AUTOMATED MODULAR SYSTEM FOR SORTING ITEMS AND SORTING PROCESSES

Abstract

A modular sorting and inventory storage system, comprising: a system for sorting articles (99), including: a plurality of transport units (50; 50a, 50b), each transport unit (50; 50a, 50b) being suitable for receiving an article (99) in a first position, each transport unit (50, 50a, 50b) comprising a conveyor (54) being suitable for ejecting the article (99) from the transport unit (50; 50a, 50b); a lifting unit (20) being suitable for vertically moving the transport units (50, 50a, 50b) from the first position to second positions, the conveyor (54) of each transport unit (50; 50a, 50b) being suitable at the second positions for ejecting the article (99) from the conveyor (54); an infeed conveyor (70, 70'; 70a, 70b, 70a', 70b') suitable for loading articles (99) onto the transport units (50; 50a, 50b);at least one inventory storage structure (200) supporting multiple storage positions arranged in at least one vertical column (C), each storage position comprising a container (300); and an inventory conveying system (100) comprising: at least one vertical track corresponding to the at least one vertical column (C); and a stock transport vehicle (106) coupled to the vertical track, the stock transport vehicle (106) comprising a vehicle body (108) and an end effector (110) supported by the vehicle body (108), the end effector (110) having a pair of tines (112) offset from each other to define a fork (113) configured to receive a container (300) between the pair of tines (112), the system being configured to transfer articles (99) sequentially from the infeed conveyor (70, 70'; 70a, 70b, 70a', 70b') to the transport units (50;50a, 50b), the lifting unit (20) moves the transport units (50; 50a, 50b) to desired second positions, where the conveyor (54) discharges the article (99) into the desired container (300), the stock transport vehicle (106) picking up the container (300) with the article (99) and delivering the container (300) to a discharge conveyor (74, 74').

Description

GENERAL STATE OF THE ART The present disclosure relates to automation and in particular an automated system for handling and sorting articles. A large number of different items arriving at a modern warehouse or distribution center must be sorted, for example (to name just one example) by placing items into a container that bears identification information. In a modern logistics center, the item might be a commercial product arriving in packaging, where it is placed together in a container and finally in external shipping packaging, such as a corrugated box, shipping bag, or the like. In a sorting center, the item might be the external packaging itself, which is placed in a Gaylord container or similar. There are many other examples of item sorting. US patent 2020 / 0172335 A1 discloses a method and a device for storing and retrieving items to / from a multitude of target areas. EP 2295155 A1 relates to a vertical sorting machine for items, in particular mail. This leads to the task of providing an improved sorting system and a corresponding method. This task is solved by a system or method according to the independent claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of an example of a modular automated system for sorting and storing items. Fig. 2 is a perspective front view of the system from Fig. 1. Fig. 3 is a perspective view of the sorting system from Fig. 1, with parts of the storage system omitted for clarity. Fig. 4 is a perspective view of parts of a sorting system from Fig. 3. Fig. 5 is an enlarged perspective view of a transport unit or conveyor from Fig. 3. Fig. 6 is an enlarged perspective view of parts of the automated system for sorting and storing items from Fig. 1. Fig. 7 is a perspective view of parts of the automated storage system from Fig. 1. Fig. 8 is a view of a part of the system from Fig. 7, with parts omitted for clarity. DETAILED DESCRIPTION An automated system for sorting, storing, and retrieving items in a high-volume environment is shown in Fig. 1. The items 99 in the embodiment of the figures represent a very large number of different or unique items handled in modern commerce, e.g., in a logistics center. A non-restrictive example of items 99 could be products provided by a manufacturer in their own packaging, products placed in outer packaging such as a corrugated cardboard box, a padded mailing bag, an envelope, or the like. Item 99 includes identification information, such as a barcode, a two-dimensional code, or the like. Referring to the right-hand sides of Figures 1 and 2, a modular automated system for sorting and storing items 99 comprises a lifting system 12, an inventory conveying system 100, an inventory storage system 200, an infeed conveyor 70, and an outfeed conveyor 74. The infeed conveyor 70 can be of any type, e.g., a conventional belt conveyor, roller conveyor, and the like. Other configurations, e.g., a tipping chute, drive rollers, and / or a pusher for ejecting the item, may be used. The