System and method for providing treatment of articles using a flow actuated

Abstract

An article handling system is disclosed, the article handling system comprising: a dispensing system for dispensing a plurality of articles in a plurality of containers; the output conveying system is used for receiving the plurality of sorted containers; and a container discharge system for emptying any contents of a container of the plurality of sorted containers to a destination location, the container discharge system comprising a discharge transport section in which the container is suspended and moved in a transport direction, and at the same time, allowing the bottom of the container to fall open so as to discharge any contents of the container to the destination location.

Description

[0001] priority

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 539,481, filed September 20, 2023, the disclosure of which is incorporated herein by reference in its entirety. Background Technology

[0003] This invention relates to unit sorting systems and other item handling systems for items such as individual items, products, packages, and other stock quantity units (SKUs), as well as totes, bins, and cartons containing these items, products, packages, and SKUs. The invention particularly relates to unit sorting systems that sort items into bulk containers such as bins, totes, cartons, etc.

[0004] Many conventional unit sorting systems are used in applications such as parcel sorting and e-commerce order fulfillment. In parcel sorting, unit sorters sort parcels entering the facility from a series of locations, grouping them by next station or hub, trailer truck, or postal code. In e-commerce order fulfillment, unit sorters sort mixed SKUs into individual customer orders or groups of customer orders. For example, this can save workload when creating heterogeneous SKU mixes from homogeneous input sources such as tote boxes or shelves.

[0005] For example, a unit sorting system can receive individual items on pallets or bomb bay carriers, and then simultaneously circulate these items along with many other carriers carrying other items. When a carrier reaches the destination of the item, the carrier is actuated in some way. If the carrier is a tilting pallet, the tilting pallet tilts to empty the load. If the carrier is a bomb bay carrier, the bomb bay floor opens to release the item. If the carrier is a cross-belt, the belt is actuated to transport the load away from the carrier, and so on. In this way, a unit sorting system can sometimes sort more than 10,000 units per hour to hundreds of sorting destinations.

[0006] The longer perimeter of a unit sorter contributes to its economic efficiency. In applications such as parcel sorting and e-commerce order fulfillment, a greater number of sorting destinations offers efficiency advantages. While the initial cost of a unit sorter is high, the marginal cost of adding more destinations is small. Therefore, many unit sorters have hundreds of destinations due to the increased efficiency.

[0007] However, the more destinations there are, the larger the perimeter becomes. This long perimeter disperses the work required to process individual items heading to sorting destinations. Workers handling sorted items must move between numerous chutes or sorting destinations. Workers must visit each of hundreds of destinations and empty the chutes, totes, or bags that received the items.

[0008] Therefore, the industry urgently needs more powerful, efficient, and economical unit sorting systems and other item handling systems to cope with scenarios that require sorting large numbers of individual items to numerous processing locations. At the same time, it is also necessary to reduce the time spent by staff on waiting, walking, and decision-making while facilitating system operation. Summary of the Invention

[0009] According to one aspect, the present invention provides an article handling system comprising: a dispensing system for dispensing multiple articles into multiple containers; an output conveying system for receiving multiple sorted containers; and a container unloading system for emptying any contents of the containers in the multiple sorted containers to a destination location, the container unloading system including a dischargeconveyor section in which containers are suspended and moved in a conveying direction while allowing the bottom of the containers to drop open to unload any contents of the containers into the destination location.

[0010] According to another aspect, the present invention provides an article handling system comprising: a dispensing system for dispensing multiple articles into multiple containers; an output conveying system for receiving multiple sorted containers, each of the sorted containers being disposed on, but not fixedly attached to, the output conveying system; and a container unloading system for emptying any contents of the containers in the multiple sorted containers to a destination location, the container unloading system including an unloading conveying section in which containers can be lowered and opened to unload any contents of the containers into the destination location.

