Sorting and conveyor systems

Abstract

A sorting system (1) comprising a first product path (2) and a second product path (3), the first product path (2) comprising a linear magnetic conveyor (4) and a first endless chain conveyor (5), the second product path (3) comprising a second conveyor (6), the sorting system (1) comprising a plurality of carriers (7) and a plurality of containers (8), the first product path (2) arranged to transport the carriers (7), the second conveyor path (3) arranged to transport the containers (8) at a constant first speed, a portion of the linear magnetic conveyor (4) arranged adjacent to and parallel to the second conveyor (6), the carriers (7) being provided with magnetic means (30) such that they can be transported by the linear magnetic conveyor (4), and the linear magnetic conveyor (4) arranged to transport the carriers (7) at a variable speed and to individually control the position of the carriers (7). It is an advantage of the present invention that product can be efficiently transferred from a carrier to a container.

Description

[Technical field]

[0001] The present invention relates to a sorting system adapted to flexibly feed products from a first product carrier to a second product carrier, as well as a method and conveyor system for flexibly and reliably transferring objects from a first product carrier to a second product carrier. [Background technology]

[0002] Conveyor systems are used, for example, to move objects between different work stations in a factory and usually comprise a conveyor track in the form of a belt or chain. Conveyor belts can be used in linear conveyor systems where the products are conveyed in a single direction or when the products are redirected from one linear belt to another. In conveyor systems where the products pass through bends and curves, endless chain conveyors are advantageous. The conveyor track can be recessed in a trench with vertical sides. Alternatively, the conveyor track can be located on the horizontal top surface of the trench or arranged in some other manner. The objects to be conveyed are slidably placed relative to the conveyor track, either directly or via a conveying means also known as a carrier. The carrier can be provided with features to hold the products securely so that they do not fall or become displaced during transport.

[0003] Other conveyor or transport systems are used to sort and distribute products into bins from a central store to individual receiving locations or locations. Such systems are often used in warehouses, where products stored in a central store are distributed to individual locations, with each location corresponding to an individual customer order or destination. Thus, each location may contain one or more different products picked from different locations within the central store. When the bins are full, they are sent to a distribution center where the packages are delivered, for example, according to zip codes or other country regions.

[0004] For larger warehouses, such systems are very complex and require a lot of space. Products must be picked from a central store by self-propelled robots, automated guided vehicles (AGVs) etc. and then sent to the different bin locations in a controlled sequence.

[0005] In some systems, the products are placed on a carrier that includes a product movement device, such as a tiltable platform or a movable belt. The carrier moves along a long path with containers placed in fixed locations so that the products can be transferred from the carrier to the containers as the carrier passes the correct container locations. Once the containers are full, they are moved to a distribution center for further transportation and empty containers are placed in the empty locations.

[0006] In other systems, the products are placed on an endless belt that extends between the bins. Once the products have passed the correct bin location, they are diverted from the belt by a diverter. Other logistics systems are also known. What all of these logistics systems have in common is that the products are transferred from some type of moving carrier to a stationary bin, and the completed bins are stored in designated locations, where the location corresponds to, for example, a zip code. While these systems work well, they are relatively inflexible and require a large amount of space.

[0007] Therefore, there is room for improvement in the sorting system. Summary of the Invention

[0008] It is therefore an object of the present invention to provide an improved sorting system.It is a further object of the present invention to provide an improved method for dispensing products.

[0009] The solution to the problem according to the invention is recited in the characterizing part of claim 1 for the sorting system and in claim 11 for the method. The further claims contain advantageous embodiments and further developments of the sorting system and the method.

[0010] In a sorting system having a first product path and a second product path, the first product path comprises a linear magnetic conveyor and a first endless chain conveyor and the second product path comprises a second conveyor, the sorting system comprises a plurality of carriers and a plurality of containers, the first product path is arranged to transport the carriers and the second product path is arranged to transport the containers at a constant first speed, the objects of the present invention are achieved by: a part of the linear magnetic conveyor is arranged adjacent to and parallel to the second conveyor; the carriers are provided with magnetic means so that they can be transported by the linear magnetic conveyor; and the linear magnetic conveyor is arranged to transport the carriers at a variable speed and to individually control the position of the carriers.

[0011] This first embodiment of the sorting system according to the invention provides a sorting system that allows products to be transported and distributed flexibly and efficiently. In the sorting system, the products to be delivered are transported in a first product path and the receiving container is transported in a second product path. The products are transported at a variable speed and the receiving container is transported at a constant speed. The first product path and the second product path are arranged adjacent and parallel to each other. The products are carried by a carrier with some type of transport means, whereby the products can be transferred to the container. When the products are transported, the carrier is transported at the same speed to align with the receiving container and the transport means transfers the products to the receiving container.

[0012] The term carrier is also referred to below as a first product carrier, and the term container is also referred to below as a second product carrier.

[0013] Due to the fact that the product to be delivered is transported by a first product carrier at a variable speed and the receiving second product carrier is transported at a constant speed, the transfer location, also called the deposit location, can vary depending on the situation.

[0014] The deposit location thus corresponds to the location of a second product carrier moving along a second product path at the time that the product carried by the first product carrier is deposited or transferred to said second product carrier.

[0015] The variation of the deposit location is sometimes called dynamic deposit location, because the actual transfer position will generally be different for each successive time that the product is transferred to the second product carrier. This variation of the deposit location is due to the fact that the second product carrier is constantly moving along the second product path, and the time of arrival of a new first product carrier to the linear magnetic conveyor is not synchronized with the position of the second product carrier. In other words, the solution of the present invention allows the second product carrier to be filled with the required amount of product while the second product carrier is moving.

[0016] As a result, in contrast to the prior art solutions discussed in the Background section, in which all containers remain in a fixed location until they are filled and replaced with empty containers, the new solution involves a substantially constant movement of the second product carriers, thereby allowing for a more compact and cost-effective sorting or conveyor system, in part because there is no need for conveyors to allow transport to and from each fixed deposit location, and in part because there are no stationary, non-full second product carriers blocking the path of other fully loaded second product carriers.

[0017] In other words, the sortation system or conveyor system according to the present disclosure provides a dynamic depository, meaning that there are no fixed storage locations for the different second product carriers.

[0018] Once the products have been transferred, the carriers return to the pick-up station and are loaded with new products. The carriers move at variable speeds so that they can move quickly to position themselves at the receiving bins and move at the same speed as the receiving bins when the products are transferred. In the sorting system, several carriers move simultaneously in a first product path. The first product path comprises a linear magnetic conveyor arranged parallel to the second product path. The first product path further comprises a conventional chain conveyor that transports the carriers from the pick-up station to the magnetic conveyor. The receiving bins are transported at a constant first speed by the second conveyor. This allows the sorting system's control system to determine the exact position of each receiving bin at all times.

[0019] In one example, the magnetic conveyor runs in a straight line and the second product path runs in parallel. A carrier with products travels on the first product path, transferring each product to the correct container. When a container has received all the products, it can exit the second product path at an outfeed area. If a container has not received all the products, it can re-enter the second product path at an infeed area one more time until it has received all the products. As full containers leave the second product path, empty containers can be introduced into the second product path so that all positions in the second product path are occupied.

[0020] The second conveyor may or may not be provided with some sort of positioning means, for example flights arranged at predetermined intervals, so that the position of each container is fixed on the conveyor and the container cannot slip or move. The second product path comprises an endless conveyor, preferably an endless chain conveyor or a belt conveyor. It may for example be a plastic chain conveyor with one or two plastic chains, or a twin track conveyor with two metal chains. The position or location of the containers on the second conveyor may be determined logically using an encoder or may be identified using RFID. Since the position of each container can be determined, the carrier can easily target and track the containers during the transfer of the product.

