System and method for loading articles for a multi-level sorter

Abstract

A multi-level sorting station is disclosed. The multi-level sorting station includes a plurality of sorting levels arranged in a vertically stacked configuration, a vertically movable automatic lift that transports articles vertically between the plurality of sorting levels along a frame arranged adjacent to the plurality of sorting levels, an information acquisition device arranged to read information from the articles on the lift, a plurality of transport devices arranged on the plurality of sorting levels for receiving the articles, and a control system that guides the multi-level sorting station to determine the destination of the articles and guide the lift to a platform where there is a transport device at the article receiving position at the sorting level for receiving the articles.

Description

Detailed Description of the Invention

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Non - Provisional Patent Application No. 17 / 812,055, entitled "Article Loading System and Method for Multilevel Sorter", filed on July 12, 2022, the entire content of which is incorporated herein by reference.

[0002] [Technical Field] The present invention generally relates to material handling technology. In particular, the present invention relates to a multilevel induction station that uses an automatic lift that enables a single operator to direct articles from a single operator position to multiple locations.

[0003] [Background Art] Induction stations for material handling facilities are well known in the art. In conventional induction stations, an operator receives an article and then “inducts” the article into a material handling device or system so that the article can be further processed. Generally, sorting of articles continues to become increasingly competitive and lead times to delivery continue to become shorter and shorter. Conventional induction stations have a bottleneck in that the operator at the induction station is subject to time limitations due to the maximum possible throughput of articles. Further, the amount of orders processed in a given time is increasing. For this reason, more space is required for order containers along the periphery of the sorter. Adding additional levels for sorting operations can serve to partially solve this problem. On the other hand, when these additional levels are spaced vertically, such vertical expansion often poses an ergonomic hazard to operators who must repeatedly reach higher to induct articles onto the sorting device. Thus, there is a need for an ergonomic induction station that enables higher throughput to multiple levels by a single operator.

[0004] [Summary] This summary is provided to introduce in a simplified form ideas further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it to be construed as limiting the scope of the claimed subject matter.

[0005] According to one or more embodiments, the multi-level sorting station includes a plurality of sorting levels arranged in a vertical stacked configuration. The multi-level sorting station further includes a mobile automatic lift having an article carrying surface. The multi-level sorting station further includes a frame disposed adjacent to the plurality of sorting levels, the frame extending to at least the same height as the highest sorting level of the plurality of sorting levels. The frame is configured to support the lift as the lift moves between the plurality of sorting levels. The multi-level sorting station may further include an information acquisition device arranged to read information from an article disposed on the article carrying surface of the lift. The multi-level sorting station further includes a plurality of transport devices, with at least one transport device at each sorting level. The multi-level sorting station further includes a control system including a processor. The processor is configured to receive article data for identifying an article disposed on the article carrying surface of the lift. The processor is further configured to determine a destination of the article disposed on the article carrying surface of the lift based on the article data. The processor is further configured to direct the lift to one of the plurality of sorting levels. Here, the transport device is an article receiving position adjacent to the frame, and is disposed at an article receiving position at one of the plurality of sorting levels. The processor is further configured to direct the lift to place the article disposed on the article carrying surface of the lift onto the transport device at the article receiving position by operating the article carrying surface of the lift. The processor is further configured to direct the transport device to the destination. The processor is further configured to direct the lift to a guiding height or guiding level.

[0006] According to one or more embodiments, a control system for a multi-level induction station is disclosed. The control system includes a processor. The processor is configured to receive article data identifying an article disposed on an article-carrying surface of an automatic lift that moves a frame of the multi-level induction station. The processor is further configured to determine a destination of the article disposed on the article-carrying surface of the lift based on the article data. The processor is further configured to direct the lift to one of a plurality of sorting levels of the multi-level induction station. Here, a transport device is waiting at an article receiving position proximate to the frame, the article receiving position being at one of the plurality of sorting levels. The processor is further configured to direct the lift to place the article disposed on the article-carrying surface of the lift onto the movable transport device at the article receiving position by operating the article-carrying surface of the lift. The processor is further configured to direct the movable transport device to the destination. The processor is further configured to direct the lift to an induction height or induction level of the multi-level induction station.

[0007] According to one or more embodiments, a multi-level induction station is disclosed. The multi-level induction station includes a plurality of sorting levels arranged in a vertical stack configuration. The multi-level induction station further includes a mobile automatic lift having an article carrying surface. The multi-level induction station further includes a frame disposed proximate to the plurality of sorting levels, the frame extending to at least the same height as the highest sorting level of the plurality of sorting levels. The frame is configured to support the lift as the lift moves between the plurality of sorting levels. The multi-level induction station includes a plurality of transport devices, with at least one transport device at each sorting level. The multi-level induction station further includes a control system. The control system includes a processor. The processor is configured to guide the lift to one of the plurality of sorting levels. Here, the transport device is at an article receiving position proximate to the frame and at an article receiving position at one of the plurality of sorting levels. The processor is further configured to guide the lift to place an article disposed on the article carrying surface of the lift onto the transport device at the article receiving position by operating the article carrying surface of the lift. The processor is further configured to guide the transport device to a destination. The processor is further configured to guide the lift to a guiding height or guiding level.

