Cage system for express delivery

Abstract

This application provides a parcel cage-packing system, belonging to the field of logistics technology. The system includes: sorting equipment, comprising a main sorting channel and sub-sorting channels, each sub-sorting channel corresponding to different major flow directions, and each major flow direction containing multiple sub-flow directions; a parcel profiling module, used to acquire parcel sorting information and physical characteristics, and generate a parcel profiling; wherein, the main sorting channel is used to allocate parcels to the corresponding sub-sorting channels according to the parcel profiling, and each sub-sorting channel is equipped with: a parcel tracking module, used to track parcels allocated to the sub-sorting channel in real time according to the parcel profiling; and a cage-packing module, including a robotic arm and a cage cart, the robotic arm being used to grab the corresponding parcel from the sub-sorting channel and place it into the cage cart of the corresponding sub-flow direction according to the parcel profiling provided by the parcel tracking module. This application embodiment can improve the efficiency of parcel sorting and cage-packing.

Description

Technical Field

[0001] This application relates to the field of logistics technology, and in particular to a parcel cage system. Background Technology

[0002] Currently, in logistics transfer scenarios, after express parcels arrive at transit centers and other locations, they need to be sorted by sorting equipment according to their flow direction, fall into the corresponding chute, and then be loaded into cage carts by operators to achieve the collection and temporary storage of express parcels.

[0003] In related technologies, a fixed matching mode of one chute corresponding to one flow direction is usually adopted. When there are many flow directions, a large number of chutes and supporting cage positions are required, which not only occupies a lot of space, but also has high equipment costs. At the same time, the method of having operators complete the cage loading is prone to high labor intensity and low work efficiency, and long-term repetitive operation is prone to problems such as incorrect loading and missing loading, making it difficult to meet the high throughput sorting requirements. Summary of the Invention

[0004] The main objective of this application is to propose a parcel cage system that can improve the efficiency of parcel sorting and cage loading.

[0005] To achieve the above objectives, this application proposes a parcel cage-loading system, the system comprising: The sorting equipment includes a main sorting channel and multiple sub-sorting channels, each sub-sorting channel corresponding to a different major flow direction, and each major flow direction includes multiple sub-flow directions. A package profiling module is installed on the main sorting channel to acquire the sorting information and physical characteristics of packages, and to generate a package profiling based on the sorting information and physical characteristics. The main sorting channel is used to allocate packages to corresponding sub-sorting channels according to the package profile. Each sub-sorting channel is equipped with: A parcel tracking module is used to track parcels assigned to the sorting sub-channels in real time based on the parcel profile. The sorting module includes at least one robotic arm and multiple cage carts, each cage cart corresponding to a different sub-flow direction. The at least one robotic arm is used to grab the corresponding parcel from the sorting sub-channel and place it into the cage cart corresponding to the sub-flow direction based on the parcel profile provided by the parcel tracking module.

[0006] The parcel cage-packing system proposed in this application sorts parcels on the main sorting channel into sub-sorting channels according to their major flow direction. Each sub-channel is equipped with a parcel tracking module and a cage-packing module. This enables the simultaneous processing of parcels from multiple sub-flow directions within a single sub-sorting channel, achieving parcel sorting and cage-packing from 1 to N flow directions. This significantly improves the utilization efficiency of the sub-sorting channels and the efficiency of parcel sorting and cage-packing, and to a certain extent avoids the problems of low efficiency and high labor intensity of manual operation. Attached Figure Description

[0007] Figure 1 This is a schematic diagram of the express parcel cage system provided in an embodiment of this application; Figure 2 This is another schematic diagram of the express parcel cage system provided in the embodiments of this application. Detailed Implementation

[0008] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0009] It should be noted that although functional modules are divided in the device schematic diagram and a logical order is shown in the flowchart, in some cases, the steps shown or described may be performed in a different order than the module division in the device or the order in the flowchart. The terms "first," "second," etc., used in the specification, claims, and the foregoing drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0010] First, let's analyze some of the terms used in this application: Cage carts are unitized mobile vehicles widely used in logistics warehousing and transportation. They consist of a metal mesh or fence enclosure and can be fitted with casters. Cage carts are used for the safe and efficient containerization and transfer of loose, small, or easily scattered goods. Specifically, the enclosure prevents goods from falling or being lost, ensures ventilation and visibility, and the wheels allow for easy manual movement within warehouses, sorting centers, or truck beds, thereby improving loading and unloading efficiency and space utilization.

[0011] Automated Guided Vehicles (AGVs): These are unmanned intelligent handling robots equipped with automated navigation systems (such as magnetic strips, lasers, vision, or SLAM technology). AGVs can autonomously, safely, and efficiently complete the transportation, loading, unloading, and handling of materials (such as parts, finished products, pallets, bins, and cages) along predetermined or dynamically planned paths in designated environments such as warehouses and factories. They are key equipment for realizing automated logistics and flexible production.

[0012] Currently, in logistics transfer scenarios, after express parcels arrive at transit centers and other locations, they need to be sorted by sorting equipment according to their flow direction, fall into the corresponding chute, and then be loaded into cage carts by operators to achieve the collection and temporary storage of express parcels.