[0021] The first product path may comprise a conventional plastic chain conveyor arranged to transport the carriers, as in the illustrated example. The first product path comprises a linear magnetic conveyor that transports the carriers using magnetic forces. The products are loaded onto the carriers in some manner prior to the linear magnetic conveyor. The chain conveyor may, for example, move the carriers from a loading position where the products are picked up from the distribution station to a magnetic conveyor where the carriers transfer the products to the containers. The magnetic conveyor is arranged parallel to at least a portion of the second product path. The magnetic conveyors are arranged to transport the carriers with asynchronous motion, and the speed of each carrier can be controlled individually. This allows several carriers to transfer products to different containers at the same time. The carriers can be rapidly transported to the required position, where they can be synchronized at the same speed as the containers, and once the products have been transferred, they can be accelerated to a higher speed and rapidly transported to the return path, where the conventional chain conveyor transports the carriers back to the distribution station.

[0022] In a typical transfer system, each receiving container is positioned at a fixed, specific, predefined location. The products are transferred from the conveyor to the container by self-propelled vehicles, such as carriers or AGVs. The control system knows in which location each container is positioned, and the completed container is picked up from this location and sent to a predefined deposit location.

[0023] Once the container has received all of the product, it may exit the second product path and be sent to a manifest location, i.e., a storage location, where the container may be temporarily stored before being shipped to the customer or sent to the consumer.

[0024] The depository is a dynamic depository, which means that there are no fixed storage locations for different containers. A typical depository has fixed, predefined locations for all possible different destinations. The destinations can be, for example, zip codes, retail locations, customers, etc. In such a system, there must be a location reserved for each destination, regardless of how much or how frequently each location is used. At the same time, each location must be able to handle the maximum amount of containers that can be predicted. The space reserved for each destination can of course vary depending on historical data, but there must be space reserved for each destination. Some spaces may be rarely used or the size of the spaces is too large most of the time. Thus, such a depository system would require a large amount of space, but most of that space is not used.

[0025] In the system of the present invention, each container is provided with some kind of individual identification tag. Preferably, a radio transmitter / receiver tag is used, e.g. an RFID tag, but it is also possible to use a barcode or the like. Since each container can be identified at all times, the location of each container can be constantly monitored and tracked by the control system of the conveyor system. This is useful when the containers are fed to the second conveyor path and when they leave the second conveyor path and are placed at a manifest location. The use of independently identifiable containers allows for dynamic deposit locations, whereby fixed, predefined locations for different destinations are not required. In this way, the deposit locations can be much smaller, which results in a great space saving.

[0026] According to some exemplary embodiments, each carrier is provided with transfer means arranged to transfer the products from the carrier to the containers. The transfer means may for example be a ramp function, a belt function or any type of pusher.

[0027] It is a further object of the present invention to provide an improved method for transferring a product from a first product carrier to a second product carrier, and to provide a conveyor system adapted for transferring a product from a first product carrier to a second product carrier.

[0028] The solution to the problem according to the present invention is described in the following part of the present disclosure.

[0029] A method of the present invention for transferring product from a first product carrier to a second product carrier includes the steps of: moving the first product carrier in a first direction and the second product carrier in the same direction, moving the second product carrier at a constant first speed; moving the first product carrier at a speed faster than the first speed until the first product carrier is aligned with the second product carrier; moving the first product carrier at the same speed as the second product carrier; activating a transport means for the first product carrier such that product is transferred from the first product carrier to the second product carrier; and moving the first product carrier away from the second product carrier at a speed faster than the first speed.

[0030] By the method of the invention, the products can be transferred flexibly and efficiently from a first product carrier to a second product carrier. The second product carrier moves at a constant known speed, preferably by some kind of endless conveyor. A suitable endless conveyor is an endless chain conveyor or an endless belt conveyor, which comprises one or two chains or belts. By using an endless plastic chain conveyor, the second product carrier can be transported through curves. By using an endless belt conveyor or a metal chain conveyor, the endless conveyor can comprise several conveyor tracks.

[0031] The second product carrier may be any type of separate carrier that can be transported by the endless conveyor and is adapted to receive products, such as containers, boxes, carrier bags, cartons, crates, etc. The second product carrier is preferably provided with some kind of identification means, for example an RFID tag, a bar code, or another computer-readable identification. The second product carrier may be fixedly attached to the conveyor. In this case, the products will be transferred from the second product carrier to the separate product carrier in an end region of the conveyor system.

[0032] The first product carrier is moved at a variable speed, whereby the first product carrier can be individually controlled with respect to speed and position. In this way, the first product carrier can be controlled to a position next to the second product carrier, where the first product carrier can align with the second product carrier and move at the same speed as the second product carrier. When the first product carrier and the second product carrier move next to each other at the same speed, the product can be reliably transferred from the first product carrier to the second product carrier by activating the transfer means of the first product carrier. Once the product has been transferred, the first product carrier can be moved away from the second product carrier at a faster speed. In this way, the first product carrier can quickly collect new products without getting in the way of other first product carriers.

[0033] In one example, the first product carrier is an automated guided vehicle (AGV) equipped with wheels. This allows the first product carrier to be individually controlled with respect to speed and position. The AGV may be loaded at a distribution station, where the product is placed on the carrying surface of the AGV. The AGV may then drive to the second product carrier proceeding at a constant speed along a linear path. The AGV drives to the second product carrier toward the product, where it drives next to the second product carrier at the same speed. When the AGV and the second product carrier are aligned with each other and moving at the same speed, the transport means of the AGV are activated to transfer the product to the second product carrier in a safe manner. Once the product has been transferred, the AGV drives away from the second product carrier and returns to the distribution station at high speed to collect new product.

[0034] In another example, the first product carrier is a pallet transported by a magnetic conveyor. This allows the pallets to be individually controlled with respect to their speed. The pallets can be loaded at a distribution station, where the products are placed on the conveying surface of the pallet. The pallets can then be transported to a straight section of a magnetic conveyor arranged parallel to the conveyor of the second product carrier, where the second product carrier travels at a constant speed along a straight path. The pallet and the second product carrier now travel in the same direction. The pallets can be transported from the distribution station by an endless conveyor chain or by a section of a magnetic conveyor.

[0035] The pallet is transported at high speed until it reaches a second product carrier toward the product, where it is transported next to the second product carrier at the same speed. When the pallet and second product carrier are aligned and moving at the same speed, the pallet's transport means is activated to transfer the product to the second product carrier in a safe manner. Once the product has been transferred, the pallet is transported away from the second product carrier and returns to the distribution station at high speed to pick up new product.

[0036] Since the cost of a magnetic conveyor is much higher than a conventional endless chain conveyor, and since the magnetic conveyor is much more complicated, it is advantageous to use the magnetic conveyor only in the transfer area of ​​the conveyor system. Thus, the infeed conveyor, which transports the pallets from the distribution station to the magnetic conveyor, and the outfeed conveyor, which transports the pallets from the magnetic conveyor back to the distribution station, may be a conventional endless plastic chain conveyor or other type of conveyor. The pallets are conventional pallets arranged to be transported by such an endless plastic chain conveyor, the pallets being provided with magnetic means so that they can also be controlled and transported by the magnetic conveyor. The pallets are provided with a rectangular base so that the pallets are led through the product path in the same position.

[0037] One advantage of the method of the invention is that both the first product carrier carrying the product and the second product carrier receiving the product move in the same direction during the transfer. In this way, the product can be transferred from the pallet to, for example, a container at high speed without excessive stress on the product, since the speed difference between the pallet and the container is zero. In conventional transfer systems, where the receiving container is fixed and the products are transferred on a conveyor, each product is pushed off the conveyor, for example by a pusher arm or a diverter arm. A high conveyor speed also results in high impacts on the product, which may damage the product. Therefore, the speed of the conveyor must be limited, which reduces the throughput of the system. With the method of the invention, there is further no risk of the product missing the container during the transfer.

[0038] Also, in conventional transfer systems where each receiving bin is assigned a specific location, a large area is required to accommodate all the different bins. Furthermore, each empty bin must be delivered and each full bin must be removed by another delivery system. A moving queue of receiving bins provides a dynamic transfer system where only the required bins are present. A number of bins are transported by a second conveyor, each bin is transported at a specific location on the conveyor. The location of the bin is determined by detecting the bin as it enters the conveyor, for example, by RFID or barcode. Since the location of the bin on the conveyor and the speed of the conveyor are known, the control system of the transfer system can determine the location of the bin so that the pallet can transfer the product to the specific bin. For example, if five different products are to be transferred to a specific bin, the control system determines five different transfer locations for five different pallets.