term "conveyor" as used in this document includes any type of device for ejecting an item, including, but not limited to, the examples provided herein. The infeed conveyor conveys individual items 99 (i.e., separately, one at a time). The lifting system 12 comprises a vertical lifting unit 20 and transport units 50. The lifting unit 20 (in the embodiment shown in the figures) includes a track 22, which is designed as a closed endless loop. The track 22 includes parallel vertical sections 24, the upper ends of which are connected by a semicircular or curved section 26. The lower ends of the vertical sections 24 are connected by another semicircular or curved section 26. The lifting unit 20 can be actuated by any type of drive, e.g., a circulating chain drive around sprockets (not shown in the figures) to form part of the track 22. The chain transports spaced-apart carriages 44, which remain fixed with respect to the horizontal as they move along the track 22. A support 40 is attached to each of the carriages 44. The support 40, as shown, includes forks 42 that project from the carriage 44 and form a platform to hold a transport unit 50. Therefore, the drive (not shown in the figures) of the lifting unit 20 moves the supports 40 along the track 22, including, when necessary, vertically lifting the transport unit 50. Each carriage 44 moves such that the platform or the forks 42 remain horizontal throughout the entire movement around the carousel track 22, including through the curved track sections 26. Therefore, the transport units 50 remain horizontally aligned. The lifting unit 20 utilizes all the structures and actuators that enable the lifting function of the transport units 50, such as chain and gear drives, belts and pulleys, rack and pinion drives, and the like. Other configurations, structures, and functions are available. For example, the lifting unit 20 can (optionally) be a Prorunner® MK5 conveyor, commercially available from Qimarox BV. Each transport unit 50 (in the example shown in the figures) includes a pair of opposing peripheral side walls 52 and a band 54 extending between an inlet end 56 and an outlet end 58. As explained in more detail below, the inlet end and the outlet end can be reversed in several ways during use. The transport units 50 can be powered by a wiring harness extending through the carriage 44 and connected to a power supply via a slip ring or other electrical contacts (not shown in the figures) between stationary and moving parts. A wide variety of known technologies are suitable for supplying the transport units 50 with electrical energy, as will be understood by those familiar with power supply technology. Alternatively, a wiring harness / hose assembly (not shown in the figures) can connect the motors of the transport unit 50 to a power supply. A wiring harness and / or hose assembly can be used for the control cables to carry control signals between a controller and the transport units. Communication for control signals can also be wireless, as will be understood by those familiar with control signal communication technology.Other means of powering the transport units, e.g., batteries without restriction for motor operation, with the batteries being recharged inductively or by other means, are being considered. Designing transport units 50 to be lightweight and energy-efficient, and / or to operate at low voltage (e.g., 24 volts), may be advantageous in some circumstances. Referring again to Fig. 1 and Fig. 2, a second infeed conveyor 70' is located on the opposite side of the lifting system 12. Therefore, the lifting system 20 can be operated to position a transport unit 50 so that it picks up an article 99 from the first infeed conveyor 70, and either simultaneously or sequentially to position another of the transport units 50 so that it picks up another article from the second infeed conveyor 70'. Furthermore, as shown in the figures, each carrier can contain two transport units 50a and 50b. The present invention is not limited to a specific number of transport units on the carrier, since the upper limit for the number of transport units is merely a matter of design. When referring to first and second components or systems, the reference number is extended by the letter 'a' or 'b', as, for example, reference numbers 50a and 50b refer individually to the transport units on the same carrier 40. The reference number without an appended letter is used to refer generally to the component or system, e.g., reference number 50 to refer to any of the transport units. To feed the transport units 50a and 50b, a pair of first infeed conveyors 70a and 70b and a pair of second infeed conveyors 70a' and 70b' can be used. To demonstrate the function of system 10, the articles 99 are transported by the infeed conveyors 70a, preferably in a spatially separated manner. When the lifting system 12 is coupled in, a control system (not shown) has identification information associated with each article 99 and can verify this information, if necessary, using a scanner (not