[0011] According to another aspect, the present invention provides a method for processing articles, the method comprising: receiving a plurality of sorted containers; and emptying any contents of a container to a destination location by moving a container of the plurality of sorted containers along an unloading conveyor section, in which the container is suspended and moved in a conveying direction while allowing the bottom of the container to fall open to unload any contents of the container into the destination location. Attached Figure Description

[0012] The following description can be further understood with reference to the accompanying drawings, in which: Figure 1 A schematic plan view of an article handling system according to one aspect of the present invention is shown; Figure 2 It shows Figure 1 A schematic high-angle side view of the system; Figure 3 It shows Figure 1 A schematic diagram of the system's processing area; Figure 4A and Figure 4B The diagram illustrates the removal of sorted cassettes by a transfer unit, showing the cassettes being lifted. Figure 4A ) and is pushed onto the supply / outbound conveyor. Figure 4B ); Figure 5A and Figure 5B This diagram illustrates an empty container being supplied to a processing area, showing the empty container approaching ( Figure 5A It also shows the empty container being pushed to the loading position. Figure 5B ); Figure 6A and Figure 6B An exploded schematic diagram of a transfer unit according to one aspect of the invention is shown, with a side view also shown. Figure 6A ) and end view ( Figure 6B ); Figure 7A and Figure 7B It shows Figure 6A and Figure 6B A schematic side view of the transfer unit, showing the cargo receiving section not raised relative to the base. Figure 7A ) and the cargo receiving section is raised relative to the base ( Figure 7B ); Figure 8 A functional schematic diagram of a container and bag fullness assessment system according to one aspect of the present invention is shown; Figure 9 It shows in Figure 1 A schematic side view of the containers used in the system; Figures 10A to 10C It shows Figure 9 The container is approaching the unloading station. Figure 10A ), unload the contents of the container ( Figure 10B ) and leaving the unloading station ( Figure 10C A schematic side view; Figure 11A and Figure 11B The container is shown approaching the unloading station. Figure 11A ) and the contents of the container ( Figure 11BA schematic end view of ( ); Figure 12A and Figure 12B A schematic diagram of the bottom of the container is shown, in which... Figure 12A The image shows the container approaching an unplanned unloading area, and Figure 12B The override bar is shown in the engaged position to prevent contents from being unloaded from the container. Figure 13 It shows Figure 9 A schematic high-angle end view of the container, showing the container's hinge assembly; Figure 14 This diagram illustrates a portion of the container being checked to ensure it is correctly oriented. Figure 15 It shows Figure 9 A schematic end elevation view of the container, illustrating the closure detection system; and Figure 16 A schematic diagram of the bottom of the unloading area is shown, illustrating the destination container integrity sensing system.

[0013] The accompanying drawings are shown for illustrative purposes only. Detailed Implementation

[0014] According to one aspect, the present invention provides a system for reducing the manual labor required for processing unit sorting machines and centralizing the handling of items, such as individual items, parcels, SKU containers, products, etc., sorted by unit sorting machines. The system, including automated electromechanical components, provides the following functions: the system can place empty containers at or below each chute or sorting destination; can remove full containers at or below each chute or sorting destination; can transport containers to a centralized processing station for loading or packaging into other containers, further sorting, or other processing; and can optionally automatically remove items from specially designed containers. As used herein, containers include at least tote boxes, cartons, and cartons. Applications of the system according to certain aspects of the invention may include parcel sorting facilities using unit sorting machines, e-commerce order fulfillment centers using unit sorting machines to sort bulk picking orders, and any other system employing unit sorting machines.

[0015] Figure 1A top view of a unit sorting system 10 according to a representative aspect of the invention is shown, comprising a circular conveyor system 12 including two straight segments 14 and two curved segments 16. Each straight segment 14 includes an input area 18 where items such as packages, products, individual items, etc., can be placed on an empty carrier of the circular conveyor system 12, for example by a worker (as shown in 13) or by using a programmable motion device (as shown in 15). Each input area may include an input conveyor (17, 19) for transporting items to be processed. For clarity, only a portion of each conveyor (17, 19) is shown. The circular conveyor system may include carriers such as tilting pallets, gated units, cross-belt conveyors, etc., which travel continuously around the loop. Items are scanned before induction or scanned by a scanning system at a point along the loop. The straight segments 14 also include receiving containers 20, which optionally receive items via chutes 22 on each straight segment of the straight segments 14. Containers can be mounted on shelves or conveyor 24, as discussed further herein. The scanned barcode determines which chute an item should be ejected from the carrier into. Items travel with the carrier until they reach the chute, whereupon the unit sorter ejects them via various mechanisms such as hatch-type carriers, tilting pallets, cross-belts, etc. Receiving containers 20 (and chute 22) can be positioned on one or both sides of loop 12 (e.g., inside and outside). According to certain aspects of the invention, containers 20 can be automatically processed using an outbound and replenishment system upon completion of sorting, which can process containers on one side or both sides. Depending on various aspects, the outbound and replenishment system may include various components and functions as discussed herein, providing container outbound and container replenishment along multiple directions to and from the system. (See again) Figure 1 System 10 includes, for example, two supply / exit conveyors 26 that connect via discharge conveyors 27 to output path conveyors 28, 29. These output path conveyors connect via inlet conveyors 31 to container emptying stations 30 (such as bagging stations) or to workstations 32, which can be manually operated (as shown in Figure 37) or automatically operated (as shown in Figure 38), at which, for example, cartons can be packed. New empty containers can be added to the system as needed at the inlet 40 of return path conveyors 34, 35, and any containers to be removed from the system can be removed at the container outlet 42 at the end of the output path conveyors 28, 29.