[0013] In related technologies, a fixed matching mode of one chute corresponding to one flow direction is usually adopted. When there are many flow directions, a large number of chutes and supporting cage positions are required, which not only occupies a lot of space, but also has high equipment costs. At the same time, the method of having operators complete the cage loading is prone to high labor intensity and low work efficiency, and long-term repetitive operation is prone to problems such as incorrect loading and missing loading, making it difficult to meet the high throughput sorting requirements.

[0014] Based on this, the embodiments of this application provide a parcel cage system that can improve the efficiency of parcel sorting and cage packing.

[0015] Reference Figure 1 and Figure 2 In some embodiments of the application, the parcel loading system includes sorting equipment and a parcel profiling module. The sorting equipment includes a main sorting channel 100 and multiple sub-sorting channels, each corresponding to a different major flow direction, and each major flow direction contains multiple sub-flow directions. The parcel profiling module is located on the main sorting channel 100 and is used to acquire the sorting information and physical characteristics of the parcels, and generate a parcel profiling based on the sorting information and physical characteristics. The main sorting channel 100 is used to allocate parcels to the corresponding sub-sorting channels according to the parcel profiling. Each sub-sorting channel is equipped with a parcel tracking module and a palletizing module. The parcel tracking module is used to track the parcels allocated to the sub-sorting channels in real time according to the parcel profiling and to continuously bind the parcel profiling to the corresponding parcel. The sorting module includes at least one robotic arm 200 and multiple cage carts, with the multiple cage carts corresponding to different sub-flow directions. At least one robotic arm 200 is used to grab the corresponding express from the sorting sub-channel and put it into the cage cart of the corresponding sub-flow direction according to the express profile provided by the express tracking module.

[0016] Specifically, in this embodiment, the main sorting channel 100 can refer to the core main line from the upstream conveyor line (such as the conveyor line in the unloading area) into the express parcel crating system. It typically includes equipment such as belt conveyors, swing wheel sorters, or cross-belt sorters to carry and transport express parcels. Sub-sorting channels can refer to branch lines branching off from the main sorting channel 100, typically including chutes 301 and belt conveyors 302. Each sub-sorting channel corresponds to a different major flow direction, such as a larger geographical area or business category like region A or region B. Each major flow direction contains multiple sub-flow directions; for example, region A can be subdivided into specific cities such as X1, X2, and X3. Figure 1 As shown, two sorting sub-channels are displayed, and the number of sorting sub-channels is not limited.

[0017] A parcel profiling module is installed on the main sorting channel 100. This module is used to acquire sorting information and physical characteristics of the parcels. Sorting information includes the parcel's barcode, waybill number, destination routing information, etc., which can be obtained by reading the barcodes on the top, bottom, and four sides of the parcel using a six-sided barcode scanner 401 (multiple barcode readers are arranged around the main sorting channel 100 to achieve omnidirectional scanning). Physical characteristics include the parcel's packaging material type (e.g., cardboard box, soft packaging, plastic bag, etc.) and shape characteristics (i.e., volume contour information, such as length, width, height, and flatness). These physical characteristics can be detected by a 3D AI camera 402 (a 3D camera that simultaneously acquires RGB color images and depth images, combined with artificial intelligence algorithms to identify object boundaries and surface features) in the parcel profiling module. The method of acquiring sorting information and physical characteristics is not specifically limited. Furthermore, the parcel profiling module can generate a parcel profiling based on the acquired sorting information and physical characteristics. A parcel profile can be a data structure or a digital identifier used to bind the route destination of the same parcel to its appearance, packaging attributes, etc., for use by subsequent modules. The main sorting channel 100, based on the major category flow indicated in the parcel profile (or sub-category flow, such as determining the sub-category flow based on destination routing information, and then determining the major category flow), uses sorting actuators such as swing wheels or pneumatic push rods to allocate parcels to the corresponding sub-sorting channels. This ensures that parcels with the same major category flow are allocated to the same sub-sorting channel, thereby simplifying the sorting granularity of the main sorting channel 100 and reducing the number of exits of the main sorting channel 100 (i.e., reducing the number of sub-sorting channels).

