device to be pushed off the carrier device by the barrier as the carrier device travels beneath the barrier,
[0026] Wherein, the at least one sorting outlet is configured to receive the at least one article when the at least one article is pushed away from the carrier device by the barrier.
[0027] The system may include a plurality of said autonomous carrier devices for transporting items, a plurality of said barriers and a plurality of said sorting outlets, each barrier being associated with a corresponding sorting outlet, each barrier being located at a different said height relative to the elevated surface, each autonomous carrier device being configured to travel to a designated sorting outlet and associated barrier deemed suitable for one or more items being carried, the designated sorting outlet and associated barrier for the carried items being determined based on information about each carried item scanned by a scanning device of the system.
[0028] In another aspect of the present disclosure, there is provided a method of unloading and sorting items, the method comprising:
[0029] a mobile carrier device configured for transporting one or more items along an elevated surface, the elevated surface including at least one sorting outlet in the elevated surface, and
[0030] moving the carrier device toward a barrier spaced at a height above the elevated surface; and
[0031] The carrier device is moved under the barrier so that when the carrier device moves under the barrier, at least one of the one or more articles hits the barrier and is pushed away from the carrier device by the barrier, and at least one of the one or more articles is received by at least one sorting outlet.
[0032] The elevated surface may include a plurality of navigation lines for navigating the carrier device, and the carrier device may include at least one sensor configured to locate the navigation lines and a processor configured to wirelessly receive navigation instructions and move the tool.
[0033] The method may further include loading one or more articles onto the upper surface of the carrier device.
[0034] The method may further include providing travel instructions to a processor of the carrier device, the travel instructions including toward which sorting outlet the carrier device should move in order to unload one or more items disposed on an upper surface of the carrier device.
[0035] The step of moving the carrier device toward the barrier may include: at least one sensor locating a navigation route of a plurality of navigation routes included in the travel instructions; and the carrier device following the navigation route toward the barrier.
[0036] The system and method described are a significant improvement over known arrangements in that the means for unloading the articles are not incorporated into the carrier means, but rather the system utilizes the forward momentum of the means to remove the articles. This is achieved by traveling under a suspended barrier located at the end of an opening in the elevated surface on which the carrier means travels. BRIEF DESCRIPTION OF THE DRAWINGS
[0037] Various embodiments / aspects of the present invention will now be described with reference to the following drawings.
[0038] Figure 1A is a perspective view of a system according to one embodiment of the present disclosure showing a plurality of carrier devices on an elevated surface during various stages of unloading articles to a sorting outlet;
[0039] Figure 1B yes Figure 1A A detailed perspective view of a portion of the system shown in , showing a carrier device passing over a sorting outlet as it approaches a barrier;
[0040] Figure 2 yes Figure 1B a rear end view of a carrier unit shown on the upper right side of FIG, passing over a sorting outlet as it approaches a barrier, the barrier being positioned at a height to allow the carrier unit to travel beneath the barrier while articles are held in position for transport prior to impact with the barrier and subsequent discharge to the sorting outlet below;
[0041] Figure 3 yes Figure 1B a detailed perspective view of the sorting outlet on the left side of the center showing the almost complete removal of the articles from the carrier device after impact with the barrier, the articles being partially on the slope of the sorting outlet in the elevated surface;
[0042] Figure 4 yes Figure 1A Detailed perspective portion of the system shown in , showing items on the ramp of the sorting outlet after passing through the opening in the raised surface;
[0043] Figures 5A to 5F is a schematic diagram of the operational steps taken by a single carrier unit using three lines to navigate to a sorting outlet, and
[0044] Figures 6A to 6F is a schematic diagram of the operational steps taken by a carrier device to travel to a sorting outlet when multiple carrier devices are present. DETAILED DESCRIPTION
[0045] Reference Figures 1A to 4 , discloses a system 1 for unloading and sorting articles 3 (e.g., packages) transported on one or more autonomous carrier devices 5 (e.g., robots). The system 1 comprises a surface, which may be in the form of an elevated table or platform, with each carrier device 5 configured to travel over the surface to place the carried one or more articles 3 to a designated sorting outlet 9 provided in the surface. The surface may be horizontally oriented and comprise one or more modular surface elements 7 connected together to form the surface. The overall layout of the tabletop need not be specifically as Figure 1A As shown in , other table layouts can be used to achieve the same effect. The system 1 also includes one or more fixed barriers 11 positioned at a height above the surface such that there is a gap between the surface and each barrier 11 sufficient to allow at least some of the carrier devices 5 to pass through without being struck by the barrier. The height of each barrier 11 is also low enough so that when a carrier device 5 passes under the barrier 11, at least one article 3 disposed on the planar loading surface 13 of the carrier device 5 is struck by the barrier 11 and is pushed away from the carrier device 5, as shown in FIG. Figure 2 . Each barrier 11 is substantially upright and has a flat surface oriented perpendicular to the surface 7 for impact with the articles 3. In another embodiment, the carrier device 5 may include one or more containers in which the articles can be placed. The containers may be attached in place and displaced when impacted by the barriers 11. For example, the containers may snap into place on the carrier device 5 and be removed by impact in only one direction. The containers, rather than the articles themselves, then fall into the sorting outlet 9.