[0016] Figure 2A high-angle end view of system 10 is shown, illustrating a chute 22 receiving items from a circular conveyor system 12, including, for example, tilting trays. The chute 22 leads to containers (e.g., crates, boxes, cartons, etc.), and the containers can be mounted on any of a fixed shelf, a fixed conveyor, or a movable conveyor 24 (e.g., Figure 1 (As shown). Each item placed on the circular conveyor system 12 is assigned a specific container, and the system feeds the item into the associated chute when it is above the chute as it moves along the circular conveyor system. Conveyor 26 leads to output path conveyors 28, 29, from which containers can be guided to a container emptying station as shown in 30 or a workstation as shown in 32 (also manually or automatically).

[0017] The operation of the system, including conveyors, tilting pallets, sensing systems, and automated handling systems, is provided by one or more computer processing systems 100. These systems coordinate the movement of conveyors and automated mobile transfer units and track the status and identity of all containers on the shelves and conveyors. For example, when a transfer unit moves a full container from a shelf to the conveyor, it can pause the advance of the preceding container to allow the full container to occupy an empty area on the conveyor when it is transferred to the conveyor by the processing transfer unit. In the case of a zero-accumulation conveyor, the spacing of the sensing units (such as photoelectric sensors) on the conveyor is optional. Empty containers can be provided as needed. For a transfer unit to transfer a container onto the conveyor, the entire area on the receiving conveyor or shelf must be empty. For a transfer unit to move a container away from the conveyor, the desired container must be positioned in front of that area. In all cases, there may be only one container per area. Note that a large number of empty containers need to continuously circulate on the conveyor. Typically, the rate of container replenishment should match the rate at which containers are removed.

[0018] Depending on certain aspects, a transfer unit that provides a lateral transfer mechanism on the transfer unit itself can be used. Figure 3 For example, an outbound and replenishment system is shown, comprising a chute 22 leading to containers 20 on a fixed shelf 24 and an adjacent replenishment and outbound conveyor 26. Automated moving transfer units 44 move (e.g., reciprocate) along a passageway beneath the shelf 24 and are used to move sorted containers onto the conveyor 26. As discussed in more detail below, each transfer unit 44 includes a liftable blade extending upward between the forks (or fixed rollers) of the slotted shelf 24 to lift the sorted containers (e.g., Figure 4AContainer 46 as shown); a narrow belt conveyor on top of each blade, which transfers the sorted container 46 from shelf 24 to conveyor 26 (as shown). Figure 4B (As shown).

[0019] Refer again Figure 4A The sorted container 46 is selected from multiple containers on shelf 24 and transferred to conveyor 26 via a narrow belt conveyor on the lifting blade of transfer unit 44. (Reference) Figure 5A Conveyor 26 can be actively moved (and its movement can be intermittently controlled, as discussed further herein) to move sorted containers 46 toward the output end of conveyor 26. The system can replace the position left on shelf 24 after container 46 has been removed with a new empty container, or shelf 24 can be configured as a roller conveyor where the rollers can be actuated individually (or in sections, such as sections associated with individual containers) (powered or gravity actuated) to move containers previously adjacent to the removed containers in a direction that fills the gaps left by the removed containers. Empty containers can then be replenished at the end of the shelf (e.g., by a worker or automated system), the replenishment location being at the starting end in the container removal direction. Depending on various aspects, containers can be moved until they contact each other, where the distal ends of the container rows remain in a fixed position. Alternatively, a sensing system can be employed in conjunction with individually actuable rollers to position containers at specific, known locations. Sensing systems may include any of the following: photodetectors, cameras, 2D scanners, and 3D scanners installed on or near the shelves, as well as weight-sensing conveyor roller supports and wireless position tracking systems (such as Bluetooth, echolocation, and GPS systems).