[0039] In one example, the container enters the second conveyor at an infeed area and exits the second conveyor at an outfeed area. If the container is not complete when it arrives at the outfeed area, i.e., the container has not received all the product that is to be delivered to it, the container can be sent to the infeed area one more time until all the product is delivered. Preferably, all the product is delivered in one go.

[0040] In a conveyor system adapted for transferring products from a first product carrier to a second product carrier, the conveyor system comprises a plurality of first product carriers, a plurality of second product carriers, a first product path and a second product path, the first product carriers being arranged to move in a first direction along the first product path and the second product carrier being arranged to move in the first direction along the second product path at a constant first speed, the object of the invention being achieved in that the first product carrier is configured to move next to the second product carrier at the first speed to a position aligned with the second product carrier at a speed faster than the first speed and to transfer the product to the second product carrier by actuating a transfer means when moving next to the second product carrier, and once the product has been transferred, to move at a speed faster than the first speed away from the second product carrier.

[0041] This first embodiment of a conveyor system adapted for the transfer of products from a first product carrier to a second product carrier according to the invention provides a conveyor system that allows products to be sorted and distributed flexibly and efficiently. In the conveyor system, the products to be delivered are moved along a first product path by a first product carrier, and a second product carrier arranged to receive the products is moved along a second product path. The first product path and the second product path are arranged parallel and adjacent to each other in a transfer area where the products are transferred from the first product carrier to the second product carrier. The first product carrier and the second product carrier are here moved in the same direction.

[0042] The second product carriers are arranged to move along the second product path at a constant first speed. The second product path in one example comprises an endless conveyor, for example an endless chain conveyor or an endless belt conveyor. The second conveyor may comprise spacer means, for example teeth, protrusions, etc., arranged to hold each second product carrier in a defined position on the conveyor. The second product carriers may also comprise identification means, for example an RFID tag or a bar code, so that they can be identified when required. The second product carriers are for example containers or boxes.

[0043] The first product carrier is positioned to move at a variable speed along the first product path such that the speed and position of the first product carrier can be controlled. The first product carrier is, in one example, an automated guided vehicle (AGV) equipped with wheels and self-propelled by an internal motor. The AGV can be controlled to move along a desired path. In a conveyor system, the AGV is controlled to pick up the product at a distribution station. The AGV then drives to position itself adjacent to a second product carrier that will receive the product. The AGV moves at a speed faster than the first speed to catch up with the second product carrier.

[0044] When the AGV is aligned with the second product carrier, the AGV travels at a first speed, which causes the AGV to move next to the second product carrier. When the speed difference between the AGV and the second product carrier is zero, the product can be transferred from the AGV to the second product carrier by a transfer means disposed on the AGV. The transfer means may be a tilt function, a motorized belt, a pusher, etc. Since the AGV travels at the same speed as the second product carrier, the product can be transferred to the second product carrier safely and smoothly without damaging the product.

[0045] The first product carrier may also be a pallet transported by a magnetic conveyor. The magnetic conveyor extends parallel to the second product path in the transfer area. The pallet may be transported by the magnetic conveyor at a variable speed, whereby it may be positioned next to a second product carrier adapted to receive the product. Once the pallet is aligned with the second product carrier and the pallet is moving at the same speed as the second product carrier, the transfer means is activated and the product is safely transferred to the second product carrier. The pallet is then transported back to the delivery station for picking up new products.

[0046] Once the product has been transferred, the first product carrier returns to the delivery station and is loaded with new product. The first product carrier can move at a variable speed so that it can move quickly to position itself at the second product carrier and move at the same speed as the second product carrier when the product is transferred. In a conveyor system, several first product carriers move simultaneously along the first product path.

[0047] In one example, the first product carrier travels in a straight line and the second product path runs parallel. The first product carrier with the products travels along the first product path, transferring each product to the correct second product carrier. When the second product carrier has received all the products and is complete, the second product carrier can exit the second product path at the outfeed area. If the second product carrier has not received all the products, the second product carrier can re-enter the second product path at the infeed area one more time until it has received all the products.

[0048] The second conveyor may be provided with some kind of spacer means so that the position of each second product carrier is fixed on the conveyor. This may be, for example, teeth or protrusions arranged at defined positions at defined intervals. The second product carriers may also be equipped with identification means, for example RFID tags or bar codes, so that they can be identified when necessary. The second product path comprises an endless conveyor, preferably an endless chain conveyor. It may be, for example, a plastic chain conveyor with one or two plastic chains, or a twin track conveyor with two metal chains. As the position of each second product carrier is known, the first product carrier can easily target and track the second product carrier during the transfer of the products.

[0049] The first product path in one example comprises a conventional endless plastic chain conveyor arranged to transport pallets. The first product path further comprises a linear magnetic conveyor adapted to transport the pallets using magnetic force. The endless chain conveyor is arranged to move the pallets from a loading position where the products are picked up from the distribution station to a magnetic conveyor where the pallets transfer the products to a second product carrier. The magnetic conveyor is arranged to transport the pallets with asynchronous motion, and the speed of each pallet can be individually controlled. This allows several pallets to transfer products simultaneously to different second product carriers. The pallets can be swiftly advanced to the required position where they can proceed at the same speed as the second product carrier, and once the products have been transferred, they can be swiftly advanced to a return path where a conventional chain conveyor transports the pallets back to the distribution station.

[0050] In a typical transfer system, each receiving bin is positioned at a fixed, specific, predefined location. The product is transferred to the bin from a conveyor or a self-propelled vehicle such as an AGV. The control system knows in which location each bin is positioned, and the completed bin is picked up from this location and sent to a predefined manifest location. In this type of system, the bins do not need to be provided with individual identification information, since they are always placed in a known, predefined location.

[0051] Once the second product carrier has received all of the product, it exits the second product path and is sent to a manifest location where the second product carrier is temporarily stored before being shipped to the customer.

[0052] The depository is a dynamic depository, meaning that there is no fixed storage location for the different second product carriers.

[0053] A typical depository has a fixed, predefined location for all possible different destinations. A destination can be, for example, a zip code, a retail location, a customer, etc. In such a system, there must be a location reserved for each destination, regardless of how much or how frequently each location is used. At the same time, each location must be able to handle the maximum amount of containers that can be predicted. The reserved space for each destination can of course vary depending on historical data, but there must be a reserved space for each destination. Some spaces may be rarely used or the size of the space is too large most of the time. Thus, such a depository system would require a large amount of space, but most of that space would be unused.

[0054] In the system of the invention, each second product carrier is provided with some kind of individual identification tag. Preferably, a radio transmitter / receiver tag is used, for example an RFID tag, but it is also possible to use a bar code or the like. Since each second product carrier can be identified at all times, the location of each second product carrier can be constantly monitored and tracked by the control system of the conveyor system. This is useful when the second product carrier is fed into the second product path and when the second product carrier leaves the second product path and is placed at a manifest location. The use of independently identifiable second product carriers allows for dynamic deposit locations, whereby fixed, predefined locations for different destinations are not required. In this way, the deposit locations can be much smaller, which results in a great space saving. [Brief description of the drawings]

[0055] The invention is explained in more detail below with reference to embodiments illustrated in the accompanying drawings.

[0056] [Figure 1] 1 shows a sorting and conveyor system according to the present invention. [Diagram 2] 1 shows details of a sorting and conveyor system according to the present invention. [Diagram 3] 1 shows a simplified sorting and conveyor system according to the present invention. [Figure 4] 1 shows a simplified sorting and conveyor system according to the present invention. [Diagram 5] 1 shows a carrier for a sorting and conveyor system according to the present invention. [Figure 6] 2 shows a flow chart of a method according to the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0057] The embodiments of the invention with further developments described below should be considered merely as examples and in no way limit the scope of protection provided by the claims. References to longitudinal, horizontal, vertical, right, left etc. are with reference to the orientation of the conveyor in normal use.

