METHOD AND SYSTEM FOR MANIPULATING ARTICLES

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 669,093, entitled "Method and System for Reorienting Articles," filed on May 9, 2018, and U.S. Nonprovisional Application No. 16 / 405,060, filed May 7, 2019.TECHNOLOGICAL FIELD

[0002] Example embodiments of the present invention relate generally to a material handling system for manipulating items, and, more particularly, to a subsystem of the material handling system for manipulating the orientation of the items.BACKGROUND

[0003] Material handling systems can convey, sort, and organize items (e.g. cartons, cases, containers, shipment boxes, totes, packages, and / or the like) at high speeds. Depending on a configuration of the material handling system, the items may travel through the material handling systems in an unregulated manner or may be repositioned, reoriented, and / or consolidated into a single stream of items on conveyors and / or other locations. Material handling systems may rely on a conveyor controller and / or warehouse management system to organize items being conveyed and / or handled.

[0004] Generally, a material handling system may be required to handle items of different physical characteristics, for example, item type, item body shape, etc. For instance, in some cases, the material handling system handles items having a rigid body shape (e.g., totes, containers, cartons, heavy shipment boxes, and / or the like) or a flexible body shape (e.g. packages, polybags, envelopes, and / or the like). These items may need to be repositioned and / or reoriented through various stages of handling and processing by the material handling system. Typically, the material handling system include equipment adapted to handle the items depending on the physical characteristics. For instance, robotic tools are installed or deployed at various locations within the material handling environment, for picking the items and further manipulating these items (i.e. re-orienting and / or re-positioning the items).

[0005] Applicant has identified several technical challenges associated with handling items in a material handling system and other associated systems and methods. Through applied effort, ingenuity, and innovation, many of these identified challenges have been overcome by developing solutions that are included in embodiments of the present invention, many examples of which are described in detail herein. US9926138B1 discloses an item that is moving along a moving surface of an inventory conveyance system may be identified. An orientation of the item with respect to the moving surface may be determined based on sensing information that describes the item and a portion of the moving surface surrounding the item. A removal strategy for operating a robotic arm to remove the item from the moving surface may be determined based at least in part on the item and the orientation. The removal strategy may include a trajectory for the robotic arm to follow as part of removing the item from the moving surface. US4697689A discloses a system for manipulating articles, such as irregular mailpieces in the U.S. Postal Service mail processing system. The system receives an agglomeration of parcels into a first subsystem where the parcels are separated and are passed to a second subsystem where each parcel is manipulated until its addressee label is directed upward. The first subsystem includes a plurality of individually rotatable cylindrical rollers which form a support surface for the parcels. The rollers produce translation of a parcel by cooperative motion or separation of parts of a pile of parcels by differential motion. The second subsystem includes a high-friction, flexible conveyor belt which in a first mode supports a parcel and in a second mode forms a downward loop in which a parcel can be rotated and inverted. The parcels in both subsystems are manipulated by a five-axis robotic arm which is responsive to a machine vision system measuring the position and physical characteristics of each parcel. US6015174A discloses an end effector system. A vacuum type end effector is provided at the end of each of two robotic tooling fingers. Each vacuum type end effector includes a flexible bellows member on the end thereof such that it can be used for vacuum acquisition. Extending down from each finger to reside adjacent a respective bellows is a pinch member. Through robotic control of the movement of the fingers, finger gripping can be accomplished to grip an object between the two bellows using the pinch members for lateral support. As the part is captured between the two bellows, each bellows is compressed against its respective pinch member. In such manner, the bellows are at least partially collapsed such that a vacuum sensor located in the vacuum supply line to the bellows registers that a vacuum is present and, thus, a part has been acquired. That same vacuum sensor allows the robot to know when a part has been acquired by the bellows in the typical vacuum-type pick-up arrangement. WO2016 / 054561A1 discloses an apparatus and method for pattern creation. One aspect provides for measuring a dimension of an object and using the dimension to pick and place the object. A first input device conveys an object into contact with a feed forward unit. The contact causes displacement of the feed forward unit and conditions the object. A distance sensor measures a distance to a surface of the object. One aspect provides for maintaining a pattern of objects in a desired position and orientation. A first surface, second surface, and third surface are mutually orthogonal and meet at a point to form a lowest corner. One aspect provides for transferring a pattern from a universal surface with finger wall slats to an ultimate package. The apparatus comprises a crowder plate with crowder plate slats. A portion of the crowder plate slats are sized to pass between a portion of mating finger wall slats.BRIEF SUMMARY

[0006] The following presents a simplified summary to provide a basic understanding of some aspects of the disclosed material handling system. This summary is not an extensive overview and is intended to neither identify key or critical elements nor delineate the scope of such elements. Its purpose is to present some concepts of the described features in a simplified form as a prelude to the more detailed description that is presented later.

[0007] The claimed invention is as defined in the appended set of claims.