[0020] Depending on certain aspects, the empty space left after the sorted container 46 is removed can be used, for example, as... Figure 5A and Figure 5B Another automated moving transfer unit 44, shown below conveyor 26, moves (e.g., reciprocates) to fill separately. Figure 5A An empty container 48 is shown moving along conveyor 26, and Figure 5BA unit 44, activated as discussed herein, is shown to transfer an empty container 48 from conveyor 26 to shelf 24. Any of the automated moving transfer units 44 disclosed herein can also be moved in directions other than the relevant reciprocating direction by activating the main central drive wheel differently (e.g., at different speeds or in opposite directions), allowing a single transfer unit to move from under one shelf or conveyor to another shelf or conveyor (thus avoiding the use of two transfer units). However, this two-dimensional movement of the transfer units requires further safeguards regarding the precise positioning of each transfer unit under the shelf or conveyor to ensure accurate rise of the blades between the upper rollers, fork teeth, slots, etc.

[0021] Figure 6A An exploded side view of the transfer unit 44 is shown, and Figure 6B An exploded end view of the transfer unit 44 is shown. The transfer unit 44 includes a unit base 50, a support structure 52, and a cargo receiving section 54. The unit base 50 includes a pair of central drive wheels 56 and two sets of leveling wheels 58. The unit base 50 also includes two pairs of gear racks 60 that engage with pinions 62 on the support structure 52. The support structure 52 includes a drive system 64 that drives the pinions 62 to rotate on their respective axes, and the rotation of the pinions 62 causes the support structure 52 to rise relative to the unit base 50. The unit base 50 also includes a sliding rod 66 with end caps that restricts the vertical movement of the support structure 52 away from the unit base 50, and specifically restricts the movement of the base plate 68 of the support structure 52 away from the top surface 70 of the unit base 50. The rotation of the pinions 62 is reversed by the drive system 64, causing the support structure to descend toward the unit base.

[0022] The support structure 52 supports the cargo receiving portion 54 mounted on the top surface 72 of the support structure 52. The cargo receiving portion 54 includes a blade 74 on which a narrow bidirectional actuating belt 116 is mounted. Figure 6A An end view with blade 74 bearing 76 is shown, and Figure 6B A side view of a blade 74 with a belt 76 is shown. The belt 76 can be actuated by one or more belt drive systems 78, such as... Figure 12B As shown. The transfer unit 44 is therefore capable of reciprocating (or two-dimensional movement as discussed above), and when the blade 74 is lifted, the narrow strip 76 can be actuated in either of the two directions to remove the cargo on it from the unit 44.

[0023] Specifically, Figure 7A The support structure 52 and cargo receiving section 54 are shown in a lowered position, such that the top surface 70 of the unit base 50 contacts the bottom plate 68 of the support structure 52. Figure 7BThe support structure 52 and cargo receiving portion 54 are shown in an elevated position, such that the top surface 70 of the unit base 50 is separated from the base plate 68 of the support structure 52 by the distance of the length the rack and pinion 60 climbs. According to various other aspects of the invention, the elevation of the support structure 92 (and cargo receiving portion 94) relative to the unit base 90 can be achieved by various alternative techniques, including, for example, screw drives, linear actuators, and mechanical cam systems.

[0024] As an alternative to replenishment by transfer units, another option is to replenish empty containers by setting up the racks as biased conveyors. Instead of replenishing empty containers via transfer units, they are then replenished via a conveyor (e.g., a destination conveyor). However, the transfer units still push full containers onto the outgoing conveyor. Once a container is pushed out, containers upstream on the destination conveyor move forward to fill the now empty space (container accumulation). This creates an empty space at the very beginning of the destination conveyor for empty containers to move in. The advantage of this is that empty containers do not need to circulate on the conveyor as in other systems, and the need for transfer units to handle empty containers is completely eliminated.