[0058] 1 and 2 show a sorting and conveying system according to the present invention, FIGS. 3-4 show a simplified sorting system, FIG. 5 shows a carrier for use in the sorting and conveying system, and FIG. 6 shows a method flow chart.

[0059] According to some exemplary embodiments of the present disclosure, the sortation system 1 comprises a first product path 2, a second product path 3, and a plurality of carriers 7.

[0060] According to some other exemplary embodiments of the present disclosure, the conveyor system 1 comprises a first product path 2, a second product path 3, a plurality of first product carriers 7, and a plurality of second product carriers 8, here represented by containers.

[0061] A first product carrier 7 is moved along a first product path 2. The first product path is used to deliver the product from the dispensing station to the second product carrier. The second product carrier is moved along a second product path 3. In the transfer area where the product is transferred from the first product carrier 7 to the second product carrier 8, the first product path 2 and the second product path 3 are arranged next to each other and extend parallel to each other. The second product carrier 8 transported by the second product path 3 is transported at a constant first speed.

[0062] In one example, the first product carrier is an automated guided vehicle (AGV) equipped with wheels and self-propelled by an internal motor. The AGV can be controlled to move along a desired path. In a conveyor system, the AGV is controlled to pick up a product at a distribution station. The AGV then drives to position itself adjacent to a second product carrier that will receive the product. The AGV moves at a speed faster than the first speed to catch up with the second product carrier.

[0063] When the AGV is aligned with the second product carrier 8, the AGV travels at a first speed, whereby the AGV moves next to the second product carrier. When the speed difference between the AGV and the second product carrier is zero, the product can be transferred from the AGV to the second product carrier by a transfer means arranged on the AGV. The transfer means may be a tilt function, a motorized belt, a pusher, etc. Since the AGV goes at the same speed as the second product carrier, the product can be transferred to the second product carrier safely and smoothly, without damaging the product.

[0064] The AGV may travel on a smooth surface and follow a predetermined trajectory, or may be controlled to travel away from the second product path until the product has been transferred. The AGV may then change lanes and move next to the second product carrier to transfer the product. Once the product has been transferred, the AGV returns to the previous lane and returns to the distribution station.

[0065] In some exemplary embodiments of the present disclosure, the first product carrier 7 is a pallet.

[0066] Also, in some exemplary embodiments of the present disclosure, the second product carrier 8 is a container.

[0067] According to some exemplary embodiments, the first product path 2 comprises a linear magnetic motion conveyor 4 and a first endless chain conveyor 5. The linear magnetic motion conveyor is in the illustrated example a flatbed magnetic conveyor that moves carriers or pallets supported by guide rails. Such a magnetic conveyor comprises straight and curved sections and may also comprise a diverter section. The magnetic conveyor can control the speed and position of several carriers or pallets simultaneously. At least a part of the magnetic conveyor is arranged adjacent and parallel to the second conveyor 6 or the second product path 3, whereby the carriers or pallets can track the containers 8 transported by the second conveyor 6.

[0068] The first endless chain conveyor 5 is arranged to transport carriers or pallets 7 from the product distribution station to the magnetic conveyor. At the product distribution station, the products are transferred from the central storage to the carriers or pallets. The product distribution station may comprise several different pick-up positions, where the products are placed on the carriers or pallets. Typically, the carriers or pallets carry one product at a time, but it would also be possible to carry several smaller products simultaneously. The product distribution station may be positioned at a relatively long distance from the transfer station, where the magnetic conveyor transfers the products from the carriers or pallets to the containers. Thus, the distance from the product distribution station to the transfer station and from the transfer station to the product distribution station is covered by a normal plastic chain conveyor, which transports the carriers or pallets in a conventional manner. The first endless chain conveyor may comprise straight tracks, curved tracks, diverters, mergers, buffers, etc., as required. The carriers or pallets may also comprise identification means, for example RFID tags, so that they can be identified when required.

[0069] In the example of the first product path 2 shown in Figure 1, the magnetic conveyor 4 comprises four branches: a feed magnetic conveyor 24, a return magnetic conveyor 25, a first transverse magnetic conveyor 26 and a second transverse magnetic conveyor 27. The first endless conveyor 5 comprises an endless delivery conveyor 28 and an endless return conveyor 29. The endless delivery conveyor 28 transports the loaded carriers or pallets 7 to the magnetic conveyor, and the endless return conveyor returns the empty carriers or pallets to the product distribution station, where new products are loaded onto the carriers or pallets.

[0070] When the carrier or pallet with the products arrives at the magnetic conveyor 4, it is first transported by the feed magnetic conveyor 24. In the illustrated example, the carrier or pallet is transported in a counterclockwise direction by the magnetic conveyor 4. On the feed magnetic conveyor 24, the carrier or pallet proceeds in the same direction as the container transported by the return B conveyor 20. If the products are to be transferred to a container on the return B conveyor, the carrier or pallet is transported to that container at high speed. At the container, once the carrier or pallet is adjacent to the container, it is transported at the same speed as the container and the transfer means 9 is activated so that the products fall from the transfer means into the container. Once the transfer is completed, the carrier or pallet is transported to the endless return conveyor 29.

[0071] Empty carriers or pallets can be transported in a counterclockwise direction from the feed magnetic conveyor 24 via the first transverse magnetic conveyor 26 to the return magnetic conveyor 25 and then to the endless return conveyor 29. Depending on the position on the feed magnetic conveyor, the carriers or pallets can also be transported backwards on the feed magnetic conveyor 24 to the second transverse magnetic conveyor 27 where they are returned to the endless return conveyor 29.

[0072] If the products are not to be transferred to a container on the return B conveyor, the carrier or pallet is further transported at high speed via the first transverse magnetic conveyor 26 to the return magnetic conveyor 25. On the return magnetic conveyor 25, the carrier or pallet proceeds in the same direction as the containers on the feed A conveyor 15. Once the carrier or pallet is adjacent to a container to which the products are to be transferred, it is transported at the same speed as the container and the transfer means 9 is activated so that the products drop from the transfer means into the container. Once the transfer is complete, the carrier or pallet is transported to the endless return conveyor 29.

[0073] In product flows where several carriers or pallets are used to deliver products simultaneously, it is advantageous to transport all carriers or pallets in the same direction. By using several carriers or pallets simultaneously, a small number of carrier or pallet trains are formed on the magnetic conveyor. When a carrier or pallet slows down to transfer a product to a container, all following carriers or pallets will also slow down to the same speed. Once the product has been transferred, the first carrier or pallet and the following carriers or pallets can resume high speed until another carrier or pallet is in position to transfer a product. The following carriers or pallets will also slow down until the product has been transferred. These dynamic carrier or pallet trains form and disappear until the carriers or pallets enter the endless return conveyor, where all the carriers or pallets are transported at the same speed by the endless conveyor.

[0074] The second product path 3 comprises a second conveyor 6, which may be an endless chain conveyor. It may be, for example, a plastic chain conveyor with one or two plastic chains. The second conveyor may also consist of several straight belt conveyors, or a twin track conveyor with two metal chains. The advantage of using a plastic chain conveyor is that such a conveyor can extend around curves, which simplifies the sorting system. Such a conveyor may also extend vertically up and down, which is advantageous when a conveyor has to pass another conveyor. Depending on the length of the second conveyor, the second conveyor may consist of several endless plastic chain conveyors. The second conveyor is arranged to transport containers 8 adapted to receive the products. The containers 8 may be any type of container or box, suitable for receiving products delivered by carriers or pallets, which can be transported on the second conveyor.

[0075] The second conveyor is arranged to transport the containers at a constant synchronous speed. In this way, the position of each container can be determined in a predictable manner by the control system. In order to make the position of the containers predictable, the second conveyor can be provided with some kind of spacer means so that the position of each container is fixed on the conveyor and the container cannot slip or move. This can be, for example, teeth or protrusions arranged at defined distances. Each container can also be provided with an identification means, for example an RFID tag or a bar code, so that the position of each container can be detected. Since the position of each container is known, the carrier or pallet can easily target and track the container during the transfer of the products.

