Object handling system and method including co-located bin feed and discharge

Abstract

An object handling system is disclosed, the object handling system comprising: a feed handling system comprising a source bin feed conveyor for providing a source bin; a distribution system for receiving the source bin and for receiving a plurality of empty bins and for providing objects from the source bin to a series of processing locations, each processing location including an empty bin of the plurality of empty bins, thereby providing a previous empty bin as a processed bin upon completion; and a discharge processing system for removing processed bins from the series of processing positions, where the empty bins and the processed bins are each located on a common discharge conveyor at a point on their respective output paths.

Description

[0001] priority

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 529,419, filed July 28, 2023, the disclosure of which is hereby incorporated by reference in its entirety. Background Technology

[0003] The present invention generally relates to automated programmable motion control systems, such as robots, sorting and other processing systems, and more particularly to programmable motion control systems intended for use in environments containing various objects (e.g., articles, packages, parcels, etc.) that need to be processed and moved to multiple processing destinations.

[0004] For example, in store replenishment applications, various replenishment models exist. In a push model, SKU boxes from the original manufacturer arrive and need to be broken down into multiple stores for immediate distribution (hence sometimes called unpacking). In a pull model, items in stores are already ordered, and buyers want to maintain a minimum required level of stock on shelves, so they retrieve inventory from, for example, an automated storage and retrieval system (AS / RS) and allocate the given SKUs to the stores that need them. Distribution centers (DCs) sometimes use a hybrid push and pull model.

[0005] Traditional approaches to this problem include manual systems, automated systems, or a combination of both. Typically, this work is done manually, with workers manually sorting items from boxes into multiple shipping cartons corresponding to each store. The manual method is labor-intensive. Automated methods include various available unit sorting machines, such as cross-belt, tilt-pallet, and bomb-cart unit sorters. However, unit sorting machines have some inherent problems, including introducing single points of failure into the facility and still requiring manual maintenance at outbound destinations. Such systems may require a large number of collection boxes (and therefore significant physical space, investment costs, and operating costs). Furthermore, such unpacking systems must monitor the volume of each similar item within the box, necessitating constant counting by human staff.

[0006] Furthermore, even the most advanced processing systems currently available rely to some extent on manual labor. This solution depends on workers who perform sorting by scanning each object from the supply area (chutes, workbenches, etc.) and placing each object in a temporary storage location, conveyor, or collection bin. More importantly, each destination requires manual service. When a bin is full, another worker emptys it into a bag, box, or other container and sends it to the next processing step. Such systems have limited throughput.

[0007] Therefore, a more efficient and cost-effective object processing system is still needed to overcome the following limitations: 1) the existence of a single point of failure; 2) the manual labor required to maintain the destination; and 3) the inability to import multiple objects into the object carrier because the carrier is in motion. Summary of the Invention

[0008] According to one aspect, the present invention provides an object processing system comprising: a feeding system including a source box feeding conveyor for providing source boxes; a distribution system for receiving the source boxes and for receiving a plurality of empty boxes and for providing objects from the source boxes to a series of processing locations, each processing location including an empty box from the plurality of empty boxes, thereby providing previously empty boxes as processed boxes upon completion; and an unloading system for removing processed boxes from the series of processing locations, wherein the empty boxes and the processed boxes are each located at a point on their respective output paths on a common unloading conveyor.

[0009] According to another aspect, the present invention provides an object processing system comprising: a distribution system for receiving a plurality of source boxes and a plurality of empty boxes and for providing objects from the source boxes to a plurality of processing locations, each of the plurality of processing locations including an empty box from the plurality of empty boxes, thereby providing the previously empty box as a processed box upon completion, wherein the plurality of processing locations are provided as at least two sets of processing locations located on both sides of the distribution system; and a discharge processing system for removing the processed box from the plurality of processing locations, wherein the empty box and the processed box are each located at a point on their respective output paths on a common discharge conveyor.

[0010] According to another aspect, the present invention provides a method for processing objects, the method comprising: receiving a plurality of source boxes at a distribution system; receiving a plurality of empty boxes at the distribution system; providing objects from the source boxes to a series of processing locations, each processing location including an empty box from the plurality of empty boxes, thereby providing the previously empty box as a processed box upon completion; and removing the processed box from the series of processing locations, wherein the empty box and the processed box are each located at a point on their respective output paths on a common discharge conveyor. Attached Figure Description

[0011] The following description can be further understood with reference to the accompanying drawings, in which: Figure 1 An illustrative diagram view of an object processing system according to one aspect of the present invention is shown; Figure 2 It shows Figure 1An illustrative diagram of the allocation system for the object processing system; Figure 3A and Figure 3B It shows Figure 2 A schematic enlarged view of the distribution conveyor of the distribution system, showing objects being loaded onto the distribution conveyor. Figure 3A And unloaded from the vehicle to the destination location. Figure 3B ); Figure 4A and Figure 4B An illustrative diagram showing an empty container being loaded, and the empty container approaching the splitter (…). Figure 4A And it is diverted to the conveyor ( Figure 4B ); Figure 5A and Figure 5B The processed container is shown being removed from the processing location. Figure 5A ) and move to the processed box temporary storage conveyor ( Figure 5B Illustrative diagram view; Figure 6A and Figure 6B An illustrative schematic view of a box assembly, including a case, a tray, and a lid, is shown. Figure 6A The components are shown in an exploded view. Figure 6B ); Figure 7 An illustrative functional diagram of a tote and bag fullness analysis procedure used in an object processing system according to one aspect of the invention is shown. Figure 8A and Figure 8B The processed containers are shown being unloaded onto a shared discharge conveyor. Figure 8A ) and then unloaded onto the pre-processed box conveyor. Figure 8B Illustrative diagram view; Figure 9 It shows Figure 1 An illustrative diagram of how the splitter of the object processing system splits empty and processed containers; Figure 10 An illustrative schematic view of a portion of an object processing system according to another aspect of the invention is shown, wherein an empty carton feed conveyor is located outside a processed carton feed conveyor; Figure 11 An illustrative diagrammatic view of an object processing system including a programmable motion device according to another aspect of the present invention is shown; Figure 12 An illustrative schematic view of an object processing system including a shared discharge conveyor, according to another aspect of the invention, is shown. Figures 13A to 13D It shows Figure 12 An illustrative plan view of the shared discharge conveyor, showing two empty boxes being introduced ( Figure 13A This shows an empty container being selected and transferred to a processing conveyor. Figure 13B The diagram shows the second empty container being selected and transferred to another processing conveyor. Figure 13C ), and shows the processed boxes being moved onto a common discharge conveyor ( Figure 13D ); Figure 14 An illustrative plan view of an object processing system according to another aspect of the invention is shown, the object processing system including a conveyor feeding and dispensing system; Figure 15 An illustrative plan view of an object processing system including a stacked processing conveyor and a discharge conveyor, according to another aspect of the invention, is shown. Figure 16 An illustrative plan view of an object processing system according to another aspect of the invention is shown, the object processing system comprising a plurality of processing stations located on opposite sides of a discharge conveyor; and Figures 17A to 17B An illustrative diagrammatic view of the process flow steps in an object processing system according to one aspect of the present invention is shown.