[0025] It is important to note that during the stacking process, some or all of the containers may be moving on the destination conveyor. During this time, the unit sorter must be controlled to avoid delivering items to those destination containers known to be in motion (otherwise, the sorted items would fall off the conveyor). If the unit sorter has items to be delivered to containers in motion, it will recycle the item, i.e., send it around the unit sorter again; this will adversely affect the unit sorter's performance. After stacking, the correspondence between destination codes and positions on the unit sorter changes because the physical tote has shifted. A new destination map is provided to the unit sorter.

[0026] The choice of accumulation method depends on the number of zones on the conveyor. One option is zero-pressure accumulation, where there is a zone for each unit sorter position so that all containers do not touch each other. Another option is minimum-pressure accumulation, where there is only one conveyor zone, resulting in containers making light contact (so that the pressure applied to each container does not exceed the maximum pressure). Both approaches have advantages and disadvantages. Zero-pressure accumulation conveyors require a photoelectric sensor or zone at each container position. When the photoelectric sensor is off (i.e., blocked), the section of the destination conveyor located below the corresponding container does not advance. Therefore, the photoelectric sensor prevents containers from touching. Container positions correspond to conveyor zones in a 1:1 ratio. This allows the system controller to control which containers are in motion. For example, if the system knows that an item will soon be sorted into a container to be accumulated, the system can wait to accumulate that container until the unit sorter completes the sorting.

[0027] On the other hand, minimum pressure stacking does not require photoelectric sensors for each unit sorter location. This reduces system costs. However, during stacking, in the worst case, all remaining containers shift forward. This prevents the unit sorter from sorting items to any destination. Furthermore, in this case, the distance between containers becomes critical. The system doesn't know where each container is located; it can only determine the container's actual position along the conveyor by multiplying its width by its location. Therefore, for example, if the containers are cartons, the width of the cartons needs to be strictly controlled, or, for example, the cartons might be placed on pallets like other shuttle sorting systems. To balance these two extremes, some compromises exist where multiple zones are set up, but the number of zones is less than the number of container locations.

[0028] According to another aspect, the systems disclosed and presented in this invention may include dynamic destination mapping and scheduling. Specifically, for parcel sorting applications, destinations on conventional unit sorters are statically assigned. In any of the automation methods, since the destination is no longer meaningful to the person from whom it is retrieved, the destination can be dynamically assigned.

[0029] In e-commerce applications, where unit sorters sort mixed items into a collection of one or more orders, this allows containers with high-priority orders (e.g., orders with expedited fulfillment or shipment) to be automatically pushed out once all items in an order have been received from the unit sorter into the order container, thus prioritizing those containers.

[0030] For example, in parcel sorting, each destination can be a combination of postal code and / or priority. In some cases where manual outbound operations are involved, it may be necessary to retrieve a set of parcels for a specific destination / postal code at a specific time to ensure that these parcels catch the next truck to that set of postal codes—in which case there is, for example, a cut time. In any of the automated methods, outbound containers can be automatically executed according to a schedule to meet these cut times.

[0031] Additionally, for package sorting, dynamic allocation from sorting points (at the end of the unit sorter chutes) to destinations allows the control system and software to adjust the number of chutes allocated to a specific destination in real time based on a variety of reasons. For package sorting, if a specific destination / city is expected to receive more packages than normal during a given sorting period, more destinations can be added in real time or pre-added. Static control algorithms or machine learning-based control algorithms can be used to allocate chutes to destinations based on volume. Dynamic chute allocation also allows for real-time real-time reassignment for redundancy if a specific part of the machine stops; this keeps the entire machine running. Dynamic allocation also allows for on-fly editing to further subgroup destinations. For example, if Boston, Massachusetts, is receiving twice the normal number of packages for a particular sorting operation, the system can allocate two destinations instead of one, dividing the two new destinations into, for example, North Boston and South Boston, which alleviates the need for downstream sorting.

[0032] In dynamic allocation scenarios, to ensure the accuracy of the entire sorting system, container identification is tracked using barcodes as shuttles place, push, or transport containers. The shuttles can be equipped with barcode scanners to scan during placement, pushing, or transport. This prevents a mismatch between the virtual and actual states of the containers.