shown) and determine the presence and position of an article 99 using a sensor, e.g., a photoelectric sensor, a proximity sensor, or the like. The control unit actuates the lifting unit 20 to position a transport unit 50a at a distal end of the conveyor 70a such that the article 99 is discharged from the conveyor 70a onto the belt 54 of the transport unit 50a. The lifting unit 20 can be stopped while the transport unit 50a is in the position at the discharge end of the conveyor 70a, so that the lifting unit switches incrementally between positions, or the vertical speed of the carrier 40 can be selected so that the carrier 40 moves continuously and is timed to move past the discharge point of the conveyor 70a to pick up the article 99. The term "discharge" is used to refer to the discharge of the article 99, regardless of whether the conveyor is stationary or moving. The movement of the lifting unit 20 can be sequenced as desired to also position a specific transport unit 50 at a second location or position to discharge or eject the article 99 from the transport unit into a desired container 300, as explained in more detail below. In this respect, a transport unit 50 can, under certain circumstances, contain more than one article 99. For example, two articles 99 can travel together on the infeed conveyor 70a according to the instructions of the control system. Or the transport unit 50, which already contains one article 99, can be moved into a position to receive a second article 99 from the conveyor 70a according to the instructions of the control system.After the lifting unit 20 has positioned the transport unit 50 at a desired second location corresponding to a desired container 300, the belt conveyor 54 is activated to eject the article 99 into the corresponding container 300. As shown in the figures, a pair of first and second transport units 50a and 50b can pick up items from conveyors 70a and 70b. Transport units 50a and 50b then travel around track 22 to be positioned to pick up items 99 from the second infeed conveyors 70a' and 70b'. Referring to Fig. 7, an inventory handling system is configured to store the items 99 in containers 300 after the items have been unloaded from the transport units 50, and to retrieve the containers 300 containing the items 99. The inventory handling system shown in Fig. 7 has an inventory storage structure 200 configured to support the containers 300 located thereon. Each container 300 can be any suitable storage container configured to carry one or more inventory items, regardless of size, structure, whether open-topped or closed-topped, and other variables. Preferably, the inventory storage containers 300 are open-topped plastic containers configured to carry items in an e-commerce supply chain and are of a size that can be lifted by a single person or a robot. The storage structure 200 can be configured to support the storage containers 300 in a vertically oriented arrangement. Thus, the storage structure or rack 200 can support the storage containers 300 such that the storage containers 300 are arranged in multiple rows R and columns C. In the embodiment shown in Fig. 7, eight columns of containers 300 are shown to illustrate the modularity of the system 10. For example, the lifting unit 20 can have four transport units 50 per support 40, and two lifting units 20 can be positioned opposite each other on opposite sides of the rack 200 such that each of the eight columns C corresponds to the positions of the transport units. The inventory storage structure 200 is shown configured as a racking system. Alternatively, the inventory storage structure 200 can be configured like any other system that supports storage containers 300 in rows and columns, e.g., a mobile storage system in which the storage containers 300 can be rotated. For example, the mobile storage system can be implemented in a similar manner to that specified in U.S. patent application number 16 / 037,424, the teachings of which are hereby incorporated by reference as if set forth herein in their entirety. The inventory processing system also includes an inventory conveying system 100, which is arranged adjacent to the inventory storage structure 200 with respect to a second horizontal direction D2, which is essentially perpendicular to both the first horizontal direction D1 and the vertical direction V. The inventory conveying system 100 is configured to accumulate the inventory storage containers 300 on the inventory storage structure 200 and / or retrieve the inventory storage containers 300 from the inventory storage structure 200. In one example, the inventory processing system may include at least one separate destination storage location 400, which is separate from and distinct from the inventory storage structure 200. In some examples, the at least one separate destination storage location 400 may be a material handling device, such as a belt conveyor or a roller conveyor, arranged adjacent to the inventory conveying system 100.For example, the inventory conveying system 100 can be