Portal of picking robots for sorting and using items

Description

FIELD OF THE INVENTION

[0001] The present invention relates to sorter systems for handling objects, specifically a stream of objects incoming in a 3D bulk. Specifically, the invention relates to a sorter system with pick and place robots for picking up incoming objects from a feeder and placing them directly in selected destination bins. The sorter system is suitable for such as: handling mail pieces, parcels, baggage, softbags, limp / non-rigid bags, polybags, items handled at a warehouse distribution, and items handled at a mail order distribution centre.BACKGROUND OF THE INVENTION

[0002] Sorters, for sorting objects such as mail and / or parcels or the like, normally include a sorter system based on a conveyor. The conveyor transports objects at a constant speed to a discharge position, and in accordance with a code or the like on the individual objects, the objects are discharged from the sorter at a given discharge position, i.e. at the destination selected for each object.

[0003] Normally, such sorter has a number of fixed positions, e.g. on totes or trays, where one single object is received and transported to the discharge to arrive at its final destination. Thus, to induct objects to the sorter from a 2D or 3D bulk of objects, e.g. an incoming stream of objects in 3D bulk, the objects needs to be singulated and placed on the fixed positions on the sorter. In sorter systems without automated inductions for handling the induction to the sorter, persons perform the rather unpleasant task of manually inducting objects to the sorter, either by placing objects directly on the sorter or by performing singulation and placing objects singulated on an induction which inducts the objects on the sorter.

[0004] Such a semi-automatic sorter system occupies a large area, especially if the system is required to have a high capacity, i.e. a high number of handled objects per time. This is caused by a high number of mechanical components involved in the handling of the objects from the input of objects in bulk to their final destinations, e.g. roller cages or other movable containers, thus being sorted and prepared for further handling.

[0005] WO 2019 / 207200 A1 (Zenrobotics) discloses a waste sorting gantry robot comprising a gantry frame, a manipulator for interacting with one or more waste objects to be sorted within a working area, and wherein the manipulator is moveably mounted on the gantry frame and the manipulator is moveable within the working area. A conveyor is used for moving one or more waste objects within the working area and at least one chute having a chute opening at least partially within the working area is provided for placing picked objects.

[0006] WO 2021 / 198053 A1 (Beumer Group) discloses a robot system for picking randomly shaped and sized object from a continuously moving stream of objects in bulk, and placing the object singulated and aligned on an induction or directly on a sorter. A control system processes a 3D image of objects upstream of a position of the pick and place robot, identifies separate objects in the 3D image, and selects which object to grip, based on parameters of the identified separate objects determined from the 3D image.SUMMARY OF THE INVENTION

[0007] In particular, it may be seen as an object of the present invention to provide a compact sorter system occupying a limited area and having at the same time a high capacity for sorting objects, and preferably the sorter system should be able to provide a high packet density in the destination bins in which the objects are placed.

[0008] In a first aspect, the invention provides a sorter system for handling a stream of objects of various shapes and sizes in bulk, as defined by appended claim 1.

[0009] Such sorting system has proven to be capable of providing a high rate of success in picking up objects in 2D or 3D bulk from the feeder and placing them directly in selected destination bins, thereby eliminating a traditional tilt tray or tote sorter. The principle of using a portal structure with pick and place robots for picking objects from a feeder system and placing directly in destination bins, e.g. roller cages, has proven to occupy only a limited area, and thereby the entire sorting system with a high capacity, i.e. a high amount of handled objects per hour, can be implemented with a small footprint.

[0010] The plurality of robot can be formed by rather simple robotic actuator components, and still, it has been found that it is possible to pick up objects from bulk reliably and fast, even in case of objects arriving at a constant speed in 3D bulk.

[0011] With a plurality of robots carried by one common portal structure, it has been found that it is possible to obtain a high total capacity, since the pick and place tasks can be coordinated for optimal utilization of the plurality of robots. Especially, a coordinated utilization can be obtained with embodiments having an additional feeder section transporting object in opposite direction of the first feeder section, since the additional feeder section can be used as an intermediate station for transferring objects between the plurality of robots. Furthermore, if the destination bin is known for the objects already when arriving to the pick and place robot system, a further advantage may be obtained in coordinating the pick and place tasks.

[0012] Still further, the sorter system can provide a high packet density of the destination bins, e.g. cage trolleys. Especially, the controller of the pick and place robot system may be arranged to operate the robots according to a filling strategy for each destination bin to ensure a high packet density by selecting objects with selecting to place objects in selected order with a suitable size and shape to provide a high packet density in each destination bin.

[0013] Implementations of a single robot has been tested to be capable of handling 1,500-2,000 handled objects per hour, depending on the layout of the system and the pick and place distances. The test has been performed with objects including rectangular shaped boxes of various size as well as plastic bags, laminated objects etc. Even with extra time required for careful placing of objects in the destination bins, at the same time ensuring a high packet density of the bins, a system having a plurality of robots can be designed to handle at least 3,000 objects per hour, e.g. more than 3,000 objects per hour. In case three or more robots are used, even higher handling capacities can be obtained.

[0014] In the following, by 'robot in gantry configuration' is generally understood a controllable device being controllable to move the gripper from one position in space to another position in space, i.e. basically the robotic actuator can move the gripper to a controllable position in space.