[0008] [Brief Description of the Drawings] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings necessary for the embodiments will be briefly introduced below. It should be noted that the following drawings merely show a part of the embodiments of the present invention, and therefore should not be construed as limiting the scope of the present invention. It should also be understood that those skilled in the art can obtain further related drawings according to the drawings without making creative efforts.

[0009] FIG. 1 is a front perspective view of an exemplary embodiment of a multi-level guidance station.

[0010] FIG. 2 is a side perspective view of an exemplary embodiment of a multi-level guidance station.

[0011] FIG. 3 is a side view of an exemplary embodiment of a multi-level guidance station.

[0012] FIG. 4 is a top perspective view of an exemplary embodiment of a multi-level guidance station.

[0013] FIG. 5 is a top perspective view of an exemplary embodiment of a multi-level guidance station.

[0014] FIG. 6 is a top view of an exemplary embodiment of a multi-level guidance station.

[0015] FIG. 7 is a side perspective view of an exemplary embodiment of a multi-level guidance station.

[0016] FIG. 8 is a side perspective view of an automatic lift according to an embodiment of a multi-level guidance station.

[0017] FIG. 9 is a side perspective view showing an automatic lift according to an embodiment of a multi-level guidance station in a first position.

[0018] FIG. 10 is a side perspective view showing an automatic lift according to an embodiment of a multi-level guidance station in a second position.

[0019] FIG. 11A is a block diagram of an exemplary embodiment of a multi-level guidance station.

[0020] FIG. 11B is a block diagram of an exemplary embodiment of a multi-level guidance station.

[0021] [Detailed Description of the Embodiment] The following clearly and comprehensively shows the technical solution means in the embodiments of the present invention with reference to the figures according to the embodiments of the present invention. Obviously, the embodiments shown here are not all of the embodiments of the present invention, but only a part of the embodiments. Generally, the components in the embodiments of the present invention shown in the drawings of this specification can be arranged and designed according to various configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the present invention described in the claims, but merely represents the selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments that can be obtained by those skilled in the art without creative efforts belong to the protection scope of the present invention.

[0022] The embodiments disclosed herein provide a solution to the problems of inefficient and ergonomically non - practical induction stations. In particular, the embodiments disclosed herein provide a multi - level induction station. With this multi - level induction station, a single operator can increase the throughput of articles in a material handling facility. The multi - level induction station described herein is automated. This helps to eliminate problems related to human error and enables the operator to work more quickly, thus improving the efficiency of the induction station. Furthermore, the multi - level induction station is more preferable for the operator. Because with the multi - level induction station, a more ergonomic working space is obtained, so that the operator uses smaller movements, and as a result, fatigue and / or tension are reduced. The multi - level induction station described herein enables an induction station that is higher than the reach of the operator's hand. Thereby, the induction station can be expanded in the vertical (longitudinal) direction so as to increase the throughput.

[0023] FIG. 1 is a front perspective view of an exemplary embodiment of a multi-level induction station. Referring to FIG. 1, the multi-level induction station 101 includes a plurality of sorting levels 103, 105, and 107 arranged in a vertical stacked configuration. In various embodiments, the multi-level induction station 101 may include two, three, four, or more sorting levels arranged in a vertical stacked configuration. In one embodiment, as shown in FIG. 1, the plurality of sorting levels includes platforms (stages) at each level.