[0012] The accompanying drawings are shown for illustrative purposes only. Detailed Implementation

[0013] According to various aspects, the system of the present invention provides object handling using a shared discharge conveyor, which is at least partially used for moving empty and processed containers. The system arrangement (rear unloading) includes a shared feed and take-out conveyor located at the rear of the system. Therefore, the front of the system remains open, without restricting personnel access across the conveyors for system operation and maintenance, thus avoiding potential safety hazards. Such a system does not include any front conveyors and therefore allows direct access to and from the system via the now-open front. For example, when the outflow of containers exceeds the capacity of a single mixed take-out line, a dedicated feed and take-out line can be located at the rear of the station.

[0014] Systems and processes according to various aspects of the invention utilize containers (boxes) re-entering the lines they are transported on. A control system manages the box status and determines when to control the boxes' entry / exit from a shared conveyor. The system also optimizes the timing of these entry and exit operations and monitors the overall system status to optimize queuing, thereby minimizing the impact of output peaks, decelerations, machine downtime, machine service, and other anomalies. Such processes enhance the overall system robustness through real-time management (cooperative scheduling) of decision points. The decision-making process self-adjusts and optimizes based on previously learned datasets and monitors the boxes as they move down the shared feed / remove conveyor to avoid scanning and identifying materials during intermediate processing (and before further decisions). Sensors can be used (as discussed herein) for error-proofing, box identification / acknowledgment, and error detection.

[0015] For example, Figure 1 An object processing system 10 is shown, which includes a feeding system 12 and a distribution system 14. The distribution system may include personnel workstations (such as...). Figure 1 (as shown) or programmable motion device workstation (such as Figure 11 (As shown). The feeding system 12 includes a source box feed conveyor 16 that feeds multiple stations (discussed below); and a station feed conveyor 18 connected to the distribution system 14. The object processing system 10 also includes an empty box feed conveyor 20 for providing empty boxes 22 to multiple series of processing positions 24, which are gravity-biased (or actively powered) to move their boxes away from the feeding system 12. The distribution system 14 includes one or more distribution conveyors 26, each leading to a reciprocating carrier 28, and each carrier can supply objects therein to any of a plurality of empty boxes at a processing position, so that the empty box becomes a processed box 30 when processing for each box is completed. Each processed box 30 is then transferred to a processed box storage conveyor 32 until it is ready to be moved to the processed box feed conveyor 34 via the empty box feed conveyor 20. Figure 1 In this system, the empty carton feed conveyor 20 becomes a shared discharge conveyor 50 on the unloading side of the distribution system 14, through which both empty and processed cartons are transported at some point in time. Alternatively, the empty carton feed conveyor may be located outside the processed carton feed conveyor, which is the shared discharge conveyor (see below for reference). Figure 10 (As discussed below). Alternatively, both empty and processed containers can be transported by a single conveyor, as referenced below. Figure 12 The discussion.

[0016] Figure 2 An enlarged view of the distribution system 14 is shown, which includes a source bin feed conveyor 16 and a station feed conveyor 18. When diverted from the source bin feed conveyor 16 by a diverter 38 (shown at the diversion location), the distribution system 14 can access objects to be processed in the source bin 36 via the source bin feed conveyor 16 and the station feed conveyor. The diverter 38 pivots to allow the source bins 36 to bypass the station feed conveyor, including those returning from the station feed conveyor 18 to the source bin feed conveyor 16. The distribution system is operated by personnel (such as...) Figure 2 (as shown) or programmable motion devices (such as Figure 11 It can be composed of any of the following (as shown), and can be used to move an object (e.g., object 44) from the source box 36 to the distribution conveyor 26, such as Figure 3A and Figure 3B As further shown. Figure 3A and Figure 3B It shows Figure 2 An alternative perspective of the magnified view of the distribution system 14 shown. (e.g.) Figure 3A As shown, a source box 36 is located on the feed conveyor 18, and objects (such as object 44) in the source box 36 are placed on the distribution conveyor 26. The distribution conveyor 26 leads to a reciprocating carrier 28 traveling along track 40. Figure 3B It shows Figure 3A A reciprocating carrier 28 moves and places an object 44 into one of a plurality of processing positions 24. The carrier 28 can place an object into either processing position 24 by tilting in one of two tilting directions. The carrier 28 then returns to the starting position 42, where it can receive another object from the distribution conveyor 26. A processed box storage conveyor 32 receives and temporarily stores processed boxes 30, as will be described in more detail below. The operation of all conveyors, sensing systems, and processing devices in each of the systems disclosed herein can be controlled by one or more computer processing systems (e.g., Figure 1 The 100 and / or shown Figure 11 The 200 shown is executed.