located between the at least one separate storage destination 400 and the inventory storage structure 200. The inventory conveying system 100 can be configured to transfer storage containers 300 between the separate destination storage location 400 and the inventory storage structure 200. For example, the separate destination storage location 400 can receive storage containers 300 from an upstream processing step (e.g., sorting), and the inventory conveying system 100 can be configured to move the storage containers 300 from the separate destination storage location 400 to the inventory storage structure 200 to accumulate the storage containers 300 on the inventory storage structure 200. Additionally or alternatively, the inventory conveying system 100 can be configured to retrieve the storage containers 300 from the inventory storage structure 200 and move the storage containers 300 to the separate destination storage location 400, which in turn transfers the storage containers 300 to downstream processing (such as...).packaging). With reference to Fig. 8, the inventory conveying system 100 according to one embodiment is shown without the inventory support structure 200. In general, the inventory conveying system 100 comprises at least one longitudinal track 102 extending along a longitudinal direction L. The inventory conveying system 100 comprises at least one transverse track 104 extending from the at least one longitudinal track 102 along a transverse direction T that is angularly offset from the longitudinal direction L. In one example, the transverse direction T can be substantially perpendicular to the longitudinal direction L, for instance, within +15 degrees of the perpendicular to the longitudinal direction L. The transverse track 104 is configured to travel along the at least one longitudinal track 102 along the longitudinal direction L. The inventory conveying system 100 comprises at least one inventory transport vehicle 106 configured to travel along at least one transverse track 104 in the transverse direction T. The at least one inventory transport vehicle 106 comprises a vehicle body 108 and at least one end effector 110 transported by the vehicle body 108. The at least one end effector 110 has a pair of tines 112 offset from each other to define a fork 113 configured to hold a storage container 300 between the pair of tines 112. The end effector 110 can be configured to move the pair of tines 112 inwards and outwards along a transverse direction A that is substantially perpendicular to the longitudinal direction L and the transverse direction T.The end effector 110, such as the pair of tines 112 of the end effector 110, can be configured to rotate relative to the vehicle body 108 about an axis extending along the transverse direction T. The at least one inventory transport vehicle 106 is configured to be detachably coupled to a storage container 300 and to transport the storage container 300 to either stack the storage container 300 on the storage structure 200 or to remove the storage container 300 from the inventory storage structure 200. In alternative embodiments, the inventory conveying system 100 can include end effectors other than forks, including any other suitable end effector configured to grasp an object from a storage structure 200. The inventory conveying system 100 can comprise either a single inventory transport vehicle 106 or multiple inventory transport vehicles 106 configured to travel along the transverse track 104. Each inventory transport vehicle 106 can carry one end effector 110. Additionally, the inventory conveying system 100 can include either a single transverse track 104 or multiple transverse tracks 104 offset from one another in the longitudinal direction L. Each transverse track 104 can carry at least one inventory transport vehicle 106 traveling transversely along the transverse track 104 and carrying one end effector 110. The multiple transverse tracks 104 can operate simultaneously for accumulating and / or retrieving storage containers 300, thereby increasing the rate at which the storage containers 300 can be accumulating and / or retrieving. In some examples, the multiple cross lanes 104 can be configured to serve shared sections of the inventory storage structure 200 (i.e.,(storage container 300, accumulating and / or retrieving). In other examples, the inventory storage structure 200 can be divided into storage sections offset from each other along the first horizontal direction D1, and each transverse lane 104 can be configured to serve a different storage section. The at least one longitudinal track 102 can include a first longitudinal track 102(1) that is elongated along the longitudinal direction L. In some examples, the at least one longitudinal track 102 can include a second longitudinal track 102(2) that is elongated along the longitudinal direction L. The first and second longitudinal tracks 102(1) and 102(2) can be spaced apart from each other along the transverse direction T. In some examples, the first and second longitudinal