[0015] By 'singulated' is understood objects placed with a distance from each other.

[0016] By 'image of objects' is understood a sensed or measured representation of the physical configuration of objects. Preferably, the image has a sufficient level of detail to identify or classify single objects from a bulk of objects by means of appropriate processing. The image may be a visual image, e.g. obtained by a 2D or 3D camera. However, other technologies may be used as well, e.g. using laser scanners or other scanner technologies providing an image by non-visual sensing or measurement techniques etc.

[0017] By 'manipulator' is understood a device or element arranged to engage with an object to move the object, so as to allow the object to be transferred from a position on the feeder section to a selected bin. This device or element may be a simple element arranged to slide or push an object, or it may be a gripper, i.e. a device with one or more suction cups or controllable fingers or the like to pick and object to allow the robot to lift and move the object.

[0018] Each object may have an identification code, such as: a bar code, a postal code, an ID tag, RFID tag, or the like. By scanning the identification code with the scanner of the scanner system, information can be read which allows the sorter system to determine a destination bin for the specific object.

[0019] Even though the sorter system is suited for handling incoming objects in a 3D bulk, it is to be understood that the sorter system can therefore also handle incoming objects in 2D bulk. However, the preferred embodiments that will be described have been tested to function even with randomly shaped and sized objects arriving in 3D bulk on the first feeder section to the pick and place robot system.

[0020] By 'lines of bins' is understood either a straight line of bins, or a curved line of bins.

[0021] In the following, preferred features and embodiments will be described.

[0022] Preferably, the first transport direction and a longitudinal axis of the portal structure are parallel, and preferably the first and second lines of destination bins are also parallel with the first transport direction. Hereby a compact and rather simple setup is provided. Especially, the first feeder section may be formed by a straight conveyor or a cascade of separate conveyors.

[0023] In some embodiments, the feeder system comprises a second feeder section arranged within reach of the pick and place robot system, preferably arranged within a width of the portal structure, and wherein the second feeder section is arranged to transport objects in a transport direction being opposite the first transport direction, such as the second feeder section being arranged adjacent to the first feeder section, such as the first line of destination bins being arranged adjacent to the first feeder section, such as the second line of destination bins being arranged adjacent to the second feeder section. Such feeder system allows the pick and place robot system can utilize the second feeder section as an intermediate parking area for objects in order to optimize a total capacity of the system. This can be achieved by optimized use of a capacity of each of the robots, e.g. by controlling two of the robots to cooperate in picking and placing an object by using the second feeder section to transfer the object from one robot to the other. Preferably, the pick and place robot system is arranged to pick one object from the first feeder section and to place the object on the second feeder section. Especially, the control system of the pick and place robot system may be arranged to optimize a total capacity of the plurality of robots by selecting to place an object on the second feeder section.

[0024] In some embodiments, at least one scanner of the scanner system is arranged upstream of the first feeder section, and wherein the control system of the pick and place robot system is arranged to distribute pick and place tasks to the respective ones of the plurality of robots based on known positions of destination bins for each of the objects arriving on the first feeder section. With such prior knowledge of the destination bins for each individual object arriving and their time of arrival, the control system of the pick and place robot system can distribute the pick and place tasks to the individual robots effectively. Especially, the control system of the pick and place robot system may be arranged to optimize a total capacity of the plurality of robots by selecting to control one of the plurality of robots to place an object on the second feeder section, and to control another one of the plurality of robots to pick said object from the second feeder section and to place said object in the selected destination bin.

[0025] In some embodiments, the scanner system is configured to read information on an object when picked by one of the plurality of robots, and wherein the control system of the pick and place robots is configured to determine, whether to control said one robot to place the object in its destination bin or whether to control said robot to place the object on the second feeder section. This may be implemented by the robot moving the object through a scanner tunnel or the robot itself may carry a scanner. Without any prior knowledge of destination bin for an object picked up by a random one of the robots, the control system determines whether the destination bin is within reach of the robot, or whether another one or the plurality of robots is closer to the destination bin, and therefore the objects can be transferred to final placing by another robot by placing the object on the second feeder section. This could also be done to simply distribute tasks among the robots.

[0026] In some embodiments, the feeder system comprises a second and a third feeder section arranged within reach of the pick and place robot system, and wherein one of or both of the second and third feeder sections is arranged to transport objects in a transport direction opposite the first transport direction, such as the first feeder section being arranged adjacent to both of the second and third feeder sections, or such as the first feeder section being arranged adjacent to the first line of destination bins. With two additional feeder sections, further possibilities for distributing tasks among the robots exist compared to embodiments with one additional feeder section by selectively use the two additional feeder sections as an intermediate parking area for objects, e.g. to transfer an object between two robots. Especially, the control system of the pick and place robot system may be arranged to control robots to pick objects from the first feeder section and to place objects selectively on the second or third feeder section. Especially, all of the first, second and third feeder sections may be arranged to transport objects on respective surfaces being on one common vertical level. With such aligned heights all of the three feeder sections, object handling is facilitated for the robots.