[0017] refer to Figure 4A and Figure 4B A total of 50 discharge conveyors are used. Figure 1 The system (provided by the empty carton feed conveyor 20) includes bidirectional diverters (e.g., 52, 54, 56, 58) that can selectively move cartons in a direction transverse to the direction of movement of the conveyor (e.g., by staggered belt sets between rollers on a liftable support, as shown). For example, diverters 54 and 56 selectively divert empty cartons to either conveyor 60 or 62, thereby providing a new carton at each processing position 24 (as discussed above). Figure 4A The empty box 22 is shown approaching the splitter 56, and Figure 4B This shows that box 22 has been diverted to conveyor 62. Figure 4A A bidirectional diverter 56 is shown, wherein the diverter belt is not raised (allowing movement along conveyor 50), and Figure 4B This illustrates the splitter belt being raised above the adjacent rollers. Similarly, splitter 54 can be engaged to split empty containers (e.g., Figure 4B The box 23 shown is diverted to the conveyor 60.

[0018] As discussed above, objects are assigned and boxes are processed at the processing location, and when each individual box being processed becomes full, the box is moved to the processed box temporary storage conveyor 32. Figure 5A and Figure 5B The processed box 31 is shown being joined, for example. Figure 5A Then unload from processing position 24. Figure 5B Specifically, Figure 5A The diagram shows the engagement of the processed container 31 (whether fully loaded or already processed) with the container unloading mechanism 64 attached to the carrier 28 (as shown). Figure 4A and Figure 4B (As shown). The box unloading mechanism 64 includes a pivot arm 66 with a roller engaging wheel 68, which engages the box 31 (as shown). Figure 5A And then push it away from processing position 24, over one or more rollers 69 onto processed box temporary storage conveyor 32. Figure 5B The processed temporary storage conveyor 24 can temporarily store each processed box until the time is right to transfer the box to the common discharge conveyor 50 (i.e., when the common discharge conveyor located before the intersection is idle).

[0019] Each of the boxes (e.g., 22) can be placed on the pallet 21 as a transport box 23, as... Figures 6A to 6B As shown. A case cover 25 may also be provided, which includes a pair of full photodetectors 27 and a pair of overfull detectors 29. For example, the detector pair may be an LED emitter-detector pair mounted on the case cover 25. In some applications, using detectors 27, 29 may be sufficient to determine whether a case is full, but the applicant has found that further analysis may be necessary in other applications.

[0020] The system directly addresses the problems raised by the applicant, including: 1) reducing walking; 2) reducing waiting time; 3) reducing mental fatigue; and 4) reducing manual manipulation of sorting destinations and handling of outgoing cartons or bags. These main objectives are achieved by integrating the sorter's outgoing paths and transporting the output to a central bagging / boxing location, thereby reducing walking. Because the integrated output can be buffered and a queuing mechanism is introduced, peak and trough outputs can be evenly distributed to manual finishing stages, reducing waiting time during troughs and avoiding congestion during peak periods. Many centralized processing (bagging / boxing) stations are required compared to the sorter's destinations. Therefore, centralized locations can be optimized through robotics and ergonomics. Furthermore, once an automated retrieval system for the sorter's outgoing destinations is implemented, many secondary optimizations are possible. Destinations can be dynamically assigned to sorter output chutes. Dynamically assigning chutes to destinations allows some popular destinations to receive more chutes, balances the output load, and prevents sorter recirculation.

[0021] The manpower required to process outputs (bagging or boxing) is roughly proportional to the number of bags / boxes used, up to the ergonomic limit. Generally, the fewer bags / boxes processed, the less manpower is required. Typically, system operators should fill bags / boxes as full as possible without exceeding ergonomic limits. Following this logic, the largest possible bag / box generally achieves the lowest operating cost without causing ergonomic problems. Incomplete bags / boxes lead to air spillage at the sorting station, increasing costs. Therefore, once the bins below the sorter are considered full, bagging / boxing processes that ensure the bag / box size precisely fills the bin's contents are the most economical option. The proposed system can monitor the actual contents of the outgoing containers and suggest manual or robotic bagging / boxing operations to select the appropriate outgoing bag / box size. The proposed system can monitor the actual contents of the output containers and suggest which is the correct outgoing bag / box size for manual or robotic bagging / boxing operations. If automated pick-up and bag / box sorting machines are used to sort sealed packages traveling from A to B, then further optimizations can be applied. The output of package sorting machines used in logistics operations must typically meet truck or air travel times. Automated pick-up systems can automatically unload from the sorting machine to its destination to meet those truck or air travel times.

[0022] For example, Figure 7A functional diagram of a bin and bag fullness analysis system 1000 used according to one aspect of the invention (e.g., in any of the object processing systems discussed herein) is shown. The analysis system 1000 determines when bins are full enough to be exchanged for empty bins and includes software and a control system 1002 (e.g., which may reside in one or more computer processing systems 100, 200). The system 1000 receives input parameters as shown at 1004 and provides a completion determination as shown at 1006 based on various reasons discussed below. The input parameters include: package delivery information as shown at 1008, package attribute information as shown at 1010, destination information as shown at 10212, human-machine interface information as shown at 1014, button information as shown at 1016, and full and overfill detection information as shown at 1018.

[0023] Package (object) delivery information (e.g., provided via an Application Programming Interface (API)) includes the package ID, chute ID, and delivery time, as shown at 1008. Package attribute information (e.g., provided via the API) includes package volume, package weight, package dimensions, and other attributes, as shown at 1010. Destination information (e.g., provided via the API) includes the chute ID (city), allowed total weight, allowed total volume, allowed bag types, and scheduled departure time (e.g., flight time), as shown at 1012. The human-machine interface can provide additional observable information about the package, as shown at 1014, and button information can include pre-programmed selection information that can be entered very quickly, as shown at 1016. Full and overfill detection information, as shown at 1018, can be referenced above. Figure 6A and Figure 6B The detector provides for one or more sensor systems discussed in 27 and 29.