[0008] The above summary is provided merely for purposes of summarizing some example embodiments to provide a basic understanding of some aspects of the disclosure. Accordingly, it will be appreciated that the above-described embodiments are merely examples and should not be construed to narrow the scope of the disclosure in any way. It will be appreciated that the scope of the disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described below.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The description of the illustrative embodiments can be read in conjunction with the accompanying figures. It will be appreciated that for simplicity and clarity of illustration, elements illustrated in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements are exaggerated relative to other elements. Embodiments incorporating teachings of the present disclosure are shown and described with respect to the figures presented herein, in which: FIG. 1 illustrates a perspective view of a material handling system, in accordance with an embodiment of the present disclosure; FIG. 2 illustrates a top view of the material handling system of FIG. 1, in accordance with an embodiment of the present disclosure; FIGS. 3a-3e illustrate different views of a robotic tool, in accordance with one or more embodiments of the present disclosure; FIG. 4 illustrates an exploded view of the robotic tool, in accordance with one or more embodiments of the present disclosure; FIGS. 14a and 14b illustrate perspective views of a vision system of the material handling system, in accordance with one or more embodiments of the present disclosure; FIG. 15 illustrates a flow chart representing a method of manipulating an item by a material handling system, in accordance with various example embodiments described herein; FIG. 16 illustrates a flowchart representing another method of manipulating an item by a material handling system, in accordance with various example embodiments described herein; and FIG. 18 illustrates a flowchart representing a method of reorienting the item from a first orientation to a second orientation, by another end effector, in accordance with some example embodiments described herein. DETAILED DESCRIPTION

[0010] Some embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The terms "or" and "optionally" are used herein in both the alternative and conjunctive sense, unless otherwise indicated. The terms "illustrative" and "exemplary" are used to be examples with no indication of quality level. Like numbers refer to like elements throughout.

[0011] The components illustrated in the figures represent components that may or may not be present in various embodiments of the invention described herein such that embodiments may include fewer or more components than those shown in the figures while not departing from the scope of the invention.

[0012] Turning now to the drawings, the detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts with like numerals denote like components throughout the several views. However, it will be apparent to those skilled in the art that these concepts may be practiced without these specific details.

[0013] Typically, in a material handling environment having items with variable physical characteristics (e.g., length of the item, width of the item, height of the item, weight of the item, center of gravity of the item, body shape of the item, material strength of the item, and / or the like) the items are to be handled carefully by equipment, with a reliability so as to avoid any physical damage at a time of handling. Also, these items are handled by the equipment, such as, robotic tools and / or conveyors, at high speeds within the material handling environment. Accordingly, the robotic tools and / or other equipment within the material handling environment are required to operate at high speeds while still maintaining the reliability of handling the items and avoiding any mishandling which may cause a physical damage to the item during its manipulation.

[0014] Various example embodiments described herein relate to a material handling system for manipulating items. Manipulating these items may be referred to hereinafter throughout the description as picking the items, gripping the items, re-positioning the items, retrieving the items, lifting the items, moving of the items, and / or reorienting the items from a first orientation to the second orientation, by equipment of the material handling system. In accordance with said example embodiments, the material handling system includes a repositioning system comprising a robotic tool. The robotic tool includes a robotic arm portion and an end effector coupled to the robotic arm portion. The robotic tool is configured to manipulate an item in a first orientation and reorient the item to a second orientation. According to various example embodiments described herein, different configurations of the end effector can be used in the repositioning system for manipulating the items.

[0015] In another example embodiment, the end effector can be a vacuum gripper having one or more flexible suction cups and at least one rigid gripper for handling items of rigid or flexible body shapes. Other configurations of the end effector are also possible as illustrated and described hereafter.

[0016] According to said example embodiments, the material handling system also includes, a vision system having one or more sensors positioned within the material handling system. The vision system is configured to generate inputs corresponding to one or more characteristics of the item. Some example characteristics of items that may be generated by the vision system may include a size of the item, position of the item, body shape of the item, orientation of the item, edges or markings on the item, presence of marker or a label on the item, and / or positioning of a label on the item.

[0017] The material handling system also includes a controller. The controller is communicatively coupled to the repositioning system, the vision system, and / or other subsystems of the material handling system. The controller includes at least one processor configured to execute instructions to cause the material handling system to at least: identify by the vision system, the item in the first orientation, based on the one or more characteristics of the item generated by the vision system, initiate, by the repositioning system, picking of the item in the first orientation, and upon picking the item in the first orientation, reorient, by the repositioning system, the item to the second orientation.

[0018] Having described example embodiments related to the present disclosure at a high level, the design of the various devices performing various example operations is provided below.

[0019] FIG. 1 and FIG. 2 illustrate a perspective view and a top view, respectively, of a material handling system 100, in accordance with one or more embodiments of the present disclosure. The material handling system 100 may handle different types of items having varying physical characteristics. For example, the material handling system 100 can handle items (e.g., totes, containers, articles, shipment packages, boxes, envelops, paper bags, parcels, polybags, and / or the like) without limitation. The material handling system 100 may include a variety of components and / or subsystems, such as an induction conveyor, sortation system, chutes, identification systems, vision systems, robotic subsystems, and / or the like, for handling and processing items.