[0018] Each sorting sub-channel is equipped with a parcel tracking module and a racking module. The sorted parcels fall onto the belt conveyor 302 of the sorting sub-channel via the chute 301. At this time, multiple parcels may stack, obstruct, roll, or change posture on the belt conveyor 302, making the boundaries between parcels blurred and their spatial positions difficult to distinguish. Traditional photoelectric or fixed-position scanning methods are insufficient to accurately identify the identity and routing information of each parcel. To address this problem, this embodiment uses a parcel tracking module to track parcels entering the sorting sub-channel in real time and continuously binds the parcel profile obtained from the parcel profile module to the tracked physical parcel. This ensures that the sorting information and physical characteristics in the parcel profile always follow the movement of the corresponding parcel, thereby enabling the robotic arm 200 to accurately determine the sub-flow direction of each parcel without repeated scanning. In this way, there is no need to set up additional secondary scanning equipment in the sorting sub-channels, nor is it necessary to manually sort and rescan stacked or tumbled parcels, significantly reducing the workload of manually placing parcels and repeatedly scanning, and improving the overall automation level and sorting efficiency of the parcel cage system. In specific implementation, an RGBD camera 303 (a camera capable of simultaneously outputting color and depth images) can be installed at the beginning of the sorting sub-channels (i.e., at the entrance where parcels fall from the main sorting channel 100 into the chute 301, or at the adjacent position of the chute 301 and the belt conveyor 302). The RGBD camera 303 acquires images at high frequency and detects and tracks each parcel through morphological features (i.e., visually distinguishable geometric and appearance attributes such as the parcel's outline, size, color, and surface texture) and kinematic features (i.e., the speed, direction, and acceleration of the parcel moving in the belt conveyor 302, which can be predicted by Kalman filtering or optical flow method for inter-frame position). For example, on the main sorting channel 100, parcels are typically transported individually. Therefore, when a parcel falls from the main sorting channel 100 into a specific sorting sub-channel, the parcel loading system can accurately record the unique unloading timestamp of that parcel at the initial moment. Simultaneously, an RGBD camera 303 positioned on that sorting sub-channel detects newly arriving parcels in real time and obtains their arrival time. By spatiotemporally matching the unloading timestamp with the camera detection time, and further correlating this with the parcel's appearance characteristics (such as outline and color), a unique tracking identifier can be assigned to each successfully matched physical parcel. The parcel image corresponding to that parcel is then bound to this tracking identifier and stored.Subsequently, as the parcel moves along the belt conveyor 302 of the sorting sub-channel, the parcel tracking module uses continuously acquired image frames to continuously identify the same tracking identifier through motion prediction (such as Kalman filtering) and appearance similarity matching, constantly updating the position and orientation of the parcel. Even when parcels are stacked or partially obscured, the binding relationship can be maintained by relying on the layered information of the depth image and local feature matching until the parcel is transported to the working area of ​​the pallet module.

[0019] The crate module includes at least one robotic arm 200 and multiple crate carts. The robotic arm 200 can be a multi-joint industrial robot. The end effector of the robotic arm 200 can be equipped with suction cups, grippers, or combined clamps, depending on the type of package. Suction cups are suitable for flat cartons, while grippers are suitable for soft packages or irregularly shaped items. Multiple crate carts correspond to different sub-flow directions, and the same crate cart is used to collect packages within the same sub-flow direction. For example, crate carts corresponding to specific cities such as X1, X2, and X3 can be placed separately within the same sorting sub-flow channel. The robotic arm 200 is used to grab the corresponding package from the belt conveyor 302 of the sorting sub-flow channel based on the package profile provided by the package tracking module and place it into the crate cart corresponding to the sub-flow direction. In specific implementation, a guide camera can be placed above or to the side of the robotic arm 200 to obtain the precise pose of the package in three-dimensional space. Based on this, the grabbing path can be planned using the volume contour information in the package profile. Simultaneously, the robotic arm 200 can determine the position coordinates of the crate cart corresponding to the grabbed package based on the package profile sent by the package tracking module. In this way, the trajectory control algorithm and the cage car position coordinates can be used to place the packages into the corresponding cage cars. In addition, the optimal placement position of the packages can be determined according to the palletizing algorithm (i.e., calculating the optimal placement posture based on the package size and the remaining space in the cage car to maximize the volume ratio). When multiple packages arrive in succession, the robotic arm 200 processes them sequentially, thereby realizing the automatic sorting of packages with multiple sub-flow directions in a sorting sub-channel to different cage cars.

[0020] The parcel cage system provided in this application sorts parcels on the main sorting channel 100 into sorting sub-channels according to their major flow direction. In each sub-channel, a parcel tracking module and a cage module are independently set up. This enables the simultaneous processing of parcels with multiple sub-flow directions in one sorting sub-channel, that is, it realizes parcel sorting and cage filling of 1 to N flow directions, which greatly improves the utilization efficiency of the sorting sub-channel and the sorting and cage filling efficiency of parcels.

[0021] In some embodiments, at least one robotic arm 200 is used to grab the corresponding package from the sorting sub-channel and place it into the cage car with the corresponding sub-flow direction when the corresponding package is determined to be a normal package based on the package profile provided by the package tracking module and preset grabbing conditions.

[0022] Specifically, in this embodiment, the robotic arm 200 only grasps normal items. A normal item can refer to a package that can be successfully grasped by the end effector of the robotic arm 200 and has complete routing information. Specifically, whether a package is a normal item can be determined by preset grasping conditions, which may include successful grasping conditions and routing information conditions.

[0023] In this embodiment, the robotic arm 200 only performs the grasping and cage-loading operations when it determines that a package is a normal package based on the package profile and preset grasping conditions. This allows the robotic arm 200 to focus on processing packages that it can reliably pick up within its capabilities, thereby avoiding failures, pauses, or equipment damage caused by grasping unreliable objects. This significantly improves the continuity of the robotic arm 200's work, grasping success rate, and overall operational stability. Simultaneously, the grasping conditions include routing information, enabling the robotic arm 200 to automatically and accurately place each normal package into the corresponding flow cage, effectively avoiding missorting and improving sorting accuracy. Furthermore, the normal package-based operation mode allows the robotic arm 200 to operate at higher speeds and lower energy consumption, facilitating the processing of more packages per unit time.