tracks 102(1) and 102(2) can be substantially parallel to each other, for example, within +15 degrees of parallelism. In such embodiments, the transverse track 104 can extend from the first longitudinal track 102(1) to the second longitudinal track 102(2). For example, the transverse track 104 can terminate at the first longitudinal track 102(1) and at the second longitudinal track 102(2). In some embodiments, the longitudinal direction L can be aligned with the first horizontal direction D1 and the transverse direction T with the vertical direction V, as shown in Fig. 1, so that the transverse track 104 is elongated along the vertical direction V. In alternative embodiments, the longitudinal direction L can be aligned with the vertical direction V and the transverse direction T with the first horizontal direction D1, so that the transverse track 104 is elongated along the first horizontal direction D1. Further details of the inventory conveying system are contained in the concurrently filed US patent application No. 16 / 253,868 entitled “Inventory Conveyance System That Transfers Storage Containers To And From A Vertically Arranged Array of Storage Containers”. A method for operating the inventory processing system involves transferring a container 300 from a specific storage position 202 of the inventory storage structure 200 to the discharge conveyors 74 and 74'. The method includes causing an inventory transport vehicle 106 to move along a longitudinal direction L and a transverse direction T, which are angularly offset from the longitudinal direction L, until the inventory transport vehicle 106 is aligned with a selected storage position 202 of the rack 200. This step may include moving the inventory transport vehicle 106 along a transverse track 104 in the transverse direction T until the inventory transport vehicle 106 is aligned transversely to the selected storage position 202.This step can additionally or alternatively include moving the transverse track 104 along at least one longitudinal track 102 in a longitudinal direction L until the inventory transport vehicle 106 is aligned longitudinally with the selected storage position 202. The inventory transport vehicle 106 can be moved along the transverse track 104 before the transverse track 104 is moved along the at least one longitudinal track 102, after the transverse track 104 is moved along the at least one longitudinal track 102, or while the transverse track 104 is moved along the at least one longitudinal track 102. The procedure may include a step to cause an end effector 110, carried by the inventory transport vehicle 106, to move relative to the vehicle body 108 in order to couple to or uncouple from a container 300 at the selected storage position 202. This step may include causing the end effector 110 to rotate relative to the vehicle body 108 about an axis extending along the transverse direction T until the end effector 110 faces the inventory storage structure 200. In some examples, causing the end effector 110 to rotate may include causing a motor 176 to rotate the end effector 110. This step may additionally or alternatively include causing the end effector 110 to move along a transverse direction A, substantially perpendicular to the longitudinal direction L. The step of causing the end effector 110 to move may include causing the end effector 110 to travel along at least one transverse path 162 of the stock transport vehicle 106. In some examples, causing the end effector 110 to move may include actuating an actuator 170, such as a linear induction motor, to cause the end effector 110 to travel along the at least one transverse path 162. In some examples, causing the end effector 110 to move may include causing wheels of the end effector 110 to travel along the at least one transverse path 162.In some examples, the step of causing the end effector 110 to move may involve moving the tines 112 of a fork 113 of the end effector 110 along the side walls 302 and 304 of a storage container 300 at the selected storage position 202 in order to couple the end effector 110 to the storage container 300 or to decouple the end effector 110 from the storage container 300. When container 300 is moved from shelf 200, the container, which holds one or more items 99, can be positioned on discharge conveyors 174 and 174'. In this context, rollers or similar structures on conveyors 174 and 174' can be spaced apart to allow the passage of the forks 113 of the end effector 110, thus depositing container 300 onto conveyors 174 or 174'. Other discharge mechanisms are considered that will be simple and understandable for those familiar with conveyor technology. A control system for implementing system 10 can receive data from one or more sensors (e.g., optical sensors, contact sensors, proximity sensors, etc.) arranged on and / or around the infeed conveyors 70, transport units 50, and / or outfeed conveyors 74. The control system can receive data on the motor position, torque, and similar parameters for the motors of any components.