[0020] According to various example embodiments described herein, the material handling system 100 is configured to manipulate an item 110 from a first orientation to a second orientation. In this regard, according to some example embodiments, a repositioning system 105 of the material handling system 100 is configured to receive the item 110 in a first orientation from a chute 125 and / or a conveyor (not shown). The repositioning system 105 may further reorient the item 110 from the first orientation to a second orientation for placement onto a conveyor 130 and / or any downstream subsystem of the material handling system 100.

[0021] As shown, the material handling system 100 also includes a vision system 115 comprising include one or more sensors such as cameras, photo detectors, proximity sensors, infra-red sensors, and / or the like. The one or more sensors of the vision system 115 may be positioned at various locations within the material handling system 100. In some example embodiments, the one or more sensors of the vision system 115 are configured to generate inputs corresponding to one or more characteristics of the item 110. It should be noted that the vision system 115 is shown as a standalone camera in FIG. 1; however, the vision system 115 is not limited to the implementation shown in FIG. 1. The vision system 115 may include a network of imagers, sensors, cameras, identification systems, and / or the like, for determining characteristics of one or more items conveyed in the material handling system 100. The characteristics of the item 110 may be utilized by one or more subsystems in the material handling environment such as, but not limited to, the repositioning system 105, the vision system 115, and / or other equipment within the material handling system 100.

[0022] The material handling system 100 may further include, a control system (not shown) including a controller which may be communicably coupled with the repositioning system 105, the vision system 115, and / or other subsystems of the material handling system 100. In accordance with some example embodiments, the controller may include at least one processor that may execute instructions to cause the material handling system 100 to perform specific operations. In accordance with the embodiments of the present disclosure, the processor may execute instructions to cause the vision system to determine a first orientation of the item 110 to be conveyed. The processor may further execute instructions to cause the repositioning system 105 to receive the item 110 in the first orientation. Further, the processor may execute instructions to cause the repositioning system 105 to reorient the item 110 to a second orientation for placement onto a conveyor 130, such as a downstream conveyor within the material handling system 100. In this regard, the repositioning system 105 may include a robotic end effector for manipulating the item 110 including reorienting and repositioning of the item 110. Details related to the end effector of the repositioning system 105 and its associated operations, are described later in reference to FIGS. 3-18.

[0023] In accordance with an embodiment of the present disclosure, the item 110, such as a parcel, may have a label placed thereon. As described herein, a label may also refer to a marker, imprinted information, encoded information marked on a surface, and / or the like. In some example embodiments, a label may correspond to a printed medium including an identifier which includes coded information, such as a barcode, QR code, 2D-code, 3D-code, Direct part marking (DPM) code, and / or the like. The label may include information corresponding to the item, such as, but not limited to, identifier for uniquely identifying a product within the item, a type of the item, a type of the product, a size of the product, product manufacturer's information, weight of the item, delivery address of the item, and / or the like.

[0024] According to some example embodiments, information corresponding to the item 110 may be coded in an identifier, such as a barcode or a QR code, on the label associated with the item 110. Accordingly, for handling and processing the item 110, one or more subsystems of the material handling system 100 may scan the identifier on the label of the item 110 at different stages of conveyance. During conveyance, an orientation of the item 110 may change frequently. In some cases, the item 110 may be orientated such that the label may not be positioned in view of a label identification system. The label identification system may correspond to a scanner configured to scan an identifier on the label. For example, the label identification may correspond to a barcode scanner, optical reader, an RFID reader, a bi-optic scanner, and / or the like configured for scanning an identifier associated with the label.

[0025] As described above, the repositioning system 105 may reorient the item 110 in a label-up position such that an identifier and / or the label associated with the item 110 may be positioned on a top face of the item 110 for scanning. According to some example embodiments, the controller may determine an orientation of the item. For instance, the controller may determine, via the vision system 115, a first orientation of the item 110 in which a top surface of the item 110 includes the label. In this case, in response to determining that the top surface of the item 110 includes the label, the controller may instruct the repositioning system 105 and / or any other subsystem of the material handling system 100 to transfer the item 110 to the conveyor 130 in the first orientation, that is, without reorienting the item 110. Alternatively, the controller may determine, via the vision system 115, another orientation of the item 110 in which the top surface of the item 110 does not includes the label. In this regard, the controller may instruct the repositioning system 105 and / or any other subsystem of the material handling system 100 to transfer the item 110 to the conveyor 130 in a second orientation different from the first orientation. In the second orientation, the label of the item would be positioned on the top surface of the item, such that, the identifier on the label is exposed in a field of view of the identification system, thereby facilitating scanning of the identifier.