[0024] The software and control system 1002 receives the aforementioned input information and processes the data to control the shuttle, monitor the cumulative total weight, monitor the cumulative total volume, monitor any changes in the schedule and / or priority, and monitor full and overfill detection information. The control system 1002 also communicates with the cartoning and bagging station managers and the workload manager. For example, the system may not rely solely on one or two information points 1020 (e.g., full or overfill sensor signals), but may consider the total weight or total volume. At 1006, a bin full / exchange assessment is performed. If the total weight and / or total volume is too low, the system will not consider the bin complete. On the other hand, if a scheduled departure time (e.g., a flight) or an upcoming departure time is approaching, the system may consider the bin complete even if other data indicates otherwise. Furthermore, the system can immediately recognize a bin as complete in response to instructions from the cartoning or bagging station manager, button requests, and / or human-machine interface instructions. When the control system 1002 determines that the hopper is complete, it prints a bag completion label, as shown at 1022, and requests a new empty hopper for hopper exchange, as shown at 1024. The detector pair on the new empty hopper can be checked to ensure the hopper is empty. Then, as shown at 1026, the completed hopper is unloaded onto the conveyor via the shuttle controller 1028 (e.g., as shown in the image). Figure 1 The box temporary storage conveyor 32 shown.

[0025] Once it is determined that the box is ready for unloading (completed), the box unloading mechanism moves the completed box onto the temporary storage conveyor 32, as described above. Figure 5A and Figure 5B The discussion. Figure 8A The processed container 31 is shown being unloaded from the temporary storage conveyor 32 onto the distributor 58 of the common discharge conveyor 50, and... Figure 8B The processed box 31 is then immediately transferred from the common discharge conveyor 50 to the box feed conveyor 34 via the diverter 58. Diverter 52 (e.g.) Figure 4A and Figure 4B As shown), 54, 56, and 58 are all installed on the common discharge conveyor 50, and further reference is made. Figure 9 Diverters 54 and 56 divert empty containers (e.g., 22) to processing location 24. Figure 1 On conveyors 60 and 62, and diverters 52 and 58 divert processed boxes (e.g., 33) from the temporary storage conveyor 32 across the common discharge conveyor 50 to the processed box conveyor 34. Thus, the processed boxes cross the common discharge conveyor 50, which originates from the empty box feed conveyor 20. Therefore, the diverters are all located on the inner conveyor (empty box feed conveyor), moving empty boxes onto the processing conveyor and moving processed boxes across the inner conveyor to the outer conveyor. Similarly... Figure 9 (and Figure 10As shown, object processing system 10 (and each of the object processing systems disclosed herein) includes sensing systems 80 distributed throughout the conveyor, which provide information about the location of all boxes (empty boxes, processed boxes, and processed boxes) on any conveyor system discussed herein.

[0026] According to another aspect, a system can be provided in which diverters are installed on both the inner and outer conveyors to move the container from the outer conveyor and across the inner conveyor to the processing conveyor. For example, Figure 10 It shows something similar to Figures 1 to 9 The object processing system includes the feeding system 12 and the distribution system 14 as described above, wherein the distribution system includes personnel workstations (such as...). Figure 1 (as shown) or programmable motion device workstation (such as Figure 11 (As shown). The feeding system 12 includes a source box feeding conveyor 16 and a station feeding conveyor 18, which is connected to the distribution system 14. The object processing system 10 also includes an empty box feeding conveyor 20 for providing empty boxes to a series of processing positions, which are gravity-biased (or actively powered) to move their boxes away from the feeding system.

[0027] Similarly, as discussed above, the distribution system 14 includes one or more distribution conveyors 26, each leading to a reciprocating carrier 28, and each carrier supplies objects therein to any one of a plurality of empty boxes at a processing location, thereby turning an empty box into a processed box upon completion of processing for each box. Each processed box is then transferred to a processed box storage conveyor 32 until it is ready to be moved onto the processed box feed conveyor. Figure 10 In the system, the empty box feed conveyor 120 is located outside the processed box feed conveyor 134, wherein the processed box feed conveyor is a common discharge conveyor 70.

[0028] Similarly, personnel (such as) can be used. Figure 2 (as shown) or programmable motion devices (such as Figure 11 Any one of the following (as shown) moves an object from the source box to one or both of the distribution conveyors, and each distribution conveyor leads to a reciprocating vehicle traveling along track 40 (as discussed above and as shown). Figure 3A As shown), the vehicle then moves and places the object into one of a plurality of processing locations 24 (as discussed above and as...). Figure 3B (As shown). The vehicle then returns to its starting position, where it can receive another object from the distribution conveyor. Similarly, the operation of all conveyors, sensing systems, and processing devices in each of the systems disclosed herein can be handled by one or more computer processing systems (e.g., Figure 1 The 100 and / or shown Figure 11 The 200 shown is executed.

[0029] exist Figure 10 In this system, the outer conveyor 120 is an empty carton feed conveyor, and the inner conveyor 134 is a processed carton feed conveyor. The outer conveyor 120 includes two bidirectional diverters 72 and 76 at each processing location, and the inner conveyor includes two bidirectional diverters 74 and 78 at each processing location. Diverters 70 and 72 selectively divert empty cartons from the empty carton feed conveyor 120 first to the processed carton feed conveyor 134, and then to the processing conveyor 60. Similarly, diverters 76 and 78 can be used to selectively divert empty cartons from the empty carton feed conveyor 120 first to the processed carton feed conveyor 134, and then to the processing conveyor 62.

[0030] The inner conveyor 134 serves as a common discharge conveyor 70, as processed boxes move along conveyor 70 and empty boxes cross conveyor 70. Therefore, empty boxes cross the common discharge conveyor 70, which originates from the processed box feed conveyor 20. Thus, diverters are located on the outer conveyor (empty box feed conveyor) and the inner conveyor (processed box feed conveyor), with processed boxes moving along the inner conveyor and empty boxes being transferred across the inner conveyor to the processing conveyor at each processing location. Therefore, each of the diverters operates only on empty boxes, where processed boxes are simply transferred from the processed box storage conveyor to the processed box feed conveyor.