[0027] Preferably, the pick and place robot system is arranged to sense a lowest point of space in a destination bin and to place an object on said lowest point of space in the destination bin. Especially, the control system of the pick and place robot is arranged to determine a weight of an object and to control placing of the object in a destination bin accordingly, so as to ensure careful handling of objects and at the same time minimize time for performing the task of placing objects. Hereby, a careful handling of objects can be achieved, and at the same time a good packet density in each bin can be obtained.

[0028] The control system of the pick and place robot is configured to control the plurality of robots according to a packet strategy for each of the destination bins, taking into account at least a size of objects to be placed in each destination bin, and a time of arrival to the plurality of robots of objects be placed in each destination bin, so as to optimize a filling or packet density of each destination bin. This allows a high packet density of the destination bin, thereby ensuring a high utilization of total space required for the sorter system and the further handing of the objects, and also the space required for the further handling of the destination bins in further transport of the objects.

[0029] In some embodiments, the sorter system comprises a system configured to distribute objects upstream of the first feeder section, such as a system configured to distribute objects in 3D bulk to objects in 2D bulk. Especially, the system may be configured to singulate objects upstream of the first feeder section. Such system can facilitate the task of picking objects for the pick and place robot system and thus helps to increase a handling capacity of the pick and place robot system.

[0030] In some embodiments, the sorter system comprising a return conveyor arranged to return objects which have not been picked by the pick and place robot system, such as a return conveyor positioned below the first feeder section and arranged to transport objects from an end of the first feeder section to a position upstream of the first feeder section. Hereby, a temporal overload of the pick and place robot system exceeding its handling capacity can be overcome, since objects can then be reintroduced to the robots on the first feeder section. Especially, the control system may be configured to keep track of objects reintroduced and to prioritize such objects in the handling by the pick and place robots. Especially, the control system may select to avoid picking an object if its destination bin is known, and it is not possible for the object to fit in the destination bin at that time, or placing the object in its destination bin at that time would result in a poor pack density of that destination bin.

[0031] In some embodiments, a plurality, e.g. 2-4, lines of destination bins, such as parallel lines of destination bins, arranged on each side of the first feeder section, wherein said plurality of lines of destination bins are arranged within reach of the pick and place robot system. This may further help to reduce the area occupied by the sorter system, since such plurality of lines of destination bins can form a compact destination area for the pick and place robots.

[0032] In some embodiments, the first feeder section is placed at an elevated position, so as to allow the destination bins to be transported below the feeder section. Especially, the first feeder section is elevated so that a filled destination bin may be manually or automatically rolled below the first feeder section from one side of the first feeder section to the opposite side of the feeder section, and at the same time the feeder section transports objects on its surface at a vertical level above the transporting of the bins. This allows a flexible handling of the destination bins, which further helps to reduce the area required for the sorter system.

[0033] In general a destination bin could be a box, a container, a roller container, or a bag or the like. The individual bins may be manually or automatically moved out of the lines of destination lines when filled and replaced by empty bins.

[0034] In some embodiments, the destination bins are roller bins arranged to be rolled in and out of said lines of destination bins either manually or by means of an actuator. Especially, the destination bins may be roller cages or cage trolleys.

[0035] In some embodiments, the portal structure may be a curved structure or at least has a curved part, i.e. wherein the portal structure has a horizontal structure carrying the plurality of robots, wherein this horizontal structure is curved to form a curved set of rails on which the plurality of robots can move.

[0036] In some embodiments, a bin is located at an end of the first feeder section to collect objects which have not been picked by the pick and place robot system.

[0037] In a second aspect, the invention provides for the use of a system as defined in claim 17.BRIEF DESCRIPTION OF THE FIGURES

[0038] The invention will now be described in more detail with regard to the accompanying figures. The figures show one way of implementing the present invention and is not to be construed as being limiting to other possible embodiments falling within the scope of the attached claim set. FIG. 1 illustrates a block diagram of a sorter system embodiment, FIG. 2 illustrates a 3D drawing of an embodiment with a single wide feeder section for transporting singulated objects to the pick and place robot system, FIG. 3 illustrates a 3D drawing of an embodiment with three separate feeder sections wherein the central feeder section transports objects in the opposite direction of the outer feeder sections, FIG. 4 illustrates a 3D drawing of an embodiment with a central feeder section for introducing objects and two outer feeder sections connected to form a loop, FIG. 5 illustrates a 3D drawing of an embodiment with a single feeder section and a cascade of conveyors and a scanner upstream of the feeder section to distribute objects before they are introduced to the feeder section and to provide knowledge of destination bins for the objects when arriving to the pick and place robots, FIG. 6 illustrates an example of a robot with a gripper with suction cups in an adjustable and controllable configuration, FIG. 7a and 7b illustrate a preferred suction cup gripper with an adjustable gripper configuration and a rotation and tilting mechanism to allow the gripper to be used with a gantry robotic actuator, and FIG. 8 illustrates steps of a method embodiment. DETAILED DESCRIPTION OF AN EMBODIMENT

[0039] FIG. 1 illustrates a block diagram of a top view of a sorter system embodiment with a single feeder section F1 arranged to transport objects (shaded boxes) in a transport direction (bold arrow) along a longitudinal direction X. The feeder section F1 receives objects from an upstream feeder F0. The objects arrive to the feeder section F1 in 2D or 3D bulk.