[0076] In the example shown in figures 1 and 2, the second product path 3 comprises two second conveyors, namely the A conveyor 14 and the B conveyor 18. The A conveyor 14 comprises an infeed A conveyor 15, a return A conveyor 16 and a turn A area 17. The B conveyor 18 comprises an infeed B conveyor 19, a return B conveyor 20 and a turn B area 21. Empty containers 8 enter the sorting system in the infeed area 10, for example on the infeed conveyor 13 or from a vertical store. In the infeed area, the empty containers can be held until they can be sent either to the infeed A conveyor or to the infeed B conveyor. The infeed area 10 comprises a first transverse conveyor 22, which can transport the containers laterally. The first transverse conveyor 22 may consist of several short conveyor paths. When there is an empty slot in the Feed A Conveyor or an empty container is required, the empty container is transferred from the infeed conveyor to the Feed A Conveyor 15, for example by a first transverse conveyor. The infeed area is positioned in the illustrated example at a low level below the magnetic conveyor 4. From the infeed area, the Feed A Conveyor extends vertically upwards to a height where the upper level of the container is slightly below the transport means of the carrier or pallet. The identification of the empty container may be read in the infeed area, so that the control system can determine the actual position of the container throughout the second product path.

[0077] The feed A conveyor 15 extends along the magnetic conveyor to the turn A area 17, where the A conveyor 14 makes a 180° turn. In the illustrated example, the feed A conveyor 15 extends inside the magnetic conveyor and in a clockwise direction when viewed from above. The turn A area may comprise a second transverse conveyor 23 that transports the containers laterally. If the A conveyor is an endless plastic conveyor chain, the turn area may also comprise a 180° turn. In the illustrated example, the turn area is also positioned at a lower level, so that the containers can pass under the magnetic conveyor. From the turn area, the return A conveyor 16 returns the containers to the first outfeed area 11. In the first outfeed area, the containers may leave the A conveyor or be returned to the feed A conveyor by the first transverse conveyor 22. If the container is not full the first time, the partially filled container may be sent another time on the Feed A conveyor.

[0078] Empty containers can also be conveyed from the infeed conveyor to the feed B conveyor 19 by a first transverse conveyor. From the infeed area, the feed B conveyor extends vertically upwards to a height where the upper level of the containers is slightly below the transport means of the carriers or pallets. The feed B conveyor 19 extends along the magnetic conveyor to the turn B area 21, where the B conveyor 18 makes a 180° turn. In the example shown, the feed B conveyor 19 extends inside the magnetic conveyor and in a counterclockwise direction when viewed from above. The turn B area may also comprise a second transverse conveyor 23 which transports the containers laterally, or a 180° turn if the B conveyor is an endless plastic conveyor chain. In the example shown, the turn area is also positioned at a lower level, so that the containers can pass under the magnetic conveyor. From the turn area, the return B conveyor 20 returns the container to the second outfeed area 12. At the second outfeed area, the container can either leave the B conveyor or be returned to the outgoing B conveyor by the first cross-machine conveyor 22. If the container is not full the first time, the partially filled container may be sent another time from the return conveyor to the outgoing B conveyor.

[0079] The first outfeed area 11 and the second outfeed area 12 are used to output the completed containers, i.e. the containers that have received all the foreseen product. The completed containers are transported from the outfeed areas to a manifest location, for example by a further chain conveyor.

[0080] At the manifest location, the containers may be temporarily stored before being shipped to the customer or sent to the consumer.

[0081] The carrier or pallet 7 is configured to be transported by both the magnetic conveyor 4 and the first endless chain conveyor 5. The carrier or pallet may resemble a conventional pallet adapted to be transported by an endless chain conveyor, but also comprises magnetic means 30 at the base of the carrier or pallet. The magnetic means may be, for example, a magnetic metal, or any type of permanent magnet. A linear magnetic motor of the magnetic conveyor creates a magnetic field that moves the carrier or pallet. The carrier or pallet is further provided with transfer means 9 arranged to transfer the products positioned on the carrier or pallet to a receiving container 8 moving on the second conveyor. The transfer means may be, for example, a ramp function, a belt function, or any type of pusher.

[0082] The magnetic conveyor 4 comprises a linear motor capable of driving the carriers or pallets in the direction of the product flow of the sorting system. The linear motor comprises a number of magnetic coils capable of controlling the movement of the carriers or pallets in the magnetic conveyor. The magnetic conveyor is capable of driving and positioning the carriers or pallets with great precision and at high speed.

[0083] The transport means are actuated by actuators arranged on the carrier or pallet. The actuators are preferably electric actuators, for example electric motors or electric linear actuators, such as solenoids. The actuators may be powered by an external power source or by a power source arranged on the carrier or pallet. In the case of an external power source, the carrier or pallet is provided with sliding contacts that interact with at least two busbars arranged on the magnetic conveyor. The busbars may for example conduct zero potential and act as a ground reference. In one example, the second busbar may conduct a positive voltage, for example 24 volts direct current. The third busbar may conduct a negative voltage, for example -24 volts direct current. To transport the products in one direction, the positive busbar is actuated such that the DC motor of the transport means rotates in a first direction. This transports the products in the first direction, for example to the right. To transport the products in the other direction, the negative busbar is actuated such that the DC motor of the transport means rotates in a second direction. This transports the products in the second direction, for example to the left.

[0084] In the example shown, the busbar is provided with a number of controllable sections, and one section can be activated when the transfer means is to transfer the product. When the carrier or pallet is in the right position for transfer, one busbar section is activated, which activates the transfer means to transfer the product to the correct container. Such a passive carrier or pallet is a simple and cost-effective solution.

[0085] In another example, the magnetic conveyor is provided with two bus bars. The bus bars can either conduct a DC voltage, for example 24 volts direct current, or an AC voltage, for example 24 volts alternating current. The sliding contacts of the carriers or pallets are in constant contact with the bus bars, whereby the carriers or pallets are always energized. The voltage can feed a control unit of the carriers or pallets, which can comprise a radio receiver that receives a transport signal when the transport means should transport a product. The bus bars can also transmit a high-frequency control signal to each carrier or pallet. The transport signal triggers an actuator of the transport means, whereby the products are transported at the right moment. It is also possible to provide the carriers or pallets with a rechargeable battery and an electronic control unit that can be instructed to transport the products, for example via a radio control signal.

[0086] When the products are transferred from the carrier or pallet to the container, the carrier or pallet is controlled to a position at the side of the container. The carrier or pallet travels at high speed until it is located at the side of the container. Once this position is reached, the speed of the carrier or pallet is controlled to correspond to the speed of the container. The speed of the container, and therefore the speed of the second conveyor, is known and the carrier or pallet is controlled to travel at the same speed. In FIG. 3, a carrier or pallet 7 picks up the products from the operator and is transported by the first chain conveyor 5 to the magnetic conveyor 4. Here, the carrier or pallet is transported at high speed to the container 8, so that the carrier or pallet is positioned at the side of the container and the carrier or pallet travels at the same speed as the container, as shown in FIG. 4.

[0087] When the carrier or pallet and the container move at the same speed, the product is transferred to the container in a controlled manner. In this way, there is no risk of the product being outside the container. Once the product has been transferred, the carrier or pallet is returned to the product dispensing station via the second product path to pick up new product.

[0088] The location where the actual product transfer takes place is also known as the deposit location, which corresponds to the location of the carrier or pallet 7 and the location of the container 8 in Figure 4.

[0089] The arrival of the carriers or pallets 7 at the magnetic conveyor 4 is not synchronized with the movement of the containers 8 located on the second endless conveyor 6. Thus, a container 8 suitable for receiving a product carried by a carrier or pallet 7 may be located virtually anywhere along the length of the second endless conveyor 6 at the time the carrier or pallet 7 arrives at the magnetic conveyor 4.

[0090] Also, the transfer means 9 required to transfer the products from the carriers or pallets 7 are preferably flexible with respect to the transfer position, although this is not strictly necessary.

[0091] As a result, the actual transfer position, i.e., the deposit position, can generally be anywhere along a significant portion of the second endless conveyor 6, i.e., where the magnetic conveyor 4 and the second endless conveyor 6 extend closely side-by-side in parallel relationship.