[0033] According to another aspect, certain systems of the invention disclosed and described herein can support mixed outbound systems. For example, in some systems, a human operator may consider a container to be sorted or full, for example, in the case of some systems disclosed and described herein, a human operator may manipulate the container by pushing it onto an outbound conveyor.

[0034] In systems according to various aspects of the invention, the removal and unloading of containers can also be accomplished in a variety of ways. For example, it may also involve unloading items from the container. This can be particularly important for parcel sorting applications where the final destination of items in a container is a plastic bag (or, for example, a permanent mailbag), which can be packed onto an outbound trailer at the facility. Furthermore, many parcels in a container may be heavy, and it may be difficult to tilt and tip the container manually; in such cases, they may have to move the parcels by hand. According to another aspect, the systems disclosed and described herein can place parcels or items into a container and automatically transfer items from that container to another container, such as a bag.

[0035] For example, one way to achieve this is to use a container with a hinged bottom. The container is constructed so that its bottom and the packages inside fall off while the container walls are supported, as discussed further below. Once the packages fall, they can drop directly into waiting empty bags. Workers then remove the now-filled bags, print labels for workers to affix to the bags, and these labels correspond to the container's identity. Workers remove the bags and replace them with new empty bags. Furthermore, bagging, labeling, and removal can all be automated. In some applications, not all containers are emptied at every dumping station. Using the system described herein, dumping can be controlled so that containers can pass through dumping stations, and be emptied or not. If a container needs to be emptied at a specific location, an actuated guide rail retracts, allowing the bottom flap to swing open. If the guide rail does not retract, the container will pass through the station without being emptied.

[0036] 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 as many bags / boxes as possible without exceeding ergonomic limits. Following this logic, the largest possible bag / box typically achieves the lowest operating cost without causing ergonomic problems. Incomplete bags / boxes result in air being transported from the sorting station, increasing costs. Therefore, once the container below the sorter is considered full, the process of bagging / boxing to the exact size of the container to hold the contents is the most economical option. The proposed system can monitor the actual contents of the output container for the item and suggest the correct size of the outgoing bag / box for manual or robotic bagging / boxing operations. Further optimization can be implemented if a sorting system with automated pick-up and bagging / boxing functions is specifically designed for sorting sealed packages transported from point A to point B. The output of parcel sorting machines used in logistics operations must typically meet truck or air travel times. The automated unloading system can automatically unload goods from the sorting machine to the destination to meet the time requirements of its truck or plane.

[0037] For example, Figure 8A functional diagram of a container and bag fullness analysis system 1000 used according to one aspect of the invention (e.g., in any of the article handling systems discussed herein) is shown. The analysis system 1000 determines when a container is full enough to be exchanged for an empty container 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 1012, human-machine interface information as shown at 1014, button information as shown at 1016, and full and overfill detection information as shown at 1018.

[0038] Package (item) 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). 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 overfull 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.

[0039] The software and control system 1002 receives the aforementioned input information and processes the data to control the transfer unit, 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 packing and bagging station manager and the workload manager. For example, the system may not rely solely on one or two information points (e.g., full or overfill sensor signals), but may consider the total weight or total volume. If the total weight and / or total volume is too low, the system will not consider the container complete. On the other hand, if the scheduled departure time (e.g., a flight) or the imminent departure time is approaching, the system may consider the container complete even if other data indicates otherwise. Furthermore, the system can immediately respond to instructions from the packing or bagging station manager, button requests, and / or human-machine interface instructions, immediately considering the container complete. When the control system 1002 considers the container complete, it prints a bag complete label, as shown at 1022, and requests a new empty container for container exchange, as shown at 1024. The detector pair on the new empty container can be checked to ensure that the container is empty. Then, as shown at 1026, the completed container is unloaded onto the shuttle or conveyor 1028 (e.g., as shown). Figure 1 The boxes are temporarily stored on the conveyor 32 shown. Once it is determined that the boxes are ready to be unloaded (sorting is complete), the system moves the sorted boxes to the replenishment and exit conveyor, as discussed above.