[0024] In some embodiments, physical characteristics include packaging material type and shape characteristics, and the robotic arm 200 is used to determine whether the package is a normal package based on the following preset gripping conditions: When the tracking of a package is successfully confirmed based on the package profile provided by the package tracking module, the packaging material category and / or shape characteristics of the package are determined based on the package profile. When the packaging material category and / or shape characteristics of a package match the type of gripping actuator of a robotic arm, the package is determined to be a normal package.

[0025] Specifically, in this embodiment, the packaging material category can refer to the material type of the outer packaging of the express delivery, such as cardboard boxes, plastic bags, foam boxes, woven bags, etc. The shape characteristics can refer to the geometric parameters of the express delivery, including length, width, height, surface flatness, edge sharpness, and overall regularity (e.g., whether it is a cuboid, whether there are concave or convex or irregular protrusions). The robotic arm 200 is used to determine whether the express delivery is a normal item based on the following preset grasping conditions: First, it determines whether the tracking status of the express delivery is successful based on the express delivery profile provided by the express delivery tracking module, that is, whether the express delivery profile contains complete routing information uniquely bound to the physical express delivery. If tracking fails, it is directly determined to be an abnormal item (i.e., an anomaly), and no further judgment is made. Second, when it is determined that the express delivery tracking is successful, the packaging material category and / or shape characteristics recorded in the express delivery profile are matched with the type of grasping actuator currently installed or preset to be available on the robotic arm 200. A gripping actuator is a device installed at the end of a robotic arm 200 for directly contacting and picking up packages. Common types include suction cups (which use negative pressure to adhere to a flat surface), grippers (which grip from both sides using two or more finger-like structures), shovels (which lift from the bottom), or combination grippers. In practical implementation, compatible packaging materials and shape conditions can be pre-defined for each type of gripping actuator. For example, suction cup actuators are suitable for packaging materials with flat upper surfaces, no large gaps, and no air permeability (such as cardboard boxes or rigid plastic boxes), and the shape characteristics require that the upper surface area of ​​the package is not less than the diameter of the suction cup. Gripper actuators are suitable for packaging materials with a certain degree of compressibility or rigid edges (such as soft packaging, woven bags, and foam boxes), and the shape characteristics require that the minimum size of the package is not less than the minimum opening size of the gripper and the maximum size does not exceed the opening range of the gripper. For example, if the packaging type in the package image is cardboard and the surface flatness is listed as flat, and the robotic arm 200 is currently equipped with a suction cup, then the packaging type and shape characteristics of the package match the gripping actuator type, thus determining that the package is a normal item. If the package material is soft packaging and the robotic arm 200 is equipped with a suction cup, the suction will fail because the surface of soft packaging is easily deformed and leaks air, thus determining a mismatch, and the package is not a normal item.

[0026] Understandably, in some embodiments, matching rules can be dynamically adjusted in batches based on parcel profiles, according to sorting requirements. For example, when a large number of soft-pack parcels are detected to be arriving soon, the parcel crating system can issue a command to automatically move the robotic arm 200 to the tool rack to replace it with a gripper actuator (or, the end effector of the robotic arm 200 includes multiple types of actuators, and the robotic arm 200 can automatically change to an actuator adapted to the current parcel according to system commands), thereby expanding the scope of normal parcels.

[0027] This application embodiment can accurately identify normal parts that the robotic arm 200 can reliably grasp by matching the packaging material type and / or shape characteristics with the gripping actuator type, providing a reliable prerequisite for subsequent automatic cage loading.

[0028] Reference Figure 1 In some embodiments, at least one robotic arm 200 is further configured to generate an anomaly signal when the corresponding package is determined to be an abnormal package based on the package profile provided by the package tracking module and preset grasping conditions. Each sorting sub-channel is also provided with a manual operation area and a transfer device 500. The transfer device 500 is used to transport packages determined to be abnormal packages to the manual operation area based on the anomaly signal. The manual operation area is used to receive packages determined to be abnormal packages so that they can be manually crated in the manual operation area.

[0029] Specifically, in this embodiment, an abnormal item refers to a package that does not meet the reliable gripping conditions of the robotic arm 200. This includes two scenarios: first, package tracking failure, where the package image loses its binding relationship with the physical package due to stacking, obstruction, or sudden movement in the sorting sub-channel, preventing the robotic arm 200 from determining its sub-flow direction; second, successful package tracking but the packaging type and / or shape characteristics do not match the type of the robotic arm 200's current gripping actuator, for example, a suction cup cannot adsorb soft packages or a gripper cannot stably hold oversized packages. The abnormal signal can be an electrical signal or data command generated by the robotic arm 200's own control unit, used to trigger subsequent abnormal item handling procedures. Each sorting sub-channel also includes a manual operation area and a transfer device 500. The transfer device 500 refers to a conveying device used to transfer packages from the robotic arm 200's working area to the manual operation area, typically employing a powered roller conveyor, belt conveyor, or similar structure. The transfer device 500 starts downstream of the robotic arm 200's gripping station (e.g., connected to the belt conveyor of the sorting sub-channel itself) and ends in the manual operation area. The manual operation area is a fixed station at the end of the transfer device 500, typically equipped with an operating table, barcode scanner, etc., for manual handling of parcels. In practice, when the robotic arm 200 determines a parcel to be abnormal, it does not perform a gripping action on the parcel. Instead, it immediately generates an abnormal signal, or when the parcel is transported to the trigger position of the transfer device 500. Upon receiving the abnormal signal, the transfer device 500 activates the powered rollers or belt, transporting the abnormal parcel along the conveying direction to the manual operation area. Upon receiving the abnormal parcel, the operator manually scans the barcode to obtain routing information and manually places the parcel into the corresponding sub-channel's cage, completing the bottom-filling process. To improve efficiency, multiple individual cages can be set up in the manual operation area, equipped with displays indicating the current destination of the abnormal parcel. In addition, the transfer device 500 can also be equipped with sensors to detect whether abnormal items have been successfully transported to the manual operation area, and feed back the arrival signal to the control unit of the robotic arm 200 so as to clear the abnormal signal of the robotic arm 200 and record the processing result. Through the coordinated work of the transfer device 500 and the manual operation area, all abnormal items that the robotic arm 200 cannot handle can be automatically transferred to the manual processing station without the need for additional operation of the robotic arm 200, and without blocking the normal grasping process of subsequent express items, realizing the bottom-line stacking of express items.