[0092] The control of the movement of the carriers or pallets 7 along the magnetic conveyor 4 can be implemented in various ways. For example, each carrier or pallet 7 may travel forward at a constant speed faster than the container speed until the carrier or pallet 7 catches up with a container dedicated to collecting the products loaded on the carrier or pallet 7. In this case, the carrier slows down to have the same speed as the container 8, the transfer means 9 of the carrier 7 are activated so that the products are transferred from the carrier 7 to the container 8, and then the speed of the carrier 7 is increased to the previous faster constant speed.

[0093] Based on such an exemplary motion control, the deposit locations will obviously be more or less randomly distributed along the length of the second endless conveyor 6 and can be transferred for each successive carrier or pallet 7. This is called a dynamic deposit location, because the deposit locations are not fixed and are generally different for each successive carrier or pallet 7 arriving at the magnetic conveyor 4. In the illustrated example, the deposit locations are dynamic deposit locations, which means that there are no fixed storage locations for the different containers. In a normal deposit location there are fixed, predefined locations for all the different possible destinations, which occupy unnecessary space that is rarely used. In the present system, each container is provided with some kind of individual identification tag. Preferably, radio transmitter / receiver tags are used, e.g. RFID tags, but it is also possible to use bar codes or the like. As each container can be identified at any time, the location of each container can be constantly monitored and tracked by the control system of the conveyor system. The use of independently identifiable containers allows for a dynamic depository location, whereby fixed, predefined locations for different containers are not required. In this manner, the depository location can be much smaller, which results in significant space savings.

[0094] In one example, the manifest location is configured according to planned deliveries for a certain time period. The time period can be, for example, an hour, or a few hours, or a day, depending on the throughput of the distribution center. For this time period, the number of different destinations and the number of containers at each destination is known. Thus, the control system can prepare a location for each container at the manifest location, for example, by allocating sufficient space for each destination in a buffer, etc. Depending on the number of different destinations, the containers can also be sent to predefined locations at the manifest location.

[0095] It is also possible that containers for different destinations are delivered at different times. In this case, when a container for one destination is delivered, this space can be used for a new destination. By using dynamic buffers, the storage space can be reduced to a minimum. At the manifest location, the contents of a container can be given directly to the customer in that container. This is possible, for example, if the customer is nearby and a certain delivery service is used, in which case the contents must not be packed in a box. This can be, for example, a store that can receive containers and return the empty container. In another example, the contents of the container are transferred to a certain box, which is then placed in a delivery depository, for example for postal delivery. When a container is emptied, its space can be used by another container.

[0096] In the method of the present invention for transferring products from a carrier to a container, the container is conveyed in a first direction by a second conveyor and the carrier is conveyed in the same direction by a magnetic conveyor. The second conveyor and the magnetic conveyor are positioned parallel and adjacent to each other. The carrier is provided with a conveying surface having a transfer means, the conveying surface being positioned at a height above the upper edge of the container.

[0097] In step 100, the containers are conveyed at a constant first speed by a second conveyor, which may be a chain or belt conveyor, on which the containers stand. The conveyor may be provided with spacer means, e.g. teeth, so that the position of each container is predetermined and the containers do not slip on the conveyor.

[0098] In step 110, the carrier is transported by the magnetic conveyor at a speed faster than the first speed of the second conveyor until the carrier is positioned to the side of the container, whereupon the carrier catches up with the container.

[0099] In step 120, the carrier is conveyed at the same speed as the second conveyor, so that the carrier and container move side by side at the same speed.

[0100] The transfer means of the carrier is actuated so that the product is transferred from the carrier to the container in step 130. Because the carrier and container are positioned side-by-side and travel at the same speed, the transfer of the product is secure and there is no risk of the product falling outside the container.

[0101] In step 140, the carriers are conveyed at a speed faster than the first speed on a second conveyor, where empty carriers can be conveyed away from the container at a high speed by a magnetic conveyor to make room for other carriers to transfer product to other containers.

[0102] The carriers are preferably transported to and from the magnetic conveyor by an endless chain conveyor, the carriers collecting the products at a product dispensing station positioned a distance from the magnetic conveyor, and for longer conveyor paths, an endless chain conveyor is much more cost effective.

[0103] According to an alternative exemplary embodiment of the method for transferring products from a first product carrier to a second product carrier, the first product carrier advances in a first direction and the second product carrier advances in the same direction. The first product carrier advances along a first product path and the second product carrier advances along a second product path, the first product path being adjacent and parallel to the second product path. The first product carrier is provided with a conveying surface equipped with a transfer means, the conveying surface being positioned at a height above an upper edge of the second product carrier.

[0104] In step 100, the second product carriers are moved at a constant first speed. The second product carriers may be transported at the constant first speed by a second endless conveyor. The second conveyor is, for example, a chain conveyor or a belt conveyor, on which the second product carriers stand. The second conveyor is provided with spacer means, for example teeth or protrusions, by which the position of each second product carrier is well defined and the second product carriers do not slip on the conveyor.

[0105] In step 110, the first product carrier is moved at a speed faster than the first speed until the first product carrier is positioned next to the second product carrier such that the first product carrier catches up with and is aligned with the second product carrier.

[0106] In step 120, the first product carrier pallet is moved at a first speed such that the first product carrier is aligned with the second product carrier such that the first product carrier and the second product carrier are moving side by side at the same speed.

[0107] The transfer means of the first product carrier is actuated so that the product is transferred from the first product carrier to the second product carrier in step 130. Because the first product carrier and the second product carrier are aligned with each other and move at the same speed, the transfer of the product is secure and there is no risk of the product being damaged or falling outside the second product carrier.

[0108] In step 140, the first product carrier is moved away from the second product carrier at a speed faster than the first speed, where an empty first product carrier can be moved away from the second product carrier at a high speed to clear space for another first product carrier to transfer product to another second product carrier.

[0109] The first product carrier is either a self-propelled AGV or a pallet transported by a magnetic conveyor. The first product carrier collects the products at a distribution station positioned a distance from the transfer area. The second product carrier may also be a self-propelled AGV or may be a container transported by an endless conveyor.

[0110] According to a further exemplary embodiment of the method of the invention for transferring products from a first product carrier to a second product carrier, the second product carrier is transported in a first direction by a second conveyor and the first product carrier is transported in the same direction by a magnetic conveyor. The second conveyor and the magnetic conveyor are positioned parallel and adjacent to each other. The first product carrier is provided with a conveying surface equipped with a transport means, the conveying surface being positioned at a height above an upper edge of the second product carrier.

[0111] The steps of the above further exemplary embodiment of the method are provided below: In this exemplary embodiment, the first product carrier may be a carrier and the second product carrier may be a container.

[0112] In a first step, the containers are transported at a constant first speed by a second conveyor, which may be a chain or belt conveyor, on which the containers stand. The conveyor may be provided with spacer means, e.g. teeth, by which the position of each container is predetermined and the containers do not slip on the conveyor.

[0113] In a second step, the carrier is conveyed by the magnetic conveyor at a speed faster than the first speed of the second conveyor until the carrier passes, i.e. runs past, the container, so that the carrier is positioned in front of the container in the direction of travel.

[0114] In a third step, the carrier is slowed down to a speed lower than the first speed of the second conveyor. In this way, the containers start to approach the stationary carrier from behind. The carrier is slowed down, for example, to a speed less than 50%, in particular less than 10%, of the first speed of the second conveyor. According to a further example, the carrier is completely stopped. Since the carrier can be stopped or moved slowly anywhere in front of the container, the carrier can be controlled to stop or move slowly in connection with or at the RFID reader or barcode reader, for example, to enable reliable location detection of the container when it is located near or at the carrier. Alternatively, or in combination with the previous example, the carrier can be controlled to stop or move slowly at a location where the carrier is connected to an external power source, for example to power the transport means. Thus, the carrier can be controlled to stop or move slowly at a location where the carrier is connected to an external power source, for example, via at least two bus bars arranged on the magnetic conveyor.

[0115] In a fourth step, when the container is positioned alongside the carrier, the transport means of the carrier is activated, thereby transferring the product from the carrier to the container, which is performed while the carrier is controlled to be stationary or moving slowly.