[0040] Two lines (dashed lines) of destination bins B1, B2 are arranged adjacent to the feeder section F1, on respective sides of the feeder section F1 and parallel with the longitudinal direction X.

[0041] A pick and place robot system serves to pick objects from the feeder section F1 and place the objects in selected ones of the destination bins B1, B2. The pick and place robot system has a portal structure PS with two parallel rails RL1, RL2 which carries four controllable robots R1, R2, R3, R4 in a gantry configuration and positioned at respective positions along the rails RL1, RL2. The robots R1, R2, R3, R4 are controlled to move along the rails RL1, RL2 of the portal structure PS, controlled by a control system CS. Each of the robots R1, R2, R3, R4 has a controllable gripper G arranged for picking objects. The gripper G may have a plurality of suction cups for gripping an object. Especially, the gripper may have a controllable configuration to allow adaptation to optimal gripping of differently sized and shaped objects. The control system is arranged to control both movement of the robots R1, R2, R3, R4 in both X and Y directions as well as a vertical direction, and further the control system CS is arranged to control the function of the grippers G.

[0042] A scanner SC serves to read information on each of the objects, e.g. by scanning an identification code or the like. Data indicative of the read information is provided to the control system CS, so as to allow the pick and place robot system to place each object in a destination bin selected in accordance with information read, e.g. a read ZIP code or the like.

[0043] In the shown embodiment the scanner SC is located upstream of the robots R1, R2, R3, R4, and thus the control system CS can, e.g. along with a visual identification based on a vision system (not shown), navigate the robots R1, R2, R3, R4 to pick an object, and to directly place the object in the selected destination bin. Hereby an effective sorting is provided, occupying only a limited area.

[0044] FIG. 2 illustrates a 3D drawing of an embodiment having a basic configuration similar to the block diagram of FIG. 1, namely with one single feeder section F1 for transporting to the pick and place robot system in a transport direction (bold arrow). In the embodiment on FIG. 2, a singulation system upstream of the feeder section F1 serves to provide objects singulated to the feeder section F1, so the feeder section F1 transports singulated objects to the robots R1, R2, R3, R4 carried on the portal structure PS.

[0045] The lines of destination bins B1, B2 adjacent to the feeder section F1 are here shown as roller cages or trolleys. Both the feeder section F1 and the destination bins B1, B2 are positioned within the portal structure PS and are parallel with a longitudinal axis of the portal structure PS, namely a direction parallel with the transport direction (bold arrow).

[0046] The feeder section F1 is shown here to be rather wide compared to a width of the portal structure PS, and the width of the feeder section F1 may especially be at least 50% of a width of the portal structure, such as 50-90%, such as 60-80% of a width of the portal structure.

[0047] FIG. 3 illustrates a 3D drawing of an embodiment which is similar to the one in FIG. 2 with respect to the portal structure PS, the robots R1, R2, R3, R4, and the destination bins B1, B2 arranged on lines. However, in the embodiment of FIG. 3, three separate and parallel feeder sections F1_1, F1_2, F3 are located within the portal structure PS to transport objects in directions (bold arrows) being either the same or opposite directions. As seen, the outer feeder sections F1_1 and F1_2 are arranged adjacent to the central feeder section F2. Feeder section F1_1 is arranged adjacent to the first line of destination bins B1, and feeder section F1_2 is arranged adjacent to the second line of destination bins B2. All of the three feeder sections F1_1, F1_2, F2 are arranged to transport objects on respective surfaces being on one common vertical level.

[0048] The two outer feeder sections F1_1, F1_2 serve to receive objects and to introduce objects from a source upstream of the pick and place robots system PS, R1, R2, R3, R4, while the central feeder section F2 transports objects in the opposite direction of the outer feeder sections F1_1, F1_2, and this central feeder section F2 serves as an intermediate area or space for parking of objects by the pick and place robots. The robots R1, R2, R3, R4 are arranged to pick objects from all of the three feeder sections F1_1, F1_2, F2. The robots R1, R2, R3, R4 are arranged to place objects on the central feeder sections F2, so as allow coordination of pick and place tasks between the plurality of robots R1, R2, R3, R4.

[0049] Especially, the scanner system may comprise a scanner located upstream of the feeder sections F1_1, F1_2, F2 to read information of destination bins for each object upstream of the robots R1, R2, R3, R4, and the control system of the robots R1, R2, R3, R4 may then be configured to coordinate pick and place tasks of the plurality of robots R1, R2, R3, R4 based on knowledge of a position of a destination bin for each object. Especially, the control system of the robots R1, R2, R3, R4 can be configured to coordinate pick and place tasks of the robots R1, R2, R3, R4 by controlling one of the robots R1, R2, R3, R4 to pick an object on one of the outer feeder sections F1_1, F1_2 and to place the object on the central feeder section F2, and to control another one of the plurality of robots to pick said object from the central feeder section F2 and to place said object in a destination bin B1, B2. In this way a capacity of the robots R1, R2, R3, R4 can be utilized taking into account e.g. the position of the robots R1, R2, R3, R4, position of the objects and the position of their destination bins B1, B2.

[0050] In the shown embodiment, all of the three feeder sections have the same width, however it is to be understood that their widths may be different, if preferred.