[0031] As described above, each of the object processing systems discussed herein may include a dispatch system having a human workstation or a programmable motion device, such as an articulated arm robot system. For example, Figure 11An object processing system 110 is shown, comprising a distribution system 140 having a programmable motion device (e.g., an articulated arm) 142 with an end effector 144 having a vacuum suction cup 146 and one or more sensing systems 150. The vacuum suction cup 146 is attached to a vacuum source 148 via a hose. The device 142 is used to move objects from source bins to a distribution conveyor leading to a reciprocating conveyor, as discussed above. The system 110 also includes a feed handling system 12 comprising a source bin feed conveyor 16 and a station feed conveyor 18 in communication with the distribution system 140. The object processing system 110 also includes an empty bin feed conveyor 20 for providing empty bins 22 to a plurality of serial processing positions 24, the serial processing positions being gravity-biased (or actively powered) to move bins on them away from the feed handling system 12. The distribution system 140 includes one or more distribution conveyors 26, each of which leads to a reciprocating carrier 28, and each carrier can supply objects therein to any one of a plurality of empty boxes at a processing location 24, so that the empty box becomes a processed box 30 when processing for each box is completed.

[0032] Each processed box 30 is then transferred to the processed box storage conveyor 32 until it is ready to be moved to the processed box feed conveyor 34 via the empty box feed conveyor 20, as described above. Figure 11 In this system, the empty carton feed conveyor 20 serves as a shared discharge conveyor 50, through which both empty and processed cartons are transported at some point in time. According to other aspects, in systems including programmable motion devices, the empty carton feed conveyor may be located outside the processed carton feed conveyor, where the processed carton feed conveyor is the shared discharge conveyor (as referenced above). Figure 10 (As discussed below). According to another aspect, in systems including programmable motion devices, both empty and processed boxes can be transported by a single conveyor, as referenced below. Figure 12 The discussion.

[0033] Each distribution conveyor 26 leads to a reciprocating vehicle 28 traveling along track 40 (as referenced above). Figure 3A As discussed above), the reciprocating vehicle then moves and deploys the object to one of a plurality of processing positions 24 (as discussed above and as...). Figure 3B (As shown). Then, vehicle 28 returns to the starting position, where it can receive another object from distribution conveyor 26. The operation of all conveyors, sensing systems, and processing devices in each of the systems disclosed herein can be handled by one or more computer processing systems (e.g., Figure 11 The 200 shown is executed.

[0034] exist Figure 9 In the system shown, the distributors are all located on the inner conveyor (empty box feed conveyor), moving all empty boxes to the processing conveyor, and moving processed boxes across the inner conveyor to the outer conveyor, as referenced above. Figures 1 to 9 As discussed above. According to another aspect, a system comprising a programmable motion device can be provided, wherein diverters are provided on both the inner and outer conveyors for moving the container from the outer conveyor and across the inner conveyor to the processing conveyor, as referenced above. Figure 10 As discussed above. In a further aspect, a system incorporating programmable motion devices can be provided, wherein a single conveyor is provided as both an empty carton feed conveyor and a processed carton discharge conveyor (sharing a discharge conveyor), as referenced below. Figures 12 to 13D The discussion.

[0035] Figure 12 An object processing system 210 is shown, which includes a feeding system 12 and a distribution system 14. The distribution system may include personnel workstations (such as...). Figure 1 (as shown) or programmable motion device workstation (such as Figure 11 (As shown). The feeding system 12 includes a source box feeding conveyor 16 and a station feeding conveyor 18, which is connected to the distribution system 14. The object processing system 210 also includes an empty box feeding conveyor 220 for providing empty boxes 22 to a plurality of serial processing locations 24, which are gravity-biased (or actively powered) away from the feeding system 12. The distribution system 14 includes one or more distribution conveyors 26, each leading to a reciprocating carrier 28, and each carrier provides objects therein to any of a plurality of empty boxes at a processing location, so that the empty box becomes a processed box 30 when processing for each box is completed. Each processed box 30 is then transferred to a processed box storage conveyor 32 until the time is right to move the box 30 to the empty box feeding conveyor 220, which serves as a common discharge conveyor.

[0036] Personnel (such as) Figure 2 (as shown) or programmable motion devices (such as Figure 11 Any of the following (as shown) can be used to move an object (e.g., object 44) from source bin 36 to distribution conveyor 26, as referenced above. Figure 3A and Figure 3BAs discussed herein. Each distribution conveyor 26 leads to a reciprocating vehicle 28 traveling along track 40, which in turn moves and delivers an object to one of a plurality of processing positions 24. The vehicle 28 then returns to its starting position, where it can receive another object from the distribution conveyor 26. The operation of all conveyors, sensing systems, and processing devices in each of the systems disclosed herein can be controlled by one or more computer processing systems (e.g., Figure 12 Execute 100 as shown.

[0037] refer to Figures 13A to 13D A shared discharge conveyor of 220 (in Figure 12 The system (provided by an empty carton feed conveyor) includes bidirectional diverters (e.g., 252, 254) that can selectively move cartons in a direction transverse to the direction of movement of the conveyor (e.g., by staggered belt sets between rollers on a liftable support, as shown and discussed above). Diverter 252 selectively diverts empty cartons to processing conveyor 60, and diverter 254 selectively diverts empty cartons to processing conveyor 62, thereby providing a new carton at each processing position 24 (as discussed above). Figure 13A Two empty containers 22 are shown approaching processing conveyors 60 and 62 respectively, and Figure 13B An empty container 22 is shown being diverted to a processing conveyor 62. Figure 13C Another empty container 22 is shown being diverted to the processing conveyor 60.

[0038] As discussed above, objects are assigned and boxes are processed at the processing location, and when each individual box being processed becomes full, the box is moved onto the common discharge conveyor 220. Boxes that have been processed (whether full or not) engage with the box unloading mechanism attached to the carrier 28 (as described above). Figure 4A and Figure 4B (As discussed above). The box unloading mechanism includes a pivoting arm with roller engaging wheels that engage the box and then push it away from the processing position, across one or more rollers to the processed box storage conveyor, as discussed above. The processed storage conveyor 32 can temporarily store each processed box until the time is right to transfer the box to the common discharge conveyor 220.