[0116] In a fifth step, the carriers are conveyed at a speed faster than the first speed on a second conveyor, where empty carriers can be conveyed away from the container at a high speed by the magnetic conveyor to clear space for other carriers to transfer product to other containers.

[0117] During all the above steps, the containers are transported by a second conveyor at a constant first speed.

[0118] The present disclosure also includes the following clauses, which define exemplary embodiments of the present disclosure.

[0119] Terms 1. A method for transferring a product from a first product carrier to a second product carrier, the first product carrier moving in a first direction and the second product carrier moving in the same direction; moving a second product carrier at a constant first speed; moving the first product carrier at a velocity faster than the first velocity until the first product carrier is positioned adjacent to the second product carrier; moving the first product carrier at the same speed as the second product carrier; activating a transfer means of the first product carrier such that the product is transferred from the first product carrier to the second product carrier; moving the first product carrier away from the second product carrier at a velocity greater than the first velocity; A method comprising: 2. The method according to clause 1, wherein the second product carrier 8 is transported by a second endless conveyor 6. 3. The method according to clause 2, wherein the second endless conveyor 6 is provided with spacer means adapted to maintain the position of the second product carrier 8. 4. The method of any of clauses 1 to 3, wherein the first product carrier 7 is a pallet transported by the first endless conveyor 5. 5. The method according to clause 4, wherein the first endless conveyor 5 is a magnetic conveyor. 6. The method according to clause 4 or 5, wherein the transport means 9 is powered through a busbar arranged on the first endless conveyor 5. 7. The method of any of clauses 1 to 3, wherein the first product carrier is a stand-alone automated guided vehicle equipped with wheels. 8. The method of claim 1, wherein the first product carrier and the second product carrier are independent automated guided vehicles equipped with wheels. 9. A conveyor system 1 adapted for transferring products from a first product carrier 7 to a second product carrier 8, the conveyor system 1 comprising a plurality of first product carriers 7, a plurality of second product carriers 8, a first product path 2, and a second product path 3, the first product carriers 7 being arranged to move in a first direction along the first product path 2, the second product carriers 8 being arranged to move in the first direction along the second product path 3 at a constant first speed, the first product carriers 7 being , arranged to move into a position aligned with a second product carrier 8 at a speed faster than the first speed, the first product carrier 7 arranged to move adjacent to the second product carrier 8 at the first speed and to transfer product to the second product carrier 8 by actuating a transfer means 9 when moving adjacent to the second product carrier 8, and the first product carrier 7 arranged to move away from the second product carrier 8 at a speed faster than the first speed once the product has been transferred. 10. A conveyor system as described in clause 9, wherein the second product path 3 comprises an endless conveyor 6. 11. A conveyor system as described in clause 9 or 10, wherein the first product carrier 7 is an automated guided vehicle 30. 12. A conveyor system as described in clause 9 or 10, wherein the first product carrier 7 is a pallet and the first product path 2 comprises a magnetic conveyor 4. 13. A conveyor system as described in any of clauses 9 to 12, wherein the first product path 2 further comprises an endless plastic chain conveyor 5. 14. A conveyor system as described in clause 12 or 13, wherein the infeed area 10 and the outfeed areas 11, 12 are positioned at a level below the magnetic conveyor 4. 15. A conveyor system as described in any of clauses 12 to 14, wherein the magnetic conveyor 4 comprises at least two bus bars arranged to conduct voltage to the pallets.

[0120] The present disclosure also includes the following clauses, which define exemplary embodiments of the present disclosure.

[0121] Terms 1. A method for transferring products from a first product carrier to a second product carrier in a conveyor system 1 comprising a plurality of first product carriers 7 and a plurality of second product carriers 8, each second product carrier being provided with some sort of individual identification tag; moving a second product carrier at a constant first speed; moving the first product carrier at a velocity greater than the first velocity until the first product carrier is positioned adjacent to the second product carrier; moving the first product carrier at the same speed as the second product carrier; activating a transfer means of the first product carrier such that the product is transferred from the first product carrier to the second product carrier; moving the first product carrier away from the second product carrier at a speed greater than the first speed; A method, wherein an independently identifiable second product carrier is used for the dynamic depository location. 2. The method of claim 1, wherein the transfer of the product from the first product carrier to the second product carrier is performed when the first product carrier travels in a first direction and the second product carrier travels in the same direction. 3. A method according to any of the preceding clauses 1 to 2, wherein the second product carrier 8 is transported by a second endless conveyor 6. 4. The method according to clause 3, wherein the second endless conveyor 6 is provided with spacer means adapted to maintain the position of the second product carrier 8. 5. The method of any of clauses 1 to 4, wherein the first product carrier 7 is a pallet transported along the first product path 2. 6. The method according to clause 5, wherein the first product path 2 comprises a first endless conveyor 5 and a magnetic conveyor 4. 7. The method according to any of clauses 1 to 6, wherein the transport means 9 is powered via a busbar arranged on the first endless conveyor 5. 8. The method of any of clauses 1 to 4, wherein the first product carrier is a stand-alone automated guided vehicle equipped with wheels. 9. The method of any of clauses 1 to 4, wherein the first product carrier and the second product carrier are independent automated guided vehicles equipped with wheels. 10. A method according to any of clauses 1 to 7, wherein the first product path comprises a first endless conveyor arranged to transport a first product carrier, and a linear magnetic conveyor arranged to transport the first product carrier using magnetic force; loading a product stored at a storage or distribution station onto a first product carrier; moving a first product carrier from a storage or distribution station to a transfer area having a straight portion of a magnetic conveyor arranged parallel to a conveyor of a second product carrier; moving the first product carrier with the magnetic conveyor to transfer the product from the first product carrier to the second product carrier; moving the empty first product carrier from the transfer area back to the dispensing station by the first endless conveyor; A method comprising: 11. The method according to any of clauses 6 to 7 and 10, wherein the second product path 3 comprises two second conveyors, namely an A conveyor 14 and a B conveyor 18, the A conveyor 14 comprising an outgoing A conveyor 15, a return A conveyor 16 and a turn A area 17, the B conveyor 18 comprising an outgoing B conveyor 19, a return B conveyor 20 and a turn B area 21, the outgoing A conveyor 15 being connected to a magnetic conveyor along a turn A area 17 where the A conveyor 14 makes a 180° turn. and a feed B conveyor 19 extends along the magnetic conveyor to a turn B area 21 where the B conveyor 18 makes a 180 degree turn, and the method comprises controlling a first product carrier to selectively transfer products conveyed by the first product carrier in a first direction into receptacles on the return A conveyor 16 or the return B conveyor 20, or to transfer products conveyed by the first product carrier in the other direction into receptacles on the feed A conveyor 15 or the feed B conveyor 19. 12. The method of claim 11, comprising feeding empty containers to an in-feed area 10 of a conveyor system and holding the empty containers until they are fed to either the Feed A Conveyor or the Feed B Conveyor. 13. Controlling the first transverse conveyor 22 so that the second product container leaves the A conveyor in the first outfeed area or is returned to the infeed A conveyor; 13. The method of any of clauses 11 to 12, comprising controlling the first transverse conveyor 22 so that the second product container leaves the B conveyor at the second outfeed area or is returned to the feed B conveyor. 14. A method as claimed in any of clauses 1 to 7 and 10 to 13, comprising transporting a first product carrier 7 by both a magnetic conveyor 4 and a first endless chain conveyor 5, and moving the first product carrier by a linear magnetic motor of the magnetic conveyor which creates a magnetic field which interacts with a magnetic means 30 at the base of the first product carrier to move the first product carrier. 15. A conveyor system 1 adapted for transferring products from a first product carrier 7 to a second product carrier 8, the conveyor system 1 comprising a plurality of first product carriers 7, a plurality of second product carriers 8, a first product path 2, and a second product path 3, the first product carriers 7 arranged to move along the first product path 2, the second product carriers 8 arranged to move along the second product path 3 in a first direction at a constant first speed, and the first product carriers 7 arranged to move into alignment with the second product carriers 8 at a speed faster than the first speed. a first product carrier 7 arranged to move adjacent to a second product carrier 8 at a first speed and to transfer product to the second product carrier 8 by actuating a transfer means 9 when moving adjacent to the second product carrier 8, the first product carrier 7 arranged to move away from the second product carrier 8 at a speed faster than the first speed once the product has been transferred, each second product carrier 8 being provided with some type of individual identification tag, and the conveyor system 1 arranged to provide a dynamic depository location. 16. A conveyor system as described in clause 15, wherein the first product carrier 7 is arranged to move in a first direction along the first product path 2. 17. A conveyor system according to any of clauses 15 to 16, wherein the second product path 3 comprises an endless conveyor 6. 18. A conveyor system according to any of clauses 15 to 17, wherein the first product carrier 7 is an automated guided vehicle 30. 19. A conveyor system according to any of clauses 15 to 17, wherein the first product carrier 7 is a pallet and the first product path 2 comprises a magnetic conveyor 4. 20. A conveyor system as described in any of clauses 15 to 17 and 19, wherein the first product path 2 further comprises a first endless chain conveyor 5. 21. A conveyor system as described in clause 19, wherein the magnetic conveyor 4 comprises at least two bus bars arranged to conduct voltage to the pallets. 22. A conveyor system as described in any of clauses 15 to 21, wherein each second product carrier is provided with a radio transmitter / receiver tag, an RFID tag, or a bar code or the like. 23. A conveyor system as described in any of clauses 15 to 17 and 19 to 22, wherein the first product path comprises a first endless chain conveyor arranged to transport a first product carrier and a linear magnetic conveyor arranged to transport the same first product carrier using magnetic force, the first endless conveyor moves the first product carrier from a loading position at the distribution station to a transfer area having a straight portion of the magnetic conveyor arranged parallel to the conveyor of the second product carrier, the magnetic conveyor being arranged to enable transfer of product from the first product carrier to the second product carrier, and the first endless conveyor is arranged to transport the empty first product carrier from the transfer area back to the distribution station. 24. The second product path 3 comprises two second conveyors, namely A conveyor 14 and B conveyor 18, the A conveyor 14 comprises an outgoing A conveyor 15, a return A conveyor 16 and a turn A area 17, the B conveyor 18 comprises an outgoing B conveyor 19, a return B conveyor 20 and a turn B area 21, the outgoing A conveyor 15 runs along the magnetic conveyor to the turn A area 17 where the A conveyor 14 makes a 180 degree turn, and the outgoing B conveyor 15 runs along the magnetic conveyor to the turn A area 17 where the A conveyor 14 makes a 180 degree turn, and the outgoing B conveyor A conveyor system as described in any of clauses 19 to 23, wherein the conveyor 19 extends along the magnetic conveyor to a turn B area 21 where the B conveyor 18 turns 180 degrees, and the products carried by the first product carrier can be selectively controlled to transfer the products in a first direction into a container on the return A conveyor 16 or the return B conveyor 20, or to transfer the products in the other direction into a container on the feed A conveyor 15 or the feed B conveyor 19. 25. A conveyor system as described in clause 24, wherein empty containers 8 enter the sortation system at an in-feed area 10, where the empty containers may be held until they can be fed to either the Feed A Conveyor or the Feed B Conveyor. 26. A conveyor system as described in any of clauses 24 to 25, wherein from the turnaround area, the return A conveyor 16 returns the containers to the first outfeed area 11, and from the turnaround area, the return B conveyor 20 returns the containers to the second outfeed area 12. 27. A conveyor system as described in clause 26, wherein in the first outfeed area the containers may leave the A conveyor or be returned by the first short-distance conveyor 22 to the feed A conveyor, and in the second outfeed area the containers may leave the B conveyor or be returned by the first short-distance conveyor 22 to the feed B conveyor. 28. A conveyor system as described in any of clauses 25 to 27, wherein the infeed area 10 and the outfeed areas 11, 12 are positioned at a level below the magnetic conveyor 4. 29. A conveyor system as described in any of clauses 15 to 28, wherein a first product carrier 7 is arranged to be transported by both the magnetic conveyor 4 and the first endless chain conveyor 5, the first product carrier being provided with magnetic means 30 at a base of the first product carrier, and a linear magnetic motor of the magnetic conveyor being arranged to create a magnetic field which moves the first product carrier.