[0051] FIG. 4 illustrates a 3D drawing of an embodiment with a central feeder section for introducing objects and two outer feeder sections connected to form a closed loop. The pick and place robot system PS, R1, R2, R3, R4 and the destination bins B1, B2 are similar the embodiments of FIG. 2 and 3. However, in FIG. 4 three feeder sections F1, F2, F3 are arranged adjacent to each other, wherein the central section F1 serves to receive objects and to introduce objects from a source upstream of the pick and place robots system PS, R1, R2, R3, R4. Especially, the central feeder section may transport objects in 2D or 3D bulk to the robots R1, R2, R3, R4. The two outer feeder sections F2, F3 are connected outside an area of the portal structure PS to form a loop, and thus one of the outer feeder sections F2 transports objects in the same direction (bold arrow) as the central feeder section F1, while the other outer feeder section F3 transports objects in the opposite direction of the two other feeder sections F1, F2. All three feeder sections F1, F2, F3 are arranged to transport objects on respective surfaces being on one common vertical level.

[0052] The two outer feeder sections F2, F3 can serve as an intermediate area or space for parking of objects by the robots R1, R2, R3, R4. This allows the control system of the robots R1, R2, R3, R4 to coordinate pick and place tasks of the robots R1, R2, R3, R4 by controlling one of the robots R1, R2, R3, R4 to pick an object on the central feeder section F1 and to place the object on one of the outer feeder sections F2, F3, and to control another one of the robots R1, R2, R3, R4 to pick said object from one of the outer feeder sections F2, F3, and to place said object in a destination bin B1, B2. Especially, the control system may be configured to optimize utilization of the plurality of robots by selecting between: 1) picking an object from the central feeder section F1 and directly placing said object in a destination bin B1, B2, 2) picking an object from the central feeder section F1 and placing said object on one of the outer feeder sections F2, F3, and 3) picking an object from one of the outer feeder sections F2, F3 and placing said object in a destination bin B1, B2, wherein this selection step can involve several inputs so as to optimize the total pick and place performance. Especially, the control system may be configured to select between 1), 2) and 3) in response to one or more inputs. Such inputs can be: a position of an object on the first feeder section, a position of at least two of the plurality of the robots, an amount of objects arriving on the first feeder section, an amount of objects on the second or third feeder section, a size of arriving objects, and a time of arrival of objects for placing in one destination bin.

[0053] The embodiment of FIG. 4 may be preferred, in case destination bins for the objects are unknown until the objects are picked by the robots R1, R2, R3, R4, where a scanner reads information on the objects. In case the destination bin B1, B2 for an object is near a location of the robot R1, R2, R3, R4 having picked up the object, the robot R1, R2, R3, R4 can be controlled to directly place the object in its destination bin B1, B2. Otherwise, the closed loop feeder sections F2, F3 can be used to place the object for handling by another robot R1, R2, R3, R4, or for handling of the same robot R1, R2, R3, R4 at a later time. Further, the closed loop of feeder sections F2, F3 can be used as a buffer for objects in periods where one or more of the robots R1, R2, R3, R4 is overloaded.

[0054] FIG. 5 illustrates a 3D drawing of an embodiment with a single feeder section F1 and a cascade of conveyors S_CNV and a scanner SC upstream of the feeder section F1 to distribute objects, e.g. from 3D to 2D bulk, before they are introduced to the feeder section F1 and to provide knowledge of destination bins B1, B2 for the objects when arriving to the robots R1, R2, R3, R4.

[0055] Again, in FIG. 5, the pick and place robot system PS, R1, R2, R3, R4 and the destination bins B1_1, B2_1 are similar to the embodiments of FIG. 2, 3 and 4, however in FIG. 5 additional lines of bins B1_2, B2_2 are added adjacent to each of the single lines of bins B1, B2 of FIG. 2, 3 and 4.

[0056] The scanning system is shown here to have a plurality of scanners SC positioned above the cascade of conveyors S_CNV and at respective positions along said cascade of conveyors S_CNV, such as 3-8 scanners SC, at respective positions along the cascade of conveyors S_CNV as a series of scanner tunnels SC, so as to allow the scanners CS to read information on the objects along with the distribution or separation of the objects by the cascade of conveyors S_CNV.

[0057] The control system of the robots R1, R2, R3, R4 may control the robots R1, R2, R3, R4 to selectively pick objects to be placed in one of a group of destination bins positioned at a longitudinal position in accordance with a longitudinal position of each of the plurality of robots R1, R2, R3, R4. In other words, with the known destination object for each of the objects arriving, the control system can distribute the pick and place tasks to the robots R1, R2, R3, R4 so that each of the robots R1, R2, R3, R4 only pick objects with destination bins B1_1, B1_2, B2_1, B2_2 positioned near the robots R1, R2, R3, R4. Thereby, the complete pick and place handling can be optimized. Especially, each of the robots R1, R2, R3, R4 may be assigned respective groups of destination bins B1_1, B1_2, B2_1, B2_2, e.g. two or more bins B1_1, B1_2, B2_1, B2_2 on each side of the feeder section F1 at a location near the robot R1, R2, R3, R4, and wherein the control system then controls each of the robots R1, R2, R3, R4 to pick objects only which are to be placed in a destination bin B1_1, B1_2, B2_1, B2_2 belonging to its assigned group of destination bins B1_1, B1_2, B2_1, B2_2. These groups of destination bins B1_1, B1_2, B2_1, B2_2 can be either non-overlapping groups of destination bins or partially overlapping groups of destination bins.