[0026] In accordance with one or more embodiments of the present disclosure, the repositioning system 105 may include a robotic tool having a robotic arm and an end effector. The repositioning system 105 is configured to have different configurations of the end effector customized for manipulating items based on its one or more characteristics (e.g., body shape, type of the item, surface material of the item, and / or the like). The end effector of the repositioning system 105 includes a vacuum gripper for manipulating the item 110. Different configurations of the end effectors of the repositioning system 105 are described hereinafter.

[0027] FIGS. 3a to 3e illustrate different views of a robotic tool 300 of the repositioning system 105 of the material handling system 100, as shown in FIG. 1 and FIG. 2, in accordance with an example embodiment. As shown, the robotic tool 300 may include a robotic arm portion 305 of a robotic arm (e.g., robotic arm 1235 illustrated in FIGS. 12a-12d) and an end effector 310 defined at an end thereof. The robotic arm may be any suitable robotic arm configured to provide sufficient degree of motion for picking, placing, repositioning, etc. an item and / or a group of items. According to some example embodiments, the robotic arm portion 305 is communicatively coupled to the control system that can control operations such as the movement, positioning, starting, and stopping, of the robotic arm portion 305. The control system of the item manipulation system 102 may initiate movement of the robotic arm portion 305 so as to position the end effector 310 to any of a picking position, gripping position, retrieval position, and a discharging position of the item 110, details of which are described hereafter.

[0028] In some alternate example embodiments, the robotic tool 300 including the robotic arm portion 305 and the end effector 310 may be controlled by a controller remotely positioned and / or any other subsystem of the material handling system 100 to pick the item 110 in a first orientation and reorient the item 110 to a second orientation for placement onto the conveyor 130.

[0029] The robotic arm portion 305, as shown in FIG. 3a, is rotatably attached to the end effector 310 through a mount 330. The end effector 310 may include any manipulator with a suitable gripping means, such as, but not limited to, vacuum, claw, finger, plate, and the like, for picking and handling the item 110.

[0030] In accordance with an example embodiment of the present disclosure, the end effector 310 may include a vacuum gripper 315, as shown in FIGS. 3a-3e. The vacuum gripper 315 may include one or more flexible suction cups 320 and / or one or more rigid gripper 325. For instance, in some example embodiments, the end effector 310 may define at its one end, a configuration of the vacuum gripper 315 having four flexible suction cups, positioned at a respective corner defined by a bottom surface of the vacuum gripper 315 and one rigid gripper positioned at a center of the bottom surface of the vacuum gripper. In an alternate example embodiment, the end effector 310 may include another configuration of the vacuum gripper 315 having six flexible suction cups and two rigid grippers positioned on the bottom surface of the vacuum gripper 315.

[0031] Accordingly, in various example embodiments, the end effector 310 may include different configurations of vacuum gripper 315 having varying number of flexible suction cups and / or rigid grippers so as to engage items of different body shapes and different characteristics (e.g., weight, center of gravity, etc.). In this way, items are not mishandled or dropped during a movement of the end effector 106 and / or re-orientation of the items, as the items are handled.

[0032] According to various example embodiments described herein, the robotic tool 300 may further include a vacuum source or a vacuum generator (not shown) for generating a vacuum suction force within the one or more flexible suction cup 320 and the one or more rigid gripper 325. In operation, the vacuum generator may draw vacuum suction force through the respective one or more flexible suction cups 320 and the one or more rigid gripper 325. For instance, in some example embodiments, the one or more flexible suction cups 320 and the one or more rigid gripper 325 may engage a surface of the item 110 based on a first vacuum suction force generated through the flexible suction cups 320 and / or a second vacuum suction force generated through the one or more rigid gripper 325. Each of the flexible suction cups 320 and the one or more rigid gripper 325 may be in fluidic communication with one or more vacuum generators (e.g., via a plenum or one or more vacuum rods (not shown)). In an example embodiment, the vacuum suction force drawn through the respective vacuum rods and through the respective one or more flexible suction cups 320 and the one or more rigid gripper 325 may enable the end effector 310 to engage a surface of the item 110 so as to manipulate the item 110.

[0033] In some examples, the one or more flexible suction cups 320 may be actuated by the controller to engage items having flexible body shape (e.g., parcels, polybags, paper bags, envelops and / or the like). In some examples, the one or more rigid gripper 325 may be actuated to grip items having rigid body shape (e.g., boxes, cartons, containers, totes, and / or the like). In some examples, both the one or more flexible suction cups 320 and the one or more rigid gripper 325 may be actuated for engagement of the item 110. Further, based on the body shape of the item 110 handled by the item manipulation system 102, varying amounts of suction forces may be generated through the respective one or more flexible suction cups 320 and the one or more rigid gripper 325.

[0034] As described above, the end effector 310 may be attached to the robotic arm portion 305 through a mount 330 such that the end effector 310 may be capable of rotating with respect to the robotic arm portion 305. For rotating an item 110, the vacuum gripper 315 may contact the item 110 in a first orientation. As described above, based on the position, size, and / or weight of the item 110, a vacuum suction force may be created in one or more of the flexible suction cups 320 and / or the one or more rigid gripper 325 for picking the item 110 in the first orientation.