[0122] The invention should not be considered limited to the above-described embodiments, and numerous additional variations and modifications are possible within the scope of the following claims. The conveyor system may comprise any number of carriers and the containers may have any size or shape. [Explanation of symbols]

[0123] 1: Sorting or conveyor systems 2: First product route 3: Secondary product pathway 4: Linear magnetic conveyor 5: First endless conveyor 6: Second conveyor 7: Carrier or first product carrier 8: Container or secondary product carrier 9:Transportation means 10: Infeed area 11: First outfeed area 12: Second outfeed area 13: Infeed conveyor 14: A Conveyor 15: Feed A conveyor 16: Return A conveyor 17: Turning A area 18: B Conveyor 19: Feed B conveyor 20: Return B conveyor 21: Turning B area 22: First short side conveyor 23: Second short-side conveyor 24:Feed magnetic conveyor 25: Return magnetic conveyor 26: First short-distance magnetic conveyor 27: Second short-distance magnetic conveyor 28: Endless delivery conveyor 29: Endless return conveyor 30: Magnetic means

Claims

1. A sorting system (1) comprising a first product path (2) and a second product path (3), The first product path (2) comprises a linear magnetic conveyor (4) and a first endless chain conveyor (5); said second product path (3) comprising a second conveyor (6); The sorting system (1) comprises a plurality of carriers (7) and a plurality of containers (8); said first product path (2) being arranged to transport said carriers (7); the second product path (3) is arranged to convey the containers (8) at a constant first speed; a portion of the linear magnetic conveyor (4) is disposed adjacent to and parallel to the second conveyor (6); The carrier (7) is provided with magnetic means (30) so that it can be transported by said linear magnetic conveyor (4); A sorting system, wherein the linear magnetic conveyor (4) is arranged to transport the carriers (7) at a variable speed and to individually control the positions of the carriers (7).

2. 2. The sorting system of claim 1, wherein the second product path (2) comprises an infeed area (10) for feeding empty containers (8) to the second conveyor (6) and an outfeed area (11, 12) for exiting loaded containers (8) from the second conveyor (6).

3. A sorting system according to claim 1 or 2, wherein the linear magnetic conveyor (4) forms a closed loop.

4. A sorting system according to any of claims 1 to 3, wherein the first endless chain conveyor (5) starts and ends at the linear magnetic conveyor (4).

5. A sorting system according to any one of claims 2 to 4, wherein the infeed area (10) and the outfeed area (11, 12) are positioned at a level below the linear magnetic conveyor (4).

6. A sorting system according to any one of claims 1 to 5, wherein the second product path (3) extends outside the linear magnetic conveyor (4).

7. 7. A sorting system according to any of the preceding claims, wherein the linear magnetic conveyor (4) comprises at least two bus bars arranged to conduct a voltage to the carriers.

8. The sorting system of claim 7 , wherein the voltage is a DC voltage.

9. The sorting system of claim 7 , wherein the voltage is an AC voltage.

10. A sorting system according to any of claims 7 to 9, wherein at least one busbar is divided into a plurality of controllable sections.

11. A method for transferring products from a carrier (7) to a container (8), said container (8) being conveyed in a first direction by a second conveyor (6) and said carrier (7) being conveyed in the same direction by a linear magnetic conveyor (4), conveying the containers (8) by the second conveyor (6) at a constant first speed; conveying said carrier (7) by said linear magnetic conveyor (4) at a speed faster than said first speed until said carrier (7) is positioned at said side of said container (8); conveying said carrier (7) at the same speed as said container (8); activating the transfer means (9) of said carrier (7) so that said product is transferred from said carrier (7) to said container (8); conveying said carrier (7) at a speed faster than said first speed; A method comprising:

12. 12. The method according to claim 11, comprising the additional steps of transporting the carriers (7) to the linear magnetic conveyor (4) by an endless chain conveyor (5) and transporting the carriers (7) from the linear magnetic conveyor (4) by an endless chain conveyor (5).

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