[0040] The above reference Figures 1 to 5B The container 20 of the system under discussion is particularly well-suited for transferring any of its contents during movement (as described above). Figure 9 A container 20 is shown, including a container body 80, which includes an upper edge 82. The container 20 also includes a bottom 84, which is attached to the body 80 via a hinge assembly 86 and an engagement feature 88.

[0041] Further reference Figure 10A Each container emptying station 36 may include an unloading conveyor section 90, which includes rollers 92 located on either side of the opening as shown in 94. For clarity, in Figures 10A to 10C A portion of station 36 was removed. Emptying station 36 also included a pair of opposing walls 96 (both walls are located in...). Figure 11A and Figure 11B (as shown in the diagram), and each wall 96 includes a flange 98 on which the upper edge 82 of each container 20 can rest when in the container emptying station 36. Each wall 96 also includes a drive system 102 (e.g., a chain drive or belt drive) that includes a paddle 104. The upper portion of the belt or chain travels along the conveyor section, and the paddle 104 engages the engagement feature 88 of each container 20.

[0042] Further reference Figure 10B When container 20 is positioned above opening 94 in the rollers (and specifically, then bottom 84 disengages from the last roller near the opening), bottom 84 swings open, emptying any contents 106 into cartons or bags positioned below the conveyor section. Reference Figure 10C As container 20 is further moved along the conveying direction by drive system 102, bottom 84 engages with guide rollers near opening 94 and is pushed to close, thus returning to body 80. This latter part of the conveying section is powered to continue moving the (now empty) container through the system. Figure 11A The container 20 is shown, wherein the upper edge 82 engages with the flange 98 of each wall 96, and Figure 11B The image shows the blade 104 of the drive system 102 engaging the blade 88 of the container 20, pulling the container 20 above the opening 94.

[0043] Refer again Figure 1 and Figure 2 The system may include multiple container emptying stations 36 arranged in series, and each station 36 may also include an override mechanism to prevent the contents of the container from being discharged into any unselected station. For example, Figure 12A A bottom view of station 36 is shown, which includes an anti-mishandling motor 106 capable of selectively rotating an anti-mishandling stop 108 above opening 94. (Reference) Figure 12B When the anti-mis-discharge lever 108 rotates above the opening 94, the container 20 is still pulled by the drive system 102, but the bottom 84 does not open. In this way, each container can only be opened at the selected station.

[0044] The system may also include a check system to ensure that any container is correctly oriented within the system, for example, to prevent jamming when opened with the bottom facing the wrong direction. (For example and reference) Figure 13 The system may include a sensing system 110 located at the inlet conveyor 31 of the container emptying station 36. The inlet conveyor 31 may have an associated bidirectional diverter 33 on the conveyor 28 that guides containers toward the inlet conveyor 31. Further reference Figure 14 The sensing system 110 (along with one or more computer processing systems) will locate the hinge assembly 86 (or a special material on it, such as a reflector) to ensure that the hinge side of the container enters first. If not, the container can be guided to the outlet 42.

[0045] Additionally, each container 20 may include a closure detection system, which may include, for example, a closure detection system such as... Figure 15The proximity elements 112, 114 shown detect when the bottom closes. This facilitates (in conjunction with one or more computer processing systems 100) confirmation that the contents have been unloaded as intended, and will further signal whether the container has been lifted within the system (e.g., by a worker) (which is not intended). The closure detection system may also include a small magnetic magnet to facilitate alignment of the bottom with the body upon closure, but does not provide sufficient force to prevent the bottom from falling due to its own weight.

[0046] According to other aspects and reference Figure 16 Each container emptying station in container emptying station 36 may also include a sensing system 116 on its underside, which can be used (in conjunction with one or more computer processing systems 100) to confirm the destination location including a movable bag hanger 118 with associated bags 120. The bag hanger may be mounted on rollers (e.g., Figure 2 As shown), and ensuring that the hangers and bag assemblies are properly positioned below any active container emptying station 36 can help prevent delays of various natures.

[0047] 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 article handling system, comprising: A distribution system for distributing multiple items in multiple containers; An output conveying system for receiving multiple sorted containers; as well as A container unloading system for emptying any contents of a plurality of sorted containers to a destination location, the container unloading system including an unloading conveyor section in which the containers are suspended and moved in a conveying direction while allowing the bottom of the containers to fall open to unload any contents of the containers into the destination location.