[0035] In one or more example embodiments of the present disclosure, the robotic tool 300 may further include one or more sensors (e.g., a force sensor, a torque sensor, and / or a distance sensor) configured to measure characteristics of the item 110 (e.g., weight, position, orientation, center of gravity, size, etc.). Thus, the position, size, and / or weight of the item 110 may be determined by the robotic tool 300 or any other subsystem of the material handling system 100.

[0036] Further, in some example embodiments, the control system and / or any other subsystem of the material handling system 100 may determine, via the vision system 115, that the item 110 is to be manipulated from the first orientation to a second orientation. For example, the control system may determine a need of reorienting the item 110 before placing the item 110 onto a downstream conveyor and / or section of the material handling system 100. As an example, a label and / or a marker placed on the item 110 may be positioned upside down, the item 110 may have a longer edge that may jam in the downstream conveyor, or the item 110 may need to be oriented in a specific orientation to fit a palletizing pattern. Upon determining that the item 110 needs to be reoriented, the end effector 106 may be controlled to rotate about the mount 330 in order to change the position and / or the orientation of the item 110. In some embodiments, the end effector 106 may be rotated in a clockwise direction to rotate the item 110 within a range from about 0 degrees to about 180 degrees to align a label placed on the item 110 for scanning. Further, once the item 110 is reoriented, the robotic arm portion 305 may be moved to position the end effector 106 at a position so as to place the item 110 on the conveyor 130.

[0037] The vacuum gripper 315 of the end effector 310 also includes one or more ejectors that may be actuated for respective flexible suction cups 362 and / or the one or more rigid gripper 364 for releasing the item 110 onto the conveyor 130 in the second orientation. Accordingly, once the item 110 is reoriented, the robotic tool 300 may place the item 110 on the conveyor 130 and may activate one or more ejectors for respective one or more flexible suction cups 320 and / or the one or more rigid gripper 325 for releasing the item 110 onto the conveyor 130 in the second orientation. In an embodiment, the ejector may receive compressed air fed into the one or more flexible suction cups 320 and the one or more rigid gripper 325. It should be noted that the robotic tool 300 may reorient the item 110 in-hand while holding the item 110, or may reorient the item 110 in one or more steps while picking and / or placing the item 110.

[0038] FIG. 4 illustrates an exploded view of the robotic tool 300, in accordance with an embodiment of the present disclosure. The robotic tool 300 includes a robotic arm portion 305 attached to a robot flange adapter 405. The robot flange adapter 405 may include and / or be attached to at least one sensor 410 mounted on a sensor mounting flange 415. In an embodiment, the at least one sensor 410 may include a plurality of sensors (e.g., force sensor, torque sensor, distance sensor, and / or the like) to measure different characteristics of the item 110. In an embodiment, the at least one sensor 410 may determine a weight distribution and / or center of gravity of the item 110 and generate sensor data. Based on processing the sensor data generated by the at least one sensor 410, the control system may cause the vacuum generators to control generation of the vacuum suction force through each of the one or more flexible suction cups 320 and / or the one or more rigid gripper 325. The sensor mounting flange 415 is further attached to the vacuum gripper 315. The vacuum gripper 315 includes a dust plate 425 at the bottom of the vacuum gripper 315, as shown in FIG. 4.

[0039] In an embodiment, the robotic tool 300 further includes a laser range finder 430, as shown in FIG. 4. As shown, the laser range finder 430 is disposed on a distal end of the end effector 310. The laser range finder 430 is configured to identify (e.g., periodically or continuously over a period of time), the item 110 positioned in the first orientation. The laser range finder 430 is also configured to determine a distance at which the item 110 is positioned with relative to the vacuum gripper 315. For example, in some embodiments, the laser range finder 430 may determine the distance between a top surface of the item 110 and an end of the vacuum gripper 315 (e.g., between the one or more flexible suction cups 320 and the one or more rigid gripper 325). Based on the determined distance, the controller may cause the robotic arm portion 305 to position the end effector 310 into different operating positions. For instance, in some example embodiments, based on the determined distance communicated to the controller, the end effector 310 may be moved into at least one of: the picking position to pick the item 110 in the first orientation, the gripping position in which the one or more flexible suction cups 320 and / or the one or more rigid gripper 325 can be selectively actuated to grip the item 110, the retrieval position in which the end effector 310 is moved to retrieve the item 110 from amongst multiple items on a conveyor, and the discharging position, in which the end effector 310 is moved to place the item 110 in the second orientation by ejecting the item 110 engaged to the end effector 310 based on ejectors of respective of the one or more flexible suction cups 320 and / or the one or more rigid gripper 325. In accordance with some example embodiments herein, the laser range finder 430 may include a light source configured to emit a laser beam or light rays, and trace a time of flight of the emitted light to contact the item 110 and return to the laser range finder 430 (e.g., reflection).