[0039] Figure 13A It also shows processed boxes 30 waiting to enter conveyor 220, and Figure 13B Another processed box 30 is shown approaching conveyor 220. Figure 13C This shows the first processed box 30 being transferred onto conveyor 220, and... Figure 13D The second processed bin 30 is shown being transferred onto conveyor 220. Therefore, the system uses two diverters for each group of two processing locations.

[0040] An object processing system according to another aspect of the invention may include, for example: Figure 14 The disclosed stacked processing system. Figure 14 An object processing system 310 is shown, including a distribution system 314, which has a personnel workstation (as shown) or a programmable motion device (e.g., as referenced above). Figure 11 As discussed above, objects are moved at this device from source bins to distribution conveyor 326 (in the double-stacked distribution conveyor 326), which leads to reciprocating carrier 328 (in the double-stacked reciprocating carrier 328), as discussed above. System 310 also includes a feeding system 312, which includes a source bin feeding conveyor 316 and a station feeding conveyor 318 (which can be lifted at a workstation or programmable motion device), the station feeding conveyor communicating with the distribution system 314. Object processing system 310 also includes a pair of stacked empty bin feeding conveyors 320 for providing empty bins 322 to a series of stacked processing positions 324, the series of stacked processing positions being gravity-biased (or actively powered) to move their bins away from the feeding system 312. The distribution system 314 includes one or more stacked distribution conveyors 326, each of which leads to a reciprocating carrier 328, and each carrier can supply objects therein to any of a plurality of empty boxes at a stacked processing location 324, thereby turning an empty box into a processed box 330 when processing for each box is completed.

[0041] Each processed box 330 is then transferred to one of the stacked processed box storage conveyors 332 until the time is right, for example, by moving the box 330 to one of the stacked processed box feed conveyors 334 across the empty box feed conveyor 320, as discussed above. Figure 14 In the system, as shown in the figure, the empty carton feed conveyor 320 is a shared discharge conveyor (two stacked), and both empty and processed cartons are transported via this shared discharge conveyor at some point in time. Alternatively, the stacked empty carton feed conveyors may be located outside the stacked processed carton feed conveyors, where the processed carton feed conveyors are the shared discharge conveyors (as referenced above). Figure 8A and Figure 8B (As discussed above). Alternatively, both empty and processed boxes can be conveyed by a pair of stacked conveyors, as referenced above. Figure 12 The discussion.

[0042] Similarly, each stack's distribution conveyor 326 leads to each layer via a reciprocating carrier 328 traveling along track 340 (as referenced above). Figure 3AThe stacking system (discussed above) in which the reciprocating vehicle moves and places objects into one of a plurality of stacked processing positions 324 (as discussed above and as...). Figure 3B (As shown). Then, the vehicle 328 returns to the starting position, where it can receive another object from the distribution conveyor 326. The operation of all conveyors, sensing systems, and processing devices in each of the systems disclosed herein can be handled by one or more computer processing systems (e.g., Figure 14 Execute 100 as shown.

[0043] exist Figure 14 In the system shown, all the splitters are located on the inner conveyor (empty carton feed conveyor) of the stack, moving all empty cartons to the processing conveyor of the stack, and moving processed cartons across the inner conveyor of the stack to the outer conveyor of the stack, as referenced above. Figures 1 to 9 As discussed above. According to another aspect, a system can be provided in which diverters are provided on both the inner and outer conveyors of the stack for moving boxes from the outer conveyor of the stack and across the inner conveyor to the stack's processing conveyor, as referenced above. Figure 10 As discussed above. In a further aspect, a system can be provided in which stacked conveyors are provided as both an empty carton feed conveyor and a processed carton discharge conveyor (sharing a common discharge conveyor), as referenced below. Figures 12 to 13D As discussed above. According to another aspect, an object processing system may be provided, wherein a stacked processing system is employed, wherein each layer of the stack includes feed and discharge conveyors and diverters of the same arrangement (as discussed above), or wherein each layer of the stack includes feed and discharge conveyors and diverters of different arrangements. The operation of all conveyors, sensing systems, and processing devices in each of the systems disclosed herein can be controlled by one or more computer processing systems (e.g., Figure 14 Execute 100 as shown.

[0044] According to another aspect, an object processing system according to an aspect of the invention can be provided, the object processing system comprising multiple sets of workstations adjacent to each other, and associated pairs of processing locations. For example, Figure 15An object processing system 410 is shown, comprising multiple adjacent stations with a feeding processing system 412 and a distribution system 414 on the same side of a source box feed conveyor 416. Each feeding processing system includes a station feed conveyor 418, multiple processing positions 424, and multiple processed box temporary storage conveyors 432, all of which operate using a distribution system (e.g., personnel or programmable motion devices) and any combination of the aforementioned shared discharge conveyors as discussed above. Such a system 410 could be used, for example, in applications where the source box feed conveyor 416, empty box feed conveyor 420, and processed box feed conveyor 434 extend along the walls of a facility.

[0045] According to another aspect, an object processing system according to an aspect of the invention can be provided, the object processing system comprising multiple sets of workstations spanning each other, and associated pairs of processing locations. For example, Figure 16 An object processing system 510 is shown, comprising multiple opposing stations on the same side of a source box feed conveyor 516, with a feed processing system 512 and a distribution system 514. Each feed processing system includes a station feed conveyor 518, multiple processing positions 524, and multiple processed box storage conveyors 532, all of which operate using a distribution system (e.g., personnel or programmable motion devices) and any combination of the aforementioned shared discharge conveyors as discussed above. Such a system 510 could be used, for example, in applications where the source box feed conveyor 516, empty box feed conveyor 520, and processed box feed conveyor 534 extend through the center of a facility.