[0030] Reference Figure 2 In some embodiments, the parcel crating system provided in this application may further include a handling module. The handling module is used to dispatch handling equipment to move the corresponding cage car to the loading area when a cage car crating completion signal is received, so as to load the parcels in the cage car.

[0031] Specifically, in this embodiment, the handling module can refer to the control unit responsible for scheduling automated handling equipment to complete the transfer of cage cars. The handling module is used to receive the cage loading completion signal and issue handling instructions. The cage loading completion signal can refer to an electrical signal or data message automatically generated by the express delivery cage loading system (or other modules) when a cage car has met the preset cage loading completion conditions. The handling equipment can refer to an automated mobile vehicle used to perform cage car transfer, such as AGVs or unmanned forklifts. The handling equipment has a lifting or traction mechanism, which can go under the cage car, lift it, and transport it to a designated location. The loading area can refer to a designated area in the sorting area near the transport vehicle docking platform, used to temporarily store cage cars that meet the cage loading completion conditions and wait for loading operations. The loading area usually has multiple cage car positions and corresponding vehicle parking spaces. In specific implementation, when the handling module receives the cage loading completion signal of a cage car, it first queries the available handling equipment (e.g., AGVs waiting at the charging station or in an available parking space), and calculates the optimal travel path from the current position of the handling equipment to the location of the cage car through a path planning algorithm. Then, a transport task is sent to the selected transport equipment via wireless communication. The task details can include the cage car's location, cage car ID, and destination loading area location. After receiving the task, the transport equipment automatically navigates to the cage car's location, uses laser or vision sensors to locate the cage car's lifting port or tow bar, completes the docking, lifts or mounts the cage car, and then transports it along the planned path to the designated berth in the loading area and releases it. Through the automatic scheduling of the transport module, a seamless connection between the cage cars and the loading area is achieved, reducing the labor intensity and waiting time of manual cage car handling.

[0032] In some embodiments, the parcel crating system provided in this application may further include a loading detection module. The loading detection module is installed on the crate car and is used to detect the loading rate inside the crate car, and generate a crating completion signal for the corresponding crate car when the loading rate reaches a preset threshold.

[0033] Specifically, in this embodiment, the loading detection module refers to a detection device and its associated data processing unit installed above or to the side of the cage car, used to assess in real time the proportion of space occupied by packages inside the cage car. The loading rate refers to the ratio of the actual volume of packages placed inside the cage car to the rated volume of the cage car, usually expressed as a percentage. The preset threshold can be a critical value for the loading rate pre-set based on the loading efficiency of the cage car and subsequent handling needs, for example, it can be set to 85% or 90%, without limitation. When the loading rate of a cage car reaches this preset threshold, it is considered that the cage car is basically full, and continuing to load packages may lead to wasted space or compression and deformation of the packages. In a specific implementation, one way to implement the loading detection module is to fix a 3D camera (i.e., a stereo vision sensor capable of simultaneously acquiring color images and depth information) directly above the cage car. The optical axis of the camera is vertically downwards, aimed at the inside of the cage car, and acquires three-dimensional point cloud data of the stacked packages inside the cage car at a certain frequency (e.g., once per second). The data processing unit analyzes the point cloud to obtain the current loading rate. Another implementation involves installing multiple through-beam photoelectric sensors (consisting of a transmitter and a receiver; when the stacked height of parcels exceeds the sensor's installation height, the beam is blocked, triggering a signal) on the side of the cage car. The sensors are arranged in layers along the height direction. The percentage of loading height is estimated by the number of blocked sensors, and the loading rate is approximated by combining this with the cage car's bottom area. When the loading rate calculated by the loading detection module reaches or exceeds a preset threshold, a cage loading completion signal is generated for the corresponding cage car. This signal can be a data message containing the cage car ID and a timestamp, sent via wired or wireless means to the parcel cage loading system, which then forwards it to the handling module, or sends it directly to the handling module. Through the above-mentioned loading detection module, it is possible to automatically and accurately determine when the cage car needs to be replaced (i.e., setting up a new empty cage car), providing a reliable triggering basis for the subsequent handling module.