[0058] The embodiment of FIG. 4 may provide a high utilization of the robots R1, R2, R3, R4, since they can be all used for directly picking from the feeder section F1 and placing in the destination bins B1_1, B1_2, B2_1, B2_2 without having to perform any intermediate pick and place step. However, a return conveyor (not shown) may transport not picked objects from an end of the feeder section F1 to a position upstream of the feeder section, e.g. a conveyor positioned below the feeder section F1. Hereby, a period of overload of one or more of the robots R1, R2, R3, R4 can be handled without any manual interaction.

[0059] In all embodiments described above, a surface of the feeder section(s) and openings of the destination bins may be at the same vertical levels, or the surface of the first feeder section(s) may be positioned at a higher vertical level than openings of the destination bins.

[0060] FIG. 6 illustrates an example of implementation of the plurality of robots, namely a gantry robotic actuator RA with an adjustable gripper G with four suction cups, here shown with a gripped object. A set of horizontal elements forming tracks for a controllably movable first cart CT1 arranged to be controllably actuated to move in a horizontal direction X, namely the first cart CT1 being arranged to move on rails forming a longitudinal part of the portal structure PS. A controllably movable second cart CT2 is arranged to be controllably actuated to move in another horizontal direction Y on tracks of the first cart CT1.

[0061] The gripper G is mounted on a member fixed to the second cart CT2 and is controllably movable in a vertical direction Z to allow height adjustment of the gripper G. The gripper G is shown mounted on this member by a controllable actuator element which allows controllable rotation around a vertical rotation axis RT_a. Further, the gripper is mounted on the member by a controllable actuator element which allows controllable tilting around a horizontal tilting axis TL_a.

[0062] The dimension of the various elements of the robotic actuator RA can easily be adapted to the required X, Y, Z distance capacity required for the pick and place robot, and also the strength of the various elements can be adapted for the load of objects to be handled. Various types of actuators for the X, Y, Z direction actuation can be used, as known in the art of gantry type of robots.

[0063] FIGs. 7a and 7b illustrate two views of a preferred gripper G embodiment with a controllable gripping configuration of four gripping members in the form of suction cups M1, M2, M3, M4. In FIG. 7a, the gripper G is shown in the fully extended gripper configuration, i.e. with the suction cups M1, M2, M3, M4 at maximum distance from each other, thus suited for gripping large objects. In FIG. 7b, the gripper is in its fully compressed gripper configuration, i.e. with the suction cups M1, M2, M3, M4 with minimum distance from each other, thus suited for gripping small objects.

[0064] A base part B serves for mounting on a robotic actuator of the robot, by means of a controllable tilting element for tiling around a tilting axis TL_a, and by means of a controllable rotation element for rotating around a rotation axis RT_a (also seen in FIG. 6). The suction cups M1, M2, M3, M4 are mounted near distal ends of respective elongated arms A1, A2, A3, A4 which are mounted to the base part B. Each arm A1, A2, A3, A4 is slidably arranged along its length relative to the base part B actuated by a controllable actuator. This allows the arm A1, A2, A3, A4 to be controllably adjusted with respect to a position of suction cups M1, M2, M3, M4 relative to the base part B. The suction cups are aligned with their suction contacts form a plane, and wherein the arms A1, A2, A3, A4 are slidably arranged to move along axes Dx, Dy which are parallel to this plane.

[0065] Especially, it is seen that arms A1 and A2 are slidably arranged along the same axis Dx, and part of the arms are arranged to slide inside each other. Arms A3, A4 are likewise arranged to slide inside each other, so as to be slidably arranged along axis Dy. Thus, the four arms A1, A2, A3, A4 are arranged to extend in four different directions in one plane, perpendicular to each other. Depending on the chosen type of actuation, all four arms A1, A2, A3, A4 can be actuated separately to allow a high degree of flexibility with respect to gripping configuration, but requiring separate actuators, or the arms A1, A2, A3, A4 can be actuated together, e.g. in pairs. Alternatively, two actuators can be used to actuate the arms A1, A2, A3, A4 in two pairs A1, A2, and A3, A4, and further one single actuator can be used to actuate all four arms A1, A2, A3, A4, thus allowing only limited variation in the gripping configuration. It may be preferred that the actuator(s) e.g. electric motor(s), for the arms is / are mounted above the tiling and rotation points, to allow reduction of weight of the gripper G. In an embodiment, a rotation cable may transfer rotation power from the motor(s) to actuate the arms A1, A2, A3, A4 by means of a gear mechanism inside the base part B. In case of individually adjustable lengths of all four arms A1, A2, A3, A4, various gripping configuration shapes can be made to fit optimal grips for irregular objects.

[0066] Such gripper G is flexible and yet compact, since even with a compact base part B, a highly flexible gripping configuration is achieved: from a very compressed and compact configuration occupying a minimum of space outside the dimension of the base part B itself, and to a fully extended gripping configuration which can be used for handling large objects. The gripper G can handle large objects at one point in time, and shortly after, it can be controlled to provide a compressed state gripping configuration to enable the gripper G to enter the space between two large objects for gripping a small object. This allows a high flexibility in the handling of bulk objects, even objects in 3D bulk.