[0046] In addition to providing multiple workstations (e.g., on one or both sides of the source bin feed conveyor), depending on various aspects, the object handling system may also include source bins that can run in continuous loops returning to the system's entry point. Furthermore, empty bins can also run in continuous loops returning to the system's entry point (e.g., where the processed bin conveyor is a shared discharge conveyor). In any application where unused empty bins are combined with processed bins, the empty bins can be separated and returned to the system's empty bin entry point. While in some applications it may be necessary to use all empty bins in each loop, in other applications, reserving additional empty bins available to provide flexibility in the handling process may be more efficient.

[0047] Figure 17A and Figure 17B Exemplary process flow steps in a processing system according to one aspect of the invention are shown (e.g., provided by one or more computer processing systems 100, 200 discussed herein). Specifically and with reference to... Figure 17AThe system can begin by supplying source boxes to the system (step 2000). The system then assesses the known vacancy status of all stations (step 2001), which are all empty at startup. Depending on some aspects, the system can begin by filling all stations with empty boxes before supplying source boxes to the system. The system can then assess the current quantity of source boxes being supplied, and the quantity of source boxes expected to be supplied in the near future (e.g., 30 to 90 minutes) (step 2002). The system can also assess the object processing rate at each station (step 2003) to better determine when and where to allocate empty boxes to each station. The system can then assess the quantity of boxes being processed at each processing location (step 2004), which may be the maximum number of boxes available at each processing location, or less, depending on whether any stations are waiting for new empty boxes. The system can then assess the number of processed boxes on the processed box storage conveyor (step 2005). These boxes are ready to be unloaded onto the shared discharge conveyor but are awaiting movement so that one or more empty boxes can be moved first when an empty box is needed in the downstream system of the waiting boxes, thereby maximizing efficiency. Based on all of the above factors, the system can then determine the appropriate number of boxes to be supplied to the system (step 2006).

[0048] Further reference Figure 17B The system can determine the appropriate spacing of empty boxes to be supplied to the system (step 2007), and then supply empty boxes in the determined quantity and spacing (step 2008). By adjusting the spacing, the system allows processed boxes to be staggered with empty boxes on a shared discharge conveyor, as discussed above. Introducing empty boxes without such spacing may slow down the system speed because processed boxes may be waiting to move. Since any and all empty boxes may later become processed boxes, and the quantity of processed boxes is at least proportional to the quantity of source boxes, the system can evaluate the relative balance between the source boxes supplied to the system and the empty boxes supplied to the system (step 2009). Furthermore, in applications where source boxes are circulated back for recycling and empty boxes are circulated back for recycling, as discussed above, the system can evaluate the relative balance between the any-looping flow of source boxes and the any-looping flow of empty boxes (step 2010). The system can then determine whether any imbalance is too large (step 10111), and if not, return to the step of evaluating the balance (step 2009), and if so, return to the step of evaluating the vacancy state, quantity, processing rate and count (step 2001).

[0049] Systems according to various aspects of the invention can provide, in certain applications, a rear unloading system with a smaller, simpler unit footprint, easier personnel access and clearing of blockages (without needing to traverse conveyors), reduced deployment effort, and significant cost savings. For example, providing a message to the outside of the system may require multiple traversals of the conveyor to assess the situation, inspect the message, clear blockages, and then return to the distribution station. Furthermore, providing empty and processed (full) containers (at least partially) on a shared conveyor reduces hardware requirements, and with the increased buffer capacity of the container storage conveyor (e.g., four per station), significant buffer capacity is provided for stations with fluctuating or drastically changing volumes. Additionally, empty containers can be replenished during periods of low throughput, thereby maintaining throughput during periods of high throughput.

[0050] Those skilled in the art will recognize that many modifications and variations can be made to the embodiments disclosed above without departing from the spirit and scope of the invention.

Claims

1. An object processing system, comprising: The feeding system includes a source box feed conveyor for providing source boxes; A distribution system for receiving the source bin and for receiving a plurality of empty bins and for providing objects from the source bin to a series of processing locations, each processing location including an empty bin from the plurality of empty bins, thereby providing the previously empty bin as a processed bin upon completion; as well as A discharge processing system for removing the processed boxes from the series of processing locations, wherein the empty boxes and the processed boxes are each located at a point on their respective output paths on a common discharge conveyor.

2. The object processing system of claim 1, wherein the common discharge conveyor is a processed box feed conveyor, and wherein the empty box traverses between processed boxes on the processed box feed conveyor.

3. The object processing system according to any one of claims 1 to 2, wherein the common discharge conveyor is an empty box feed conveyor, and wherein the processed box traverses between empty boxes on the empty box feed conveyor.

4. The object processing system according to any one of claims 1 to 3, wherein the empty box and the processed box are both provided together on the common discharge conveyor.

5. The object processing system according to any one of claims 1 to 4, wherein the discharge processing system further includes a processed box temporary storage conveyor, on which completed boxes are moved from the distribution system to the processed box temporary storage conveyor, the processed box temporary storage conveyor being connected to the common discharge conveyor.

6. The object processing system of claim 5, wherein the distribution system includes a distribution conveyor, the empty container is provided on the distribution conveyor for processing, and the distribution conveyor is biased to push the empty container away from the feed processing system.

7. The object processing system of claim 6, wherein when a removed processed box is moved from the distribution conveyor to the processed box storage conveyor, the remaining boxes on the distribution conveyor are moved to fill the space left by the removed processed box.

8. The object processing system of claim 5, wherein the system further comprises a processing system for controlling the movement of at least some of the empty boxes or processed boxes on the common discharge conveyor, such that the processed boxes are temporarily stored at the processed box storage conveyor until the common discharge conveyor is ready to receive them.

9. The object processing system according to any one of claims 1 to 8, wherein the distribution system includes a personnel workstation located near the source box feed conveyor and the distribution conveyor of the distribution system.

10. The object processing system according to any one of claims 1 to 9, wherein the distribution system includes a programmable motion device adjacent to the source bin feed conveyor and the distribution conveyor of the distribution system, the programmable motion device being used to provide objects from the source bin to the distribution conveyor.