[0034] In some embodiments, the loading detection module is further configured to detect the current gap data of the cage car, and when it is determined based on the current gap data that an unusable gap area will be formed inside the cage car after the current parcel to be grabbed is placed in the cage car, a cage-stacking pause signal is generated. At least one robotic arm is further configured to place parcels into the corresponding cage car according to the cage-stacking pause signal.

[0035] Specifically, in this embodiment, the loading detection module is further used to detect the current gap data inside the cage cart and determine whether placing the currently to-be-grabbed parcel into the cage cart will create a gap area that cannot be effectively utilized by subsequent parcels. Here, "a gap area that cannot be effectively utilized" (hereinafter referred to as an invalid gap area) refers to one or more large but irregularly shaped or isolated space areas left inside the cage cart due to improper size, shape, or placement of the newly placed parcel in the existing parcel stack. This prevents subsequent smaller parcels from filling these gaps, resulting in a loss of volumetric efficiency. For example, if the surface of the parcels already stacked in the cage cart presents a "peak" shape with a high center and low edges, placing a small parcel in the low-lying area will leave multiple narrow and shallow gaps around it, making it impossible to stably place subsequent parcels. For example, if a large package is already in a corner of a cage cart, and a medium-sized package is placed next to it but not placed close enough, a narrow gap will form between them. While the gap may be long and deep, its width is too narrow to accommodate any packages. A specific implementation method to determine that "continuing to load the cage will create an invalid gap area" can be: The loading detection module includes a 3D camera mounted above the cage cart. This camera acquires 3D point cloud data of the current stack of packages inside the cage cart and obtains the volumetric contour information (length, width, and height) of the package image to be grabbed. The data processing unit in the loading detection module runs a palletizing algorithm, simulating placing the package in all possible positions above the existing stack in different orientations (e.g., horizontal rotation of 0°, 90°, 180°, and 270°). For each simulated placement, the algorithm calculates all unoccupied space areas inside the cage cart after placement and extracts the circumscribed cuboid dimensions (length, width, and height) of each space area. If a placement scheme exists such that the largest usable cuboid size among all remaining gaps can still accommodate at least one package in the subsequent package queue (estimated based on package profile), then it is considered that no invalid gap area will be generated. Conversely, if all possible placement schemes result in the largest usable cuboid size of the remaining gaps being smaller than the minimum size of any subsequent package, or if the resulting gaps are all elongated, shallow, isolated, or otherwise unusable, then it is determined that "continuing to load the package will create an invalid gap area." When the loading detection module makes the above determination, it generates a cage-stacking pause signal for the currently to-be-grabbed package. After receiving the cage-stacking pause signal, the robotic arm 200 stops placing the currently to-be-grabbed package into the current cage car. At this time, the package will be transported to the manual operation area via the sorting subdivision channel transfer device 500, where it will be manually placed into a suitable cage car according to the package's routing information (either the current cage car is manually sewed, or it is placed into another cage car). In this way, the large gaps caused by the robotic arm blindly loading cages are avoided to a certain extent, and instead experienced personnel handle them flexibly to maximize the final loading rate of the cage car.Understandably, if it is determined that continuing to fill the cage will not create any invalid gaps, the robotic arm 200 will normally grab the package and place it into the corresponding cage cart. This judgment process can be performed in real time upon the arrival of each package, thus enabling dynamic decision-making.

[0036] In some embodiments, the robotic arm 200 or the loading detection module is also used to generate a call signal if an abnormal change in the stacking pattern is detected when the package is placed into the corresponding cage car.

[0037] Specifically, in this embodiment, after the robotic arm 200 normally grabs a package and places it into the corresponding cage cart, it can determine whether there is an abnormal change in the stacking pattern inside the cage cart. When an abnormal change in the stacking pattern is detected, a call signal is generated. This abnormal change in stacking pattern can refer to an unexpected change in the stacking shape of the packages already placed inside the cage cart, such as: stack collapse (i.e., packages that were originally stably stacked tilt entirely or partially due to a shift in the center of gravity, vibration, or the impact of newly placed packages), package slippage (e.g., cylindrical packages rolling away from their original position), partial collapse (upper-layer packages falling into the gaps between lower layers), or a tilting posture exceeding a set threshold. The call signal can refer to a command issued by the control unit of the robotic arm 200 or the data processing unit in the loading detection module to request manual intervention, which can manifest as an audible and visual alarm (e.g., a buzzer and warning light), a notification message pushed to the manager's handheld terminal, or a red warning icon displayed on the system monitoring interface. In practical implementation, before and after the robotic arm 200 performs the action of placing the package, it uses a camera mounted on its own end effector or a 3D camera fixed on the top of the cage to perform real-time imaging of the inside of the cage. Before the robotic arm 200 places the package, it collects reference point cloud data inside the cage to record the position and orientation of all currently placed packages. After the robotic arm 200 places the package into the cage and removes the end effector, it collects the current point cloud data inside the cage again and compares and analyzes the two point cloud data. If the comparison analysis results indicate that the displacement of any package exceeds a preset threshold (e.g., horizontal movement greater than 20mm or vertical settlement greater than 30mm), or its tilt angle exceeds a preset angle, or multiple point cloud clusters appear scattered in the originally neatly stacked packages (indicating a collapse), it is determined to be an abnormal change in the stacking shape. Another implementation method is to only monitor the impact of the newly placed package on the surrounding packages: before the robotic arm 200 grabs the current package, it records the point cloud characteristics of the packages in the vicinity of its target placement position. After placement, the same area is sampled again. If any packages are found to have moved out of their original positions, fallen over, or new point cloud fragments appear, it is immediately identified as a stacking anomaly. Through this stacking anomaly judgment mechanism, the robotic arm can autonomously identify stacking anomalies during the cage loading process and promptly call for manual intervention, preventing subsequent packages from being unable to be placed or from further deteriorating due to unstable stacking.