[0046] Each sorting outlet 9 comprises an opening or hole in the surface 7, preferably positioned directly in front of the corresponding barrier 11. The opening can be, for example, rectangular in shape and generally aligned relative to the barrier 11 such that the longitudinal side edges of the opening are perpendicular to the bottom edge 21 of the barrier 11. In another embodiment, the opening can be on either side of the barrier 11, with the barrier 11 angled in such a way as to push the articles 3 to the side rather than the back of the carrier device 5. Each sorting outlet can also include a ramp 15 descending below the surface, along which articles 3 pushed off the carrier device 5 can slide to a designated storage area. In another embodiment, the ramp 15 can be replaced by a conveyor belt that is stationary while the carrier device 5 moves over it and under the barrier, and then moves once the carrier device 5 passes.
[0047] like Figure 1B and Figure 2 As best shown in , the track width of each carrier device 5 is preferably greater than the width of the sorting outlet 9, so that each carrier device 5 can cross the sorting outlet 9 when approaching the barrier 11 without falling or getting stuck on the sorting outlet 9. In this regard, in one embodiment, each carrier device 5 can have at least one wheel on either side of the carrier device 5 to cross the sorting outlet 9 when approaching the barrier 11. In another embodiment, the wheels of the carrier device 5 can travel along a rail track set on a surface. In yet another embodiment, the carrier device 5 can be suspended from an overhead rail system. Each carrier device 5 preferably travels toward the barrier 11 in general alignment with the longitudinal side edge of the sorting outlet 9, as shown in FIG. Figure 1A , so that when the carrier device 5 passes under the barrier 11, the articles 3 are pushed and thereby unloaded from the back of the carrier device 5. The unloaded articles can then slide down the ramp 15 and onto the sorting trough 19, where the articles 3 can be accumulated at the end of the trough 19, as shown in FIG. Figure 1A In another embodiment, the barrier 11 may have motorized wheels to push the items on the carrier device 5 to the left or right instead of hitting the items 3 with direct contact.
[0048] Multiple carrier devices 5, barriers 11, and sorting outlets 9 can be provided. In this regard, multiple barriers 11 can be arranged in a row and interlocked with adjacent barriers via upright support members. In another embodiment, the barriers 11 can be separate and arranged one after another with each associated sorting outlet 9. The system 1 can also be fully modular and include carrier devices 5 in multiple sizes, with customizable elevated surface configurations to accommodate different item types. Each barrier 11 can be positioned at a different height above the surface to accommodate different item sizes and / or carrier devices. For example, the barriers 11 can be suspended at a level to allow smaller objects to pass underneath while blocking larger objects. More specifically, the carrier device 5 can, for example, be positioned adjacent to a first barrier 11 positioned at a height that provides a 100 mm clearance between the barrier 11 and the surface. The device 5 can, for example, carry a first item 3 50 mm in height and a second item 3 200 mm in height. The second item 3 will be blocked by the first barrier 11 and fall into the associated first sorting outlet 9, while the first item 3 will remain on the carrier device 5. Then, the first object 3, which is 50 mm in height, can be blocked by a second barrier positioned behind the first barrier 11. The second barrier 11 is positioned, for example, at a height that provides a clearance of only 30 mm between the second barrier 11 and the surface. The first object 3 thus strikes the second barrier 11 and is pushed away from the carrier device 5 and into the second sorting outlet 9 associated with the second barrier 11. This process allows larger objects to be easily separated from smaller objects, which facilitates the determination of which transport method to use. For example, the larger objects collected from the first sorting outlet 9 can then be transported on pallets, as their larger size justifies the expense of stacking the objects on pallets, while the smaller objects collected from the second outlet 9 can be efficiently transported in bags.