[0040] FIGS. 14a and 14b illustrate a vision and control subsystem of the material handling system 100, in accordance with one or more embodiments of the present disclosure. An identification of the item 110 and its orientation, (e.g., a label up orientation), may be performed by a sensing system comprising one or more sensors. For example, in some example embodiments, a vision system 1400 may include the one or more sensors including a camera and / or multiple cameras (not shown) installed around an area in a material handling environment having the item 110 which is be handled by the repositioning system 105. In this regard, in some example embodiments, the one or more cameras of the vision system 1400, may feed image data to the controller, and the controller may analyze the images at a high rate to identify a position of the item 110, an orientation of the item, and / or a label placed on the item 110. In addition, the cameras and / or the controller may also assess physical characteristics associated with the item, (e.g., a size, weight, and / or the like) of the item 110. The one or more sensors of the vision system 1400 may also include, e.g., a laser sensor, force sensor, torque sensor, and / or the like, to monitor such physical characteristics of the item 110. The vision system 1400 and / or the controller may also make an initial assessment of the physical characteristics of the item 110 to select an item handling procedure based on which the end effector 310 of the repositioning system 105, handles the item 110. For example, in some cases, the controller may perform the initial assessment to determine at least one of a type of the item 110, body shape of the item, orientation of the item 110, and / or the like. For instance, in some cases, the controller may determine the item 110 to be a bag, a box, a tote, a polybag, an envelope, and / or the like. The initial assessment may be performed based on colleting sensor and / or image data, before picking the item and / or at the time of picking the item 110, and further throughout an item handling process.

[0041] Further, the vision system 1400 and / or the controller may classify the item 110 based on utilizing machine learning classification. In this regard, the sensor data and / or the images collected by the controller may be used as a training set to generate a trainable model for automatically classifying the item 110 and selecting an item handling procedure for the end effector 310 based on the classification of the item 110. The selection of the item handling procedure can be done, prior to picking of the item 110 by the end effector 310. In some cases, in order to adjust a picking strategy and enabling the end effector 310 to react to pick the item 110 by using feedback from one or more sensors, such as, a force, torque, and / or vacuum sensor, to make real time assessment of how to best handle motions of one or more subsystems of the material handling system 100 to successfully handle the item 110. Further, labels and / or other identifiers associated with the item 110 may be scanned while the item 110 is picked and / or is in motion.

[0042] FIGS. 15, 16, and 18 illustrates example flowcharts of operations performed by a material handling system for manipulating an item, in accordance with example embodiments of the present invention. It will be understood that each block of the flowcharts, and combinations of blocks in the flowcharts, may be implemented by various means, such as hardware, firmware, one or more processors, circuitry and / or other devices associated with execution of software including one or more computer program instructions. For example, one or more of the procedures described above may be embodied by computer program instructions. In this regard, the computer program instructions which embody the procedures described above may be stored by a memory of an apparatus employing an embodiment of the present invention and executed by a processor in the apparatus. As will be appreciated, any such computer program instructions may be loaded onto a computer or other programmable apparatus (e.g., hardware) to produce a machine, such that the resulting computer or other programmable apparatus provides for implementation of the functions specified in the flowcharts' block(s). These computer program instructions may also be stored in a non-transitory computer-readable storage memory that may direct a computer or other programmable apparatus to function in a particular manner, such that the instructions stored in the computer-readable storage memory produce an item of manufacture, the execution of which implements the function specified in the flowcharts' block(s). The computer program instructions may also be loaded onto a computer or other programmable apparatus to cause a series of operations to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus provide operations for implementing the functions specified in the flowcharts' block(s). As such, the operations of FIGS. 15, 16, & 18 when executed, convert a computer or processing circuitry into a particular machine configured to perform an example embodiment of the present invention. Accordingly, the operations of FIGS. 15, 16, & 18 define an algorithm for configuring a computer or processor, to perform an example embodiment. In some cases, a general purpose computer may be provided with an instance of the processor which performs the algorithm of FIGS. 15, 16, & 18 to transform the general purpose computer into a particular machine configured to perform an example embodiment.

[0043] Accordingly, blocks of the flowcharts support combinations of means for performing the specified functions and combinations of operations for performing the specified functions. It will also be understood that one or more blocks of the flowcharts, and combinations of blocks in the flowchart, can be implemented by special purpose hardware-based computer systems which perform the specified functions, or combinations of special purpose hardware and computer instructions.

[0044] FIG. 15 illustrates a flowchart describing a method 1500 for manipulating an item, by the material handling system 100, from a first orientation to a second orientation in a material handling environment. According to some example embodiments, at step 1502, the material handling system 100 may include means such as, the vision system (115, 1400) and / or the end effector 310, comprising one or more sensors from which at least one of a plurality of images comprising the item 110 or sensor data sensed by the one or more sensors, may be accessed by the controller. In this regard, in some examples, the one or more sensors may include, a force sensor, a torque sensor, a distance sensor, photo diodes, barcode scanners, RFID readers, and / or the like.