[0038] In some embodiments, the parcel tracking module is further configured to generate a sorting pause signal when it is determined that the number of parcels in the corresponding sorting sub-channel has reached a saturation threshold. The main sorting channel is also configured to pause the dispatch of parcels to the corresponding sorting sub-channel based on the sorting pause signal.

[0039] Specifically, in this embodiment, the saturation threshold can refer to the maximum number of parcels that a pre-set sorting sub-channel can accommodate. The saturation threshold can be determined based on the execution time of the robotic arm 200's gripping and placing actions, the length of the belt conveyor 302 in the sorting sub-channel, etc. The saturation threshold is used to prevent parcels from overflowing or squeezing each other due to complete channel blockage. The sorting pause signal can refer to a control command issued by the parcel tracking module, used to notify the main sorting channel 100 to temporarily stop allocating new parcels to the sorting sub-channel. In specific implementation, the parcel tracking module can also monitor and analyze the number of parcels in the sorting sub-channel in real time. When the number of parcels reaches or exceeds the preset saturation threshold, the parcel tracking module generates a sorting pause signal. Upon receiving the sorting pause signal, the main sorting channel 100 immediately stops distributing packages to the sub-sorting channel. For example, the swing wheel sorter or pneumatic pusher on the main sorting channel 100, upon receiving the pause signal, will no longer direct subsequent packages belonging to that category to the entrance of the sub-sorting channel, but will instead allow these packages to continue moving along the main channel. This flow control of the sub-sorting channels effectively prevents blockages and overflows caused by package accumulation, ensuring the smooth operation of the entire sorting line.

[0040] In some embodiments, the parcel crating system provided in this application further includes a return receiving device. The return receiving device is connected to the main sorting channel and is used to receive parcels that have not been assigned to the corresponding sub-sorting channel. The handling module is also used to schedule handling equipment to send the parcels in the return receiving device back to the main sorting channel for re-sorting.

[0041] Specifically, in this embodiment, the return receiving device can refer to a container located at the end or side of the main sorting channel 100, used to temporarily store parcels that failed to be successfully sorted to the sorting sub-channels due to reasons such as saturation of the corresponding sorting sub-channels, malfunction of the sorting execution mechanism, or missing parcel profile information. The entrance of the return receiving device can be connected to the end of the main sorting channel 100 via a chute or belt conveyor. When a parcel travels along the main sorting channel 100 to the end without receiving a sorting instruction, the end wheel or push rod of the main sorting channel 100 automatically pushes the parcel into the return receiving device. When the number of parcels in the return receiving device reaches a certain amount, the handling module can receive a full load signal from the return receiving device (which can be emitted by the weighing sensor or volume detection device in the return receiving device), and then dispatch an idle handling device to the location of the return receiving device. The handling device can then transport the return receiving device to the loading area of ​​the main sorting channel 100. The loading area is equipped with a feeding station or belt conveyor. Parcels from the return collection device are placed one by one at the beginning of the main sorting channel 100 via manual or automatic unloading. This allows the parcels to re-enter the sorting process. Through this return circulation mechanism, all parcels that have not been sorted in time can be automatically collected and re-entered into the sorting system, preventing parcel delays or losses and reducing the amount of manual labor required to handle these returned parcels.

[0042] The parcel cage-loading system provided in this application, through the organic linkage of multiple modules such as the parcel profiling module, parcel tracking module, robotic arm cage-loading module, and handling module, constructs a complete "1-to-N" cage-loading and sorting system applicable to various parcel types and multiple flow scenarios. Specifically, the parcel profiling module acquires the sorting information and physical characteristics of the parcels in one go on the main sorting channel and generates a parcel profile. The parcel tracking module tracks the parcels in real time and continuously binds the profiles in the sub-sorting channels, so that the robotic arm can accurately know the sub-flow of each parcel without secondary scanning. Thus, multiple sub-flow parcels can be caged simultaneously in one sub-sorting channel, greatly improving the utilization efficiency of the chute and sorting channel. The robotic arm automatically cages normal items based on preset grasping conditions, and optimizes the cage volume ratio using a palletizing algorithm. For abnormal items that fail to track or are physically mismatched, a transfer device automatically transports them to the manual operation area for handling. This achieves efficient collaboration between the robotic arm and humans, ensuring automated processing of over 80% of parcels while avoiding system downtime caused by robotic arm mismatch. The loading detection module monitors the loading rate and gap data within the cages in real time. When the loading rate reaches a preset threshold, it automatically generates a cage-filling completion signal, triggering the AGV to move the fully loaded cage to the loading area. It also generates a cage-pausing signal when it determines that continuing cage-filling will create large gaps, allowing manual filling to maximize the actual loading rate of each cage. Furthermore, the robotic arm can identify abnormal changes in the stack shape in real time during cage-filling and generate a call signal to ensure timely manual intervention to maintain stack stability. The active flow control mechanism monitors the number of packages in the sorting sub-channels through the package tracking module. When a saturation threshold is reached, upstream (i.e., the main sorting channel) sorting is suspended, preventing channel congestion and package accumulation. The return circulation mechanism uses a return receiving device to collect unsorted packages, which are then automatically returned to the main sorting channel by the handling module for re-sorting, forming a closed-loop flow. In summary, the embodiments of this application significantly improve the processing capacity, sorting accuracy, cage car volume utilization rate, and overall system stability and fault tolerance of the sorting system, while greatly reducing manual operation intensity and equipment costs. It has a high degree of automation, intelligence, and industrial applicability.