[0049] The sorting process begins by placing one or more items 3 (e.g., packages) directly onto the carrier device 5 at the sensing point. In one embodiment, the carrier device 5 can then advance to a scanning position where an overhead scanner 17 can capture a barcode on the item. In another embodiment, an image can be captured and the dimensions of the item calculated. Once scanned, a web application can be used to match the barcode with a sorting point (otherwise referred to as a sorting outlet 9) and transmit travel instructions to the carrier device 5. The carrier device 5 then advances to the sorting outlet. In a detailed embodiment, the carrier device 5 does not stop while moving, and preferably uses a line tracking sensor in front of the carrier device 5 to maintain the route of the carrier device 5. The carrier device 5 is able to identify and navigate the path required to reach the designated sorting outlet while avoiding other carrier devices 5 on the same platform. In one embodiment, navigation is based on a navigation line set on the surface being traversed. In other embodiments, navigation can be based on a camera or radio waves. The carrier device 5 will travel over an opening set in the elevated surface at the designated sorting outlet 9. If the carrier device 5 is as Figures 1A to 4 , the wheels are provided on either side of the opening so as to enable the sorting outlet 9 to be passed. The carrier device 5 then passes under an associated barrier 11 suspended above the surface. As the carrier device 5 passes under the barrier 11, the onboard items 3 slide gently off the back of the carrier device 5 and onto the ramp 15 which leads to the sorting chute 19. Then, as Figure 1A As shown in FIG, the articles 3 can be accumulated at the end of the slot 19. The carrier device 5 then navigates back to the return position to be ready for the next article.
[0050] Figures 5A to 5F This is a schematic diagram of the operating steps for navigating a single carrier unit to a sorting exit / point using a line for navigation. Figure 5A In , the carrier device X is initially in the "return" state. When the right sensor of the carrier device X senses the right navigation line, the carrier device X will change to the "ready item" state. Then, one or more items will be loaded onto the carrier device X. Once the designated sorting exit is determined, the carrier device X is provided with the required travel instructions, and the carrier device X will change to the "outbound" state and follow the left navigation line. Figure 5B In the process, the carrier device X will continue to move forward until the intermediate sensor detects the line, then the variable sort point value passed will be increased by 1 and will be compared with the required sort point value. If the sort point passed is less than the required sort point value, the carrier device X will continue, as shown in the following example: Figure 5C As shown in . Once the sorting point passed is equal to the required sorting point, the carrier device X will change to the "through" state, as shown in Figure 5DAs shown in , and then starts to travel along the right navigation line. When the left sensor of the carrier device X detects the left navigation line, as shown in Figure 5E As shown in FIG, the carrier device X will be transformed into the "sorting" state and start to travel along the left line sensor. After unloading at the second sorting outlet, the carrier device X continues to Figure 5F , where the right sensor detects the right navigation line.
[0051] Figures 6A to 6F is a schematic diagram of the operational steps taken by a carrier device when navigating to a sorting exit when there are multiple carrier devices. Figure 6A In the figure, carrier device A is moving towards sorting point 3. Figure 6B When carrier device A in the network starts to pass through the sort point before its destination, namely sort point 2, it starts to warn all other carrier devices on the network that carrier device A will pass through sort point 3. It does this by increasing the "flow" count at sort point 3. Figure 6B , it is shown that the carrier device B has unloaded the items of the carrier device B at a sorting point other than the sorting point 4 on its return journey. Figure 6C In , carrier device B has reached sorting point 4 on its return trip. Carrier device B knows that there is traffic at sorting point 3, so carrier device B stops and waits. Only when the "traffic" count at sorting point 3 is zero, carrier device B can pass freely. Figure 6D and Figure 6E In , carrier device C traverses to sorting point 2, and carrier device A traverses to sorting point 3, while carrier device B remains waiting until it receives a full clearance or a predetermined length of time has passed. Figure 6F In Figure 2, when carrier device A recognizes on its return trip that it is passing sort point 2, it signals to all other carrier devices that there is a smaller "flow" volume at sort point 3. Carrier device B receives the new "flow" volume for sort point 3, which is zero. This allows carrier device B to continue. Both carrier devices return safely with minimal disruption to outbound traffic.
[0052] The disclosed system advantageously enables a carrier device to use its forward momentum to unload items such as parcels, thereby eliminating the need for a mechanical unloading mechanism. The system advantageously provides a low-cost automated sorting solution.
[0053] The word "comprise" and forms of the word "comprising" as used in this description and in the claims do not limit the claimed invention to exclude any modifications or additions.
[0054] Modifications and improvements to the present invention will be readily apparent to those skilled in the art and are intended to be within the scope of the present invention.
Claims
1. A system for unloading and sorting articles transported on an autonomous carrier device, the system comprising: a surface on which the carrier device is configured to travel, the surface comprising at least one sorting outlet in the surface, and at least one barrier spaced above the surface at a height high enough to allow the carrier device to travel beneath the barrier without being obstructed, and low enough to allow at least one item on the carrier device to be pushed off the carrier device by the barrier as the carrier device travels beneath the barrier, Wherein, the at least one sorting outlet is configured to receive the at least one article when the at least one article is pushed away from the carrier device by the barrier.