Claims

A modular sorting and inventory storage system, comprising: a system for sorting articles (99), including: a plurality of transport units (50; 50a, 50b), each transport unit (50; 50a, 50b) being suitable for receiving an article (99) in a first position, each transport unit (50, 50a, 50b) comprising a conveyor (54) being suitable for ejecting the article (99) from the transport unit (50; 50a, 50b); a lifting unit (20) being suitable for vertically moving the transport units (50, 50a, 50b) from the first position to second positions, the conveyor (54) of each transport unit (50; 50a, 50b) being suitable at the second positions for ejecting the article (99) from the conveyor (54); an infeed conveyor (70, 70'; 70a, 70b, 70a', 70b') suitable for loading articles (99) onto the transport units (50; 50a, 50b);at least one inventory storage structure (200) supporting multiple storage positions arranged in at least one vertical column (C), each storage position comprising a container (300); and an inventory conveying system (100) comprising: at least one vertical track corresponding to the at least one vertical column (C); and a stock transport vehicle (106) coupled to the vertical track, the stock transport vehicle (106) comprising a vehicle body (108) and an end effector (110) supported by the vehicle body (108), the end effector (110) having a pair of tines (112) offset from each other to define a fork (113) configured to receive a container (300) between the pair of tines (112), the system being configured to transfer articles (99) sequentially from the infeed conveyor (70, 70'; 70a, 70b, 70a', 70b') to the transport units (50;50a, 50b), the lifting unit (20) moves the transport units (50; 50a, 50b) to desired second positions, where the conveyor (54) discharges the article (99) into the desired container (300), the stock transport vehicle (106) picking up the container (300) with the article (99) and delivering the container (300) to a discharge conveyor (74, 74'). Sorting and inventory storage system according to claim 1, wherein the lifting unit (20) is a carousel with an endless track, wherein the carousel includes carriers (40) suitable for conveying the transport units (50, 50a, 50b), wherein the sorting and inventory storage system is configured to be arranged close together with other sorting and inventory storage systems, so that the sorting and inventory storage system is modular. Sorting and inventory storage system according to claim 2, wherein the carriers (40) are designed to move on carriages (44) over the track, and wherein the carriers (40) and the transport units (50, 50a, 50b) are horizontal during the entire movement over the track. Sorting and inventory storage system according to claim 2, wherein the system comprises two or more transport units (50; 50a, 50b) on each carrier (40), two or more infeed conveyors (70, 70'; 70a, 70b, 70a', 70b') suitable for loading articles (99) onto the transport units (50, 50a, 50b), and two or more vertical columns (C) of containers (300). Sorting and inventory storage system according to claim 1, wherein the at least one inventory storage structure (200) comprises a pair of opposing inventory storage structures (200), wherein a first inventory storage structure (200) is arranged on a first side of the carousel and a second inventory storage structure (200) is arranged on a second side of the carousel. Sorting and inventory storage system according to claim 1, wherein the conveyor (54) of the transport unit (50; 50a, 50b) is a belt conveyor. System for sorting articles (99), comprising: two or more infeed conveyors (70, 70'; 70a, 70b, 70a', 70b') suitable for loading articles (99) onto two or more transport units (50; 50a, 50b); two or more transport units (50; 50a, 50b) suitable for receiving the articles (99) from the two or more infeed conveyors (70, 70'; 70a, 70b, 70a', 70b') in a first position, each transport unit (50; 50a, 50b) comprising a conveyor (54); a lifting unit (20) comprising supports (40), the two or more transport units (50, 50a, 50b) being attached to one of the supports (40), the lifting unit (20) being suitable for lifting the two or more Transport units (50; 50a, 50b) are moved vertically from the first position to second positions, wherein the conveyors (54) of the two or more transport units (50; 50a, 50b) are suitable for ejecting the articles (99) from the conveyor (54) at the second positions. System according to claim 7, wherein the lifting unit (20) is a carousel with an endless track. System according to claim 7, wherein the conveyor (54) of the transport unit (50; 50a, 50b) is a belt conveyor. System according to claim 8, wherein the carousel comprises carriers (40) adapted to move on carriages over the track. System according to claim 10, wherein the carriers (40) and the two or more transport units (50; 50a, 50b) are horizontal during the entire movement on the track. System according to claim 7, further comprising several containers (300) and a storage structure (200) with shelves for holding the containers (300), wherein the containers (300) correspond to the second positions, such that the transport units (50; 50a, 50b) eject articles (99) into the containers (300). Method for sorting articles (99) comprising the following steps: sequentially loading articles (99) onto conveyors (54) from transport units (50; 50a, 50b) at a first location; lifting the transport units (50; 50a, 50b) to second locations corresponding to a support structure; and inserting each of the conveyors (54) to discharge the articles (99) into containers (300) at the corresponding desired second positions; moving the containers (300) from the support structure onto transport vehicles (106); moving the transport vehicles (106) to at least one discharge conveyor (74, 74'); and loading the containers (300) onto the discharge conveyor (74, 74').

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