[0067] FIG. 8 illustrates steps of an embodiment of a method for automatically sorting a stream of objects of various sizes and shapes in bulk, the method comprises transporting T_O the objects on a first feeder section in a first transport direction to a pick and place robot system with a plurality of robots carried by a portal structure and being movable along the portal structure, placing P_DB first and second lines of destination bins on opposite sides of the first feeder section, so that the destination bins are within reach of the pick and place robot system, reading R_I information on each object, selecting D_DB a destination bin for each object in accordance with the information read, and controlling C_P_P the plurality of robots to pick each of the objects from the first feeder section and place the objects in the selected destination bins.

[0068] The method preferably comprising the step of providing the objects on the first feeder section. The step of reading information R_I on each object may be performed prior to providing the objects on the first feeder section, or this step of reading information, e.g. scanning, may be performed along with the robots picking the objects.

[0069] It is to be understood that in principle, all types of objects or items can be handled by the described robot systems. I.e. objects or items can be of various shapes, sizes, and with various surface characteristics. Especially, the stream of objects or items arriving at the first feeder section may comprise at least one of: mail pieces, parcels, baggage, items handled at a warehouse distribution, and items handled at a mail order distribution centre, such as shoes, clothes, textiles etc. Especially, the pick and place robot system may be designed for handling objects or items which have a maximum weight of 1-100 kg, such as 1-10 kg, such as a maximum weight of 2-3 kg. Especially, objects or items with a maximum weight of 2-3 kg can be picked up and moved at a high speed even with moderately sized robots. It is to be understood that the robot system can alternatively be designed for handling heavier objects than 100 kg.

[0070] It is understood that the function of the control system is preferably implemented by a processor system. The processor may be a computerized controller including a digital processor executing the control algorithm which is implemented in software, so as to allow easy updating and adaptation of the function of the system, e.g. by changes in sorter configuration, and by including more pick and place robots to the system which need to be controlled in order to most effectively cooperate to handle the incoming stream of objects or items.

[0071] In some embodiments, the control system can be implemented by means of a Programmable Logic Controller (PLC). The processor may be or may comprise a dedicated robot controlling processor, or it may be implemented as part of or sharing the processor serving to control the sorter. Hereby, the addition of one or more pick and place robots to an existing sorter system may be implemented with a minimum of extra hardware for controlling the robot(s), and thus in such implementations, the program code for controlling the robot(s) can be implemented purely as processor executable program code. Likewise, the processor may be implemented as part of or sharing the processor serving to control the one or more induction for transporting items to the sorter. Still further, the processor may be implemented as part of or sharing the processor serving to control the feeder and / or the sorter, which may be advantageous to allow information from feeder and / or sorter to be used in the control of the pick and place robots. Yet other versions may have separate robot controls with interfaces to one common machine controller for controlling sorter, inductions and feeding conveyor(s). The machine controller may then have an interface to an overall system controller, which may have an interface to an ever higher order control, e.g. a Warehouse Management System (WMS).

[0072] The pick and place robot system may comprise a vision system for control of the plurality of robots to pick and place objects in an efficient manner, i.e. based on an image of objects provided upstream of and / or at the area of the plurality or robots. For such vision system various types of cameras or other image sensors exist, but preferably the may be capable of providing a high quality 3D image allowing a precise identification of shapes to allow identification of separate objects in a bulk, and also with a sufficient precise height dimension to allow precise navigation of the gripper of the robots for gripping the object. The camera may especially be a 3D line camera, a Time of Flight type 3D camera, and a stereo 3D camera. Further, it is to be understood that a 2D camera may be used, where the height dimension of the 3D image IM is computed based on image processing of a 2D photo, or it may be obtained by an alternative technology, e.g. a separate height sensor placed separate from the camera CM.

[0073] The control system can be performed with many of its functions implemented as computer program code, and in practice the program code may be partly or fully integrated with existing systems for controlling the sorter. However, it may be preferred that the control system has two or more separate processors, e.g. a separate processor serving to perform at least some of the required image processing on one or a plurality of images, e.g. 3D images to provide a fast and precise identification of objects upstream of each of the pick and place robots.

[0074] The sorter system may have a capacity for handling at least 2,000 objects per hour, preferably at least 3,000 objects per hour, especially for smalls. For heavy parts or baggage, the handling capacity may be smaller than 2,000 objects per hour.

[0075] The first feeder section may be arranged to operate at a transporting speed of up to 1.0 m / s, such as up to 1.5 m / s. For bulk unloading an initial speed of 0.1-0.3 m / s may be preferred, and thereafter a speed of such as 0.5-1.2 m / s.