[0043] The embodiments described in this application are for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.

[0044] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this application, and may include more or fewer steps than shown, or combine certain steps, or different steps.

[0045] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0046] Those skilled in the art will understand that all or some of the steps in the methods disclosed above, as well as the functional modules / units in the systems and devices, can be implemented as software, firmware, hardware, or suitable combinations thereof.

[0047] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0048] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.

[0049] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of the units described above is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0050] The units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0051] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0052] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes multiple instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this application. The aforementioned storage medium includes various media capable of storing programs, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0053] The preferred embodiments of the present application have been described above with reference to the accompanying drawings, but this does not limit the scope of the claims of the present application. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and substance of the embodiments of the present application shall be within the scope of the claims of the present application.

Claims

1. A parcel crate loading system, characterized in that, The system includes: The sorting equipment includes a main sorting channel and multiple sub-sorting channels, each sub-sorting channel corresponding to a different major flow direction, and each major flow direction includes multiple sub-flow directions. A package profiling module is installed on the main sorting channel to acquire the sorting information and physical characteristics of packages, and to generate a package profiling based on the sorting information and physical characteristics. The main sorting channel is used to allocate packages to corresponding sub-sorting channels according to the package profile. Each sub-sorting channel is equipped with: A parcel tracking module is used to track parcels assigned to the sorting sub-channels in real time based on the parcel profile. The sorting module includes at least one robotic arm and multiple cage carts, each cage cart corresponding to a different sub-flow direction. The at least one robotic arm is used to grab the corresponding parcel from the sorting sub-channel and place it into the cage cart corresponding to the sub-flow direction based on the parcel profile provided by the parcel tracking module.

2. The system according to claim 1, characterized in that, The at least one robotic arm is used to, when the corresponding package is determined to be a normal package based on the package profile provided by the package tracking module and preset grasping conditions, grasp the corresponding package from the sorting sub-channel and place it into the cage car with the corresponding sub-flow direction.

3. The system according to claim 2, characterized in that, The physical characteristics include packaging material type and shape characteristics. The robotic arm is used to determine whether the package is a normal item based on the following preset gripping conditions: When the tracking of a package is successfully determined based on the package profile provided by the package tracking module, the packaging material category and / or shape characteristics of the package are determined based on the package profile. When the packaging material type and / or shape characteristics of the parcel match the type of gripping actuator of the robotic arm, the parcel is determined to be a normal parcel.

4. The system according to claim 2, characterized in that, The at least one robotic arm is also used to generate an abnormal signal when the corresponding express delivery is determined to be an abnormal delivery based on the express delivery profile and preset grasping conditions provided by the express delivery tracking module. Each sorting sub-channel is also equipped with a manual operation area and a transfer device. The transfer device is used to transport packages identified as abnormal items to the manual operation area based on the abnormal signal. The manual operation area is used to receive packages identified as abnormal items so that they can be manually stacked in the manual operation area.

5. The system according to claim 1, characterized in that, The system also includes: The transport module is used to dispatch transport equipment to transport the corresponding cage car to the loading area when a cage car loading completion signal is received, so as to load the express items in the cage car.

6. The system according to claim 5, characterized in that, The system also includes: A loading detection module is installed on the cage car to detect the loading rate inside the cage car and generate a cage loading completion signal for the corresponding cage car when the loading rate reaches a preset threshold.

7. The system according to claim 6, characterized in that, The loading detection module is also used to detect the current gap data of the cage car, and when it is determined from the current gap data that after the current parcel to be grabbed is placed in the cage car, an unusable gap area will be formed inside the cage car, a cage pausing signal will be generated. The at least one robotic arm is also used to stop placing packages into the corresponding cage car according to the cage pause signal.

8. The system according to claim 5, characterized in that, The express tracking module is also used to generate a sorting pause signal when it is determined that the number of express items in the corresponding sorting sub-channel has reached a saturation threshold. The main sorting channel is also used to pause the sorting of parcels to the corresponding sub-sorting channels according to the sorting pause signal.

9. The system according to claim 8, characterized in that, The system also includes: A return receiving device, which is connected to the main sorting channel, is used to receive parcels that have not been assigned to the corresponding sub-sorting channel; The transport module is also used to call the transport equipment to send the packages in the return receiving device back to the main sorting channel for re-sorting.

10. The system according to claim 6, characterized in that, The robotic arm or loading detection module is also used to generate a call signal if an abnormal change in the stacking pattern is detected when the package is placed into the corresponding cage car.

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