[0045] At step 1504, the controller of the material handling system may, via the vision system (115, 1400) process, either the plurality of images or the sensor data, to generate one or more characteristics of the item and a first orientation of the item 110. In some examples, the one or more characteristics comprise at least one of physical characteristics of the item 110, for example, a size of the item 110, body shape of the item 110, texture of the item 110, features like, edges, blobs on body of the item 110, surfaces of the item 110, label of the item 110, orientation of the label of the item 110, location of the label of the item 110, type of the item 110, identifier on the label of the item 110, distance of the item 110 from the end effector 310, and / or the like.

[0046] Moving to step 1506, the controller of the material handling system 100 may select an item handling procedure indicative of a configuration of the robotic tool 300, based on which the end effector 310 of the repositioning system 105 manipulates the item. In this regard, the controller may select the item handling procedure based on the identified one or more characteristics and the first orientation of the item, at step 1504. It may be understood that procedures for handling different items by robotic tools in a material handling system may vary depending on different physical characteristics of respective items. For instance, depending on a product type, in an example, the end effector 310 may be configured to manipulate the item 110 based on a first item handling procedure for grasping an item which is a hard-sided box. Similarly, in another example, the end effector 310 may be configured to manipulate the item 110 based on a second item handling procedure for grasping the item which is a flexible and squishy polybag. In some cases, an item handling procedure for which the end effector 310 is pre-configured may be adjusted based on the identified one or more characteristics of the item 110.

[0047] Based on the selected item handling procedure, at step 1508, the material handling system 100 may include the repositioning system 105 comprising the robotic tool to pick, by the end effector 310, the item in the first orientation. In this regard, the item 110 may be picked based on engagement of the item 110 with the end effector 310 using any suitable configurations of the end effector 310, as described earlier, in various embodiments related to FIGS. 3a-14b.

[0048] At step 1510, the material handling system 100 may include means such as the end effector of the repositioning system 105 to reorient the item in a second orientation. In this regard, the item 110 may be reoriented based on any of: flipping of the item 110 or rotating of the item 110 etc., via any configuration of the end effector 310 as described earlier, in various embodiments related to FIGS. 3a-14b.

[0049] FIG. 16 illustrates another flowchart describing another method 1600 for manipulating an item from a first orientation to a second orientation in a material handling environment by the material handling system 100, as described in reference to FIG. 1. In this regard, in some cases, it is required to operate the end effector 310 so as to, pick an item from a first conveyor, reorient the item, and place the item to either the first conveyor or a second conveyor. In accordance with some example embodiments, upon generating the one or more characteristics of the item 110, as described at step 1504 of FIG. 15, at step 1602, the material handling system 100 may include means such as, the vision system (115, 1400) to determine the first orientation of the item 110 to be conveyed on a conveyor such as, the conveyor 130. In this regard, at step 1604, the vision system (115, 1400) may determine if in the first orientation of the item 110, a top surface of the item 110 includes a label. Here, the top surface of the item refers to a surface of the item which is exposed to a field of view of one or more sensors of the vision system (115, 1400). In response to determining that the top surface of the item 110 includes the label, the method moves to step 1606, where the controller of the material handling system 100, may transfer the item to the conveyor 130 in the first orientation.

[0050] Otherwise, at step 1604, in response to determining that the top surface of the item 110 does not include the label, the method moves to step 1608, where the controller of the material handling system 100, may initiate, via the reposition system 105, reorientation of the item from the first orientation to the second orientation. Here, the second orientation the top surface of the item includes the label. To this extent, the reorientation of the item 110 may be performed using any configuration of the end effector 310 of the robotic tool 300 of the repositioning system 105, based on as described earlier, in various embodiments related to FIGS. 3a-14b. Thus, the controller of the material handling system 100 causes to manipulate the item 110, via the robotic tool 300, from the first orientation to the second orientation for cases, where the item 110 includes a label which is not positioned on a top surface exposed in a field of view of the vision system (115, 1400). Otherwise, the item 110 is conveyed as such, without any handling by the robotic tool 300 for reorienting the item 110.

[0051] FIG. 18 illustrates another flowchart representing a method 1800 of repositioning the item 110 from a first orientation to a second orientation, by another end effector, in accordance with some example embodiments. In this regard, the end effector comprises the vacuum gripper 315 having the one or more flexible suction cups 320 and / or the one or more rigid gripper 325, as described earlier in reference to FIGS. 3a-3e.