Claims

1. A sorter system for handling a stream of objects of various shapes and sizes in bulk, the system comprising - a feeder system (F0, F1) comprising at least a first feeder section (F1) arranged to transport the objects in a first transport direction, - a destination system comprising at least first and second separate lines of destination bins (B1, B2), - a pick and place robot system comprising - a portal structure (RL1, RL2) carrying a plurality of controllable robots (R1, R2, R3, R4) in a gantry configuration and being controllably movable along said portal structure (RL1, RL2), wherein each of said robots (R1, R2, R3, R4) are configured with a manipulator (G) arranged for engaging with objects from the at least first feeder section (F1) and transferring objects to the destination bins (B1, B2), and - a control system (CS) arranged to control movement of the plurality of robots (R1, R2, R3, R4) and their manipulators (G) to transfer objects from the first feeder section (F1) to selected destination bins (B1, B2), and - a scanner system comprising a scanner (SC) configured to read information on the objects, and wherein the scanner system is configured to provide data to the control system (CS) according to the information read, so as to allow the pick and place robot system to place objects in a destination bin (B1, B2) selected in accordance with information read, wherein the first feeder section (F1) and the first and second lines of destination bins (B1, B2) are arranged within reach of the pick and place robot system, , characterized in that the control system (CS) of the pick and place robot is configured to control the plurality of robots (R1, R2, R3, R4) according to a packet strategy for each of the destination bins (B1, B2), taking into account at least a size of objects to be placed in each destination bin, and a time of arrival to the plurality of robots (R1, R2, R3, R4) of objects be placed in each destination bin (B1, B2), so as to optimize a filling or packet density of each destination bin (B1, B2).

2. The system according to claim 1, wherein the first transport direction and a longitudinal axis of the portal structure (R1, R2) are parallel.

3. The system according to claim 1 or 2, wherein the feeder system comprises a second feeder section arranged within reach of the pick and place robot system, preferably arranged within a width of the portal structure, and wherein the second feeder section is arranged to transport objects in a transport direction being opposite the first transport direction, such as the second feeder section being arranged adjacent to the first feeder section, such as the first line of destination bins being arranged adjacent to the first feeder section, such as the second line of destination bins being arranged adjacent to the second feeder section.

4. The system according to claim 3, wherein the pick and place robot system is arranged to pick one object from the first feeder section and to place the object on the second feeder section.

5. The system according to claim 4, wherein the control system (CS) of the pick and place robot system is arranged to optimize a total capacity of the plurality of robots (R1, R2, R3, R4) by selecting to place an object on the second feeder section (F2).

6. The system according to any of the preceding claims, wherein at least one scanner (SC) of the scanner system is arranged upstream of the first feeder section (F1), and wherein the control system (CS) of the pick and place robot system is arranged to distribute pick and place tasks to the respective ones of the plurality of robots (R1, R2, R3, R4) based on known positions of destination bins (B1, B2) for each of the objects arriving on the first feeder section (F1).

7. The system according to claim 5 and 6, wherein the control system (CS) of the pick and place robot system is arranged to optimize a total capacity of the plurality of robots by selecting to control one of the plurality of robots (R1, R2, R3, R4) to place an object on the second feeder section (F2), and to control another one of the plurality of robots (R1, R2, R3, R4) to pick said object from the second feeder section (F2) and to place said object in the selected destination bin (B1, B2).

8. The system according to claim 4 or 5, wherein the scanner system is configured to read information on an object when picked by one of the plurality of robots (R1, R2, R3, R4), and wherein the control system (CS) of the pick and place robots is configured to determine, whether to control said one robot (R1, R2, R3, R4) to place the object in its destination bin or whether to control said robot (R1, R2, R3, R4) to place the object on the second feeder section (F2).

9. The system according to any of the preceding claims, wherein the feeder system comprises a second and a third feeder section (F2, F3) arranged within reach of the pick and place robot system, and wherein one of or both of the second and third feeder sections (F2, F3) is arranged to transport objects in a transport direction opposite the first transport direction.

10. The system according to claim 9, wherein the control system (CS) of the pick and place robot system is arranged to control robots (R1, R2, R3, R4) to pick objects from the first feeder section (F1) and to place objects selectively on the second or third feeder section (F2, F3).

11. The system according to claim 9 or 10, wherein all of the first, second and third feeder sections (F1, F2, F3) are arranged to transport objects on respective surfaces being on one common vertical level.

12. The system according to any of the preceding claims, wherein the pick and place robot system is arranged to sense a lowest point of space in a destination bin (B1, B2) and to place an object on said lowest point of space in the destination bin, so as to ensure careful handling of objects and at the same time minimize time for performing the task of placing objects.

13. The system according to any of the preceding claims, comprising a system configured to distribute objects upstream of the first feeder section (F1).

14. The system according to any of the preceding claims, comprising a plurality of lines of destination bins (B1_1, B1_2), B2_1, B2_2), wherein said plurality of lines of destination bins (B1_1, B1_2), B2_1, B2_2) are arranged within reach of the pick and place robot system.

15. The system according to any of the preceding claims, wherein the destination bins are roller bins arranged to be rolled in and out of said lines of destination bins (B1, B2) either manually or by means of an actuator.

16. The system according to any of the preceding claims, wherein the first feeder section (F1) is placed at an elevated position, so as to allow the destination bins (B1, B2) to be transported below the feeder section (F1).

17. Use of the system according to any of claim 1-16 for handling objects comprising at least one of: mail pieces, parcels, baggage, items handled at a warehouse distribution, items handled at a mail order distribution centre, and items handled at a smalls handling centre.