11. The object processing system according to any one of claims 1 to 10, wherein the distribution system further comprises a reciprocating carrier that receives objects from the feeding processing system.

12. The object processing system according to any one of claims 1 to 11, wherein the object processing system further comprises a plurality of series of processing positions and a discharge processing system, wherein each of the plurality of processing positions is connected to the distribution system.

13. The object processing system of claim 12, wherein the plurality of sequentially arranged processing locations are provided on both sides of the distribution system.

14. The object processing system of claim 12, wherein the plurality of sequential processing positions are stacked one on top of the other.

15. The object processing system according to any one of claims 1 to 14, wherein the object processing system further comprises multiple sets of distribution systems, a series of processing positions, and an output processing system.

16. The object processing system of claim 15, wherein the multiple distribution systems, the series of processing positions, and the discharge processing system are provided on the same side of the source box processing conveyor.

17. The object processing system of claim 15, wherein the multiple sets of distribution systems, the series of processing positions, and the discharge processing system are provided on opposite sides of the source box processing conveyor.

18. An object processing system, comprising: A distribution system for receiving multiple source boxes and multiple empty boxes and for providing objects from the source boxes to multiple processing locations, each of the multiple processing locations including an empty box from the multiple empty boxes, thereby providing the previously empty box as a processed box upon completion, wherein the multiple processing locations are provided as at least two sets of processing locations located on both sides of the distribution system. as well as A discharge processing system for removing processed boxes from the plurality of processing locations, wherein the empty boxes and the processed boxes are each located at a point on their respective output paths on a common discharge conveyor.

19. The object processing system of claim 18, wherein the common discharge conveyor is a processed box feed conveyor, and wherein the empty box traverses between processed boxes on the processed box feed conveyor.

20. The object processing system according to any one of claims 18 to 19, wherein the common discharge conveyor is an empty box feed conveyor, and wherein the processed boxes traverse between empty boxes on the empty box feed conveyor.

21. The object processing system according to any one of claims 18 to 20, wherein the empty box and the processed box are both provided mixed on the common discharge conveyor.

22. The object processing system according to any one of claims 18 to 21, wherein the discharge processing system further includes a processed box storage conveyor, on which completed boxes are moved from the distribution system to the processed box storage conveyor, the processed box storage conveyor being connected to the common discharge conveyor.

23. The object processing system of claim 22, wherein the distribution system includes a distribution conveyor, the empty container is provided on the distribution conveyor for processing, and the distribution conveyor is biased to push the empty container away from the feeding processing system.

24. The object processing system of claim 23, wherein when a removed processed box is moved from the distribution conveyor to the processed box storage conveyor, the remaining boxes on the distribution conveyor are moved to fill the space left by the removed processed box.

25. The object processing system of claim 22, wherein the system further comprises a processing system for controlling the movement of at least some of the empty boxes or processed boxes on the common discharge conveyor, such that the processed boxes are temporarily stored at the processed box storage conveyor until the common discharge conveyor is ready to receive them.

26. The object processing system according to any one of claims 18 to 25, wherein the distribution system includes a personnel workstation located near the source box feed conveyor and the distribution conveyor of the distribution system.

27. The object processing system according to any one of claims 18 to 26, wherein the distribution system includes a programmable motion device adjacent to the source bin feed conveyor and the distribution conveyor of the distribution system, the programmable motion device being used to provide objects from the source bin to the distribution conveyor.

28. The object processing system according to any one of claims 18 to 27, wherein the distribution system further comprises a reciprocating carrier that receives objects from the feed processing system.

29. The object processing system according to any one of claims 18 to 28, wherein the object processing system further comprises a plurality of series of processing positions and an output processing system, wherein each of the plurality of processing positions is connected to the distribution system.

30. The object processing system of claim 29, wherein the plurality of sequentially arranged processing locations are provided on both sides of the distribution system.

31. The object processing system of claim 29, wherein the plurality of sequential processing positions are stacked one on top of the other.

32. The object processing system according to any one of claims 18 to 31, wherein the object processing system further comprises multiple sets of distribution systems, a series of processing positions, and an output processing system.

33. The object processing system of claim 32, wherein the multiple distribution systems, the series of processing positions, and the discharge processing system are provided on the same side of the source box processing conveyor.

34. The object processing system of claim 32, wherein the multiple distribution systems, the series of processing positions, and the discharge processing systems are provided on opposite sides of the source box processing conveyor.

35. A method for processing objects, comprising: Receives multiple source boxes at the distribution system; Multiple empty boxes are received at the distribution system; The object is provided from the source bin to a series of processing locations, each processing location including an empty bin from the plurality of empty bins, so that the previously empty bin is provided as a processed bin upon completion; as well as The processed bins are removed from the series of processing locations, wherein the empty bins and the processed bins are each located at a point on their respective output paths on a common discharge conveyor.

36. The method of claim 35, wherein the common discharge conveyor is a processed box feed conveyor, and wherein the empty box traverses between processed boxes on the processed box feed conveyor.

37. The method according to any one of claims 35 to 36, wherein the common discharge conveyor is an empty box feed conveyor, and wherein the processed box traverses between empty boxes on the empty box feed conveyor.

38. The method according to any one of claims 35 to 37, wherein the empty box and the processed box are both provided mixed on the common discharge conveyor.

39. The method according to any one of claims 35 to 38, wherein the discharge processing system further comprises a processed box storage conveyor, on which completed boxes are moved from the distribution system to the processed box storage conveyor, the processed box storage conveyor being in communication with the common discharge conveyor.

40. The method of claim 39, wherein the distribution system includes a distribution conveyor, the empty container is provided on the distribution conveyor for processing, and the distribution conveyor is biased to push the empty container away from the feeding processing system.

41. The method of claim 40, wherein when the removed processed box is moved from the distribution conveyor to the processed box storage conveyor, the remaining boxes on the distribution conveyor are moved to fill the space left by the removed processed box.

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