2. The system according to claim 1, wherein: The surface includes a plurality of spaced-apart sorting outlets, each sorting outlet being positioned adjacent to the barrier.
3. The system according to claim 2, wherein: The carrier device has a track width, and the multiple sorting outlets each include two longitudinal side edges, which define a width of each sorting outlet between the two longitudinal side edges, which is smaller than the track width of the carrier device, so that the carrier device can cross one of the multiple sorting outlets when approaching the barrier.
4. The system according to claim 3, wherein: The barrier is substantially upright and has a planar surface for impact with the article, the planar surface being disposed substantially perpendicular to the surface.
5. The system according to claim 4, wherein: Each sorting outlet is aligned relative to the barrier so that a longitudinal side edge of each sorting outlet is perpendicular to a bottom edge of the plane, and the carrier device is configured to move toward the barrier substantially aligned with a longitudinal side edge of one of the plurality of sorting outlets so that the articles are pushed away from a rear end of the carrier device.
6. The system according to any one of claims 4 to 5, wherein: The surface on which the carrier means travel is elevated, and each sorting outlet comprises a ramp provided between longitudinal side edges of the sorting outlet, the ramp descending below the surface for transporting articles pushed off the carrier means.
7. A system according to any one of the preceding claims, wherein: The barrier is at a height above the surface to enable one or more articles to remain on the carrier means and pass under the barrier means, and to enable one or more articles to be struck by the barrier.
8. The system according to any one of claims 2 to 7, wherein: The system includes a plurality of barriers, each barrier being associated with a corresponding one or more sorting outlets among the plurality of sorting outlets, at least two of the barriers having heights different from each other, such that articles of a certain height can remain on the carrier device and pass under one barrier device, and articles of a certain height can be hit by another barrier and pushed away from the carrier device, such that articles can be allocated to specific sorting outlets based on their heights.
9. The system according to claim 8, wherein: The barriers are mounted on one or more upright support members and are configured to interlock with adjacent barriers.
10. The system according to claim 8, wherein: The barriers are arranged one after the other with each associated sorting outlet.
11. A system according to any one of the preceding claims, wherein: The surface is arranged substantially horizontally relative to a ground surface and comprises one or more modular surface elements connected together to form the surface.
12. A system for unloading and sorting items, the system comprising: at least one autonomous carrier device for transporting one or more items, an elevated surface on which the carrier device is configured to travel, the elevated surface comprising at least one sorting outlet in the elevated surface, and at least one barrier spaced above the elevated surface at a height sufficient to allow the carrier device to travel beneath the barrier without being obstructed and sufficiently low to allow at least one item on the carrier device to be pushed off the carrier device by the barrier as the carrier device travels beneath the barrier, Wherein, the at least one sorting outlet is configured to receive the at least one article when the at least one article is pushed away from the carrier device by the barrier.
13. The system according to claim 12, wherein: The system includes a plurality of the autonomous carrier devices for transporting items, a plurality of the barriers and a plurality of the sorting outlets, each barrier being associated with a corresponding sorting outlet, each barrier being located at a different height relative to the elevated surface, each autonomous carrier device being configured to: travel to a designated sorting outlet and associated barrier deemed suitable for one or more items to be carried, the designated sorting outlet and associated barrier for the carried items being determined based on information about each carried item scanned by a scanning device of the system.
14. A method of unloading and sorting items, the method comprising: a mobile carrier device configured for transporting one or more items along an elevated surface, the elevated surface including at least one sorting outlet in the elevated surface, and moving the carrier device toward a barrier spaced at a height above the elevated surface; as well as The carrier device is moved under the barrier so that when the carrier device moves under the barrier, at least one of the one or more items hits the barrier and is pushed away from the carrier device by the barrier, and the at least one of the one or more items is received by at least one sorting outlet.
15. The method according to claim 14, wherein The elevated surface includes a plurality of navigation lines for navigating the carrier device, and the carrier device includes at least one sensor configured to locate the navigation lines and a processor configured to wirelessly receive navigation instructions and move the tool.
16. The method according to claim 15, further comprising: One or more articles are loaded onto the upper surface of the carrier device.
17. The method according to claim 16, further comprising: Travel instructions are provided to a processor of the carrier device, the travel instructions including which sorting outlet the carrier device should move toward in order to unload one or more articles disposed on an upper surface of the carrier device.
18. The method according to claim 17, wherein: Moving the carrier device toward the barrier includes: locating, by the at least one sensor, one of a plurality of guide routes included in the travel instructions; and moving the carrier device along the guide route toward the barrier.