2. The article handling system of claim 1, wherein each of the plurality of sorted containers includes an openable bottom.

3. The article handling system of any one of claims 1 to 2, wherein each of the plurality of sorted containers includes a bottom that opens freely by gravity.

4. The article handling system of claim 3, wherein the bottom of each of the plurality of sorted containers is hinged to the body portion of each of the plurality of sorted containers.

5. The article handling system as claimed in any one of claims 1 to 4, wherein the unloading conveyor section is a roller conveyor, the roller conveyor not having the selected roller.

6. The article handling system of any one of claims 1 to 5, wherein the container unloading system includes at least one drive belt or chain for moving the container in the conveying direction.

7. The article handling system of claim 6, wherein the at least one drive belt or chain includes blades attached thereto.

8. The article handling system of claim 6, wherein the container includes an engagement feature for engaging the blades of the drive belt or chain.

9. The article handling system of any one of claims 1 to 8, wherein the destination location includes a bag for receiving the contents of the container.

10. The article handling system of any one of claims 1 to 9, wherein the container unloading system includes an anti-mis-unloading mechanism to selectively prevent the bottom of the container from opening.

11. An article handling system, comprising: A distribution system for distributing multiple items in multiple containers; An output conveying system for receiving a plurality of sorted containers, each of the sorted containers being disposed on, but not fixedly attached to, the output conveying system; as well as A container unloading system for emptying any contents of a plurality of sorted containers to a destination location, the container unloading system including an unloading conveyor section in which the containers can be lowered and opened to unload any contents of the containers into the destination location.

12. The article handling system of claim 11, wherein each of the plurality of sorted containers includes an openable bottom.

13. The article handling system of any one of claims 11 to 12, wherein each of the plurality of sorted containers includes a bottom that opens freely by gravity.

14. The article handling system of claim 13, wherein the bottom of each of the plurality of sorted containers is hinged to the body portion of each of the plurality of sorted containers.

15. The article handling system of any one of claims 11 to 14, wherein the unloading conveyor section is a roller conveyor, the roller conveyor not having the selected roller.

16. The article handling system of any one of claims 11 to 15, wherein the container unloading system includes at least one drive belt or chain for moving the container in the conveying direction.

17. The article handling system of claim 16, wherein the at least one drive belt or chain includes blades attached thereto.

18. The article handling system of claim 16, wherein the container includes an engagement feature for engaging the blades of the drive belt or chain.

19. The article handling system of any one of claims 11 to 18, wherein the destination location includes a bag for receiving the contents of the container.

20. The article handling system of any one of claims 11 to 19, wherein the container unloading system includes an anti-mis-unloading mechanism to selectively prevent the bottom of the container from opening.

21. A method of processing articles, comprising: Receive multiple sorted containers; as well as Any contents of the containers are emptied to the destination location by moving the containers from the plurality of sorted containers along an unloading conveyor section, in which the containers are suspended and moved in the conveying direction while allowing the bottom of the containers to fall open to unload any contents of the containers into the destination location.

22. The method of claim 21, wherein each of the plurality of sorted containers includes a bottom that opens freely by gravity.

23. The method of claim 22, wherein the bottom of each of the plurality of sorted containers is hinged to the body portion of each of the plurality of sorted containers.

24. The method of any one of claims 21 to 23, wherein the unloading conveying section is a roller conveyor, the roller conveyor not having the selected roller.

25. The method of any one of claims 21 to 23, wherein the container unloading system includes at least one drive belt or chain for moving the container in the conveying direction.

26. The method of claim 25, wherein the at least one drive belt or chain includes blades attached thereto.

27. The method of claim 25, wherein the container includes an engagement feature for engaging the blades of the drive belt or chain.

28. The method of any one of claims 21 to 23, wherein the method further comprises an actuated anti-mis-discharge mechanism to selectively prevent the bottom of the container from opening.

29. A container for use in an article handling system, comprising a body having an open top and a bottom, the bottom being movably attached to the body such that the bottom can be opened away from the body when it is not supported from below.

30. The container of claim 29, wherein the container further comprises a suspension feature for suspending the container when the bottom is not supported.

31. The container of any one of claims 29 to 30, wherein the container further comprises an engagement feature for engaging by a translation system to move the container when the bottom is not supported.

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