[0052] In accordance with some example embodiments, upon picking the item 110 in the first orientation by the repositioning system 105, as described at step 1508 of FIG. 15. For reorienting the item in the second orientation, the method 1800, at step 1802 includes, picking, by the end effector of the repositioning system 105, the item 110 in the first orientation. In this regard, the controller may selectively actuate one or more of the flexible suction cups 320 and / or the one or more rigid gripper 325 of the end effector 310 to cause engage of the item 110 with the vacuum gripper 315. For instance, in an example case, if the item 110 is of a flexible body shape such as, but not limited to, an envelope, a poly bag, a paper bag package and / or the like, the controller may actuate the one or more flexible suction cups 320 to grip the item 110 by vacuum suction force generated through the one or more flexible suction cups 320. Accordingly, in another example case, if the item 110 is of a rigid body shape such as, but not limited to, a tote, a container, a heavy box, carton, and / or the like, the controller may actuate the one or more rigid gripper 325 to grip the item 110 by vacuum suction force generated through the rigid gripper 325.

[0053] The method further includes, at step 1804, moving, the robotic arm portion 305 rotatably engaged to the end effector 310, to reorient the item 110 gripped by at least one of the one or more flexible suction cups 320 and / or the one or more rigid gripper 325 of the end effector, in the second orientation. In this regard, the end effector 310 may be rotated to change the orientation of the item 110 engaged to the vacuum gripper 315.

[0054] Further, upon moving the robotic arm, the method 1800, at step 1806 includes, placing, by the end effector 310 of the repositioning system 105, the item 110 in the second orientation. In this regard, upon placement of the item 110, one or more ejectors of the end effector 310 may eject the item 110 engaged with the vacuum gripper 315.

[0055] It must be noted that, as used in this specification and the appended claims, the singular forms "a," "an" and "the" include plural referents unless the content clearly dictates otherwise.

[0056] References within the specification to "one embodiment," "an embodiment," "embodiments", or "one or more embodiments" are intended to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of such phrases in various places within the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.

[0057] It should be noted that, when employed in the present disclosure, the terms "comprises," "comprising," and other derivatives from the root term "comprise" are intended to be open-ended terms that specify the presence of any stated features, elements, integers, steps, or components, and are not intended to preclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.

[0058] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

[0059] While it is apparent that the illustrative embodiments of the invention herein disclosed fulfill the objectives stated above, it will be appreciated that numerous modifications and other embodiments may be devised by one of ordinary skill in the art. Accordingly, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which come within the scope of the appended claims.

Claims

1. A material handling system (100) for manipulating items, the material handling system comprising: a repositioning system (105) comprising: a robotic tool (300), wherein the robotic tool comprises: a robotic arm portion (305), and an end effector (310), coupled to the robotic arm portion, and comprising a vacuum gripper (315) rotatably engaged to the robotic arm, wherein the vacuum gripper comprises at least one flexible suction cup and at least one rigid gripper cup adapted to grip an item and rotate about an axis to manipulate the item from a first orientation to a second orientation; a vision system (115), comprising one or more sensors positioned within the material handling system, wherein the vision system is configured to generate inputs corresponding to one or more characteristics of the item; and a controller communicatively coupled to the repositioning system and the vision system, wherein the controller comprises at least one processor configured to execute instructions to cause the material handling system to: identify, by the vision system, the item in the first orientation, including determining the first orientation of the item being conveyed on a conveyor; based on the one or more characteristics of the item generated by the vision system, initiate, by the repositioning system, receiving of the item in the first orientation; determine if in the first orientation of the item, a top surface of the item includes a label, marker, or barcode; in response to determining that the top surface of the item includes the label, marker, or barcode, transfer the item to the conveyor in the first orientation; and in response to determining that the top surface of the item does not include the label, marker, or barcode, initiate, via the repositioning system, reorientation of the item to the second orientation, wherein in the second orientation the top surface of the item includes the label, marker, or barcode, and transferring the item to the conveyor in the second orientation.

2. The material handling system (100) of claim 1, wherein the controller is further configured to: access, from the vision system (115), at least one of: a plurality of images captured by at least a camera of the vision system, wherein the plurality of images comprise the item, or sensor data collected from the one or more sensors; process, via the vision system, either the plurality of images or the sensor data to generate the one or more characteristics of the item (110), wherein the one or more characteristics comprise one or more of: a shape of the item, a weight of the item, an edge of the item, a label on the item, a marker on the item, or a category of the item; classify the item based on the one or more characteristics of the item; and based on the classification, select, an item handling procedure indicative of a configuration of the repositioning system based on which the repositioning system (105) manipulates the item.

3. The material handling system (100) of claim 1, wherein the robotic tool (300) further comprises one or more sensors, wherein the one or more sensors include at least one of a force sensor, a torque sensor, or a distance sensor.

4. The material handling system (100) of claim 1, wherein the repositioning system (105) is configured to receive the item (110) from a chute or a conveyor in the first orientation, wherein the chute or the conveyor is configured to receive the item from an upstream conveyor of the material handling system.

5. The material handling system (100) of claim 1, wherein the item (110) is positioned in the first orientation on a conveyor, wherein the conveyor is: a section of the material handling system positioned downstream from the repositioning system; or an induction conveyor for a sortation system of the material handling system.