[0024] The multi-level induction station 101 is configured to induct articles 133, 135, 137, 145, and 147. Each article may include identifiers 151, 159, 161, 163, and 165. In various embodiments, the identifier may take the form of a barcode, QR code, text label, RFID, etc. The articles may be delivered to the multi-level induction station using an article delivery device 129. The article delivery device 129 may be a manual rolling cart (shown in FIG. 1), an automatic movable transport device, a conveyor, a pick port from an automatic storage system, etc. The article delivery device 129 may directly carry one or more articles 133, 135, and / or 137 on the delivery device, or the article delivery device 129 may carry one or more articles 133, 135, and / or 137 in a bin 127. The articles may be manually loaded onto a lift such as lifts 131, 141, and 143 from the article delivery device 129, and then the articles may be automatically loaded onto the transport device by intelligently controlling the lift through a control system. In one embodiment, the operator may select one or more articles from the article delivery device 129 or the bin 127 and place the article on the lift with the identifier disposed on the article so that it can be read by an information acquisition device (e.g., information acquisition devices 153, 155, 157). The information acquisition device automatically interacts with the identifier to perform article recognition. One or more information acquisition devices (e.g., information acquisition devices 153, 155, 157) may be disposed above the article to read the identifier of the article from above. Instead of being disposed above the article, or in addition to being disposed above the article, one or more information acquisition devices may be disposed on the side of the article, or may be disposed in proximity to the article in other manners. Within the scope of the present invention, any configuration that enables the reading of the identifier of the article by one or more information acquisition devices, either before or after the article is placed on the lift, is envisioned to be included.For example, in at least one embodiment, the identifier of the article may be read by an information acquisition device in the form of a handheld scanner (either before or after the article is placed on the lift). In one example, a human operator may scan the identifier of the article using an information acquisition device in the form of a handheld scanner (either before or after the article is placed on the lift tray). Thereafter, the information acquisition device communicates the identifier information associated with the article to the control system. For example, in one embodiment, the information acquisition device communicates with a sorter execution system (e.g., execution system 1164 as shown in FIG. 11B), and then the sorter execution system communicates with a lift and sorter control server (e.g., sorter control server 1152). In at least one embodiment, the height of the article delivery device may be established, adjusted, or calibrated by the execution system 1164 such that the height of the article is approximately the same as the induction height or induction level. Thereby, the operator can work at an optimal induction height or induction level (e.g., an adjustable induction height dynamically calculated according to the body anatomy of a particular operator) in an ergonomic manner that avoids unnecessary or non-ergonomic hand bending, stretching, and / or vertical movement.

[0025] In at least one embodiment, the multi-level induction station 101 enables placing two or more articles on the lift, thereby enabling multiple inductions to a single lift by the lifts 131, 141, or 143. In such an embodiment, the identifier of each article may be scanned (either by the information acquisition device or a human operator) before, simultaneously with, or after placing the multiple articles on the lift. In one embodiment, correspondingly, the control system may be configured to communicate to the operator regarding a particular plurality of articles that need to be induced to a single one of the lifts 131, 141, or 143, and the control system may further request that the operator approve that all the particular articles have been induced to the single lift before the next step of the process is initiated.

[0026] The multi-level induction station 101 further includes one or more mobile automatic lifts such as lifts 131, 141, and 143. Each lift has an article-carrying surface. In some embodiments, the lift may be configured to move in a vertical (longitudinal) direction. In some embodiments, the lift may be configured to move in three dimensions. In various embodiments, the article-carrying surface may be configured to carry or otherwise support oddly shaped articles including articles such as clothes with hangers. The article-carrying surface may be operated to place (lower) the article from the lift onto a transport device disposed at an article receiving position at one of a plurality of sorting levels. In one embodiment, the article-carrying surface may be an inclined tray or may include an inclined tray. In the inclined tray, as the tray tilts to one side, the article is pulled away from the tray by gravity. The article slides onto the transport device at the article receiving position at the sorting level. Thereafter, the tray rights itself in preparation to receive another article. The inclined tray can typically handle a variety of articles. The variety of articles can be small or large, irregular or shaped, light or heavy. The tilting motion of the inclined tray includes a forward motion (i.e., a motion towards the transport device such as transport devices 109, 111, 113, 115, 117, or 119) simultaneous with the tilting motion such that the leading edge of the lift tray (i.e., the edge closest to the transport device) covers at least a portion of the transport device at the article receiving position at the sorting level when tilted, so that the article can be delivered more smoothly from the lift tray to the transport device. In another embodiment, the article-carrying surface may be a cross-belt including a belt conveyor powered by a small motor or may include the cross-belt. The motor moves the conveyor to lower the article to the side of the cross-belt onto a transport device at the article receiving position at the sorting level. The cross-belt sorter can typically handle articles having irregular shapes. In another embodiment, the lift or the article-carrying surface may include a non-inclined tray having an article-pushing mechanism.In another embodiment, the lift or the article-carrying surface may include a cross belt, or an article pushing mechanism, or an article diverting mechanism.

[0027] In one embodiment, the lift may include a crane or may take the form of a crane. In one embodiment, the lift may include a telescopic robotic arm or may take the form of a telescopic robotic arm. In one embodiment, the robotic arm may be configured to hold an article, carry the article, and place the article onto a transport device disposed at an article receiving position at one of a plurality of sorting levels. In one embodiment, the lift may be replaced by any of known diverting mechanisms that operate to transfer an article from the lift onto the transport device.

[0028] Each of the lifts 131, 141, and 143 may be set to a specific induction height or induction level. This induction height or induction level is, for example, the height at which the lift stops to receive an article from the operator 139 within frames such as frames 121, 123, and 125. The induction height or induction level may be set by default to a specific pre-calculated height or dynamically calculated to a specific real-time height. In some embodiments, the induction height is set to a default height determined by a processor of the control system. Alternatively, the induction height or induction level may be set or customized by the operator 139 to take into account attributes such as the height of the operator, the length of the operator's arm, and whether the operator is sitting or standing. In some embodiments, the processor of the control system is configured to enable setting of the induction height to a user-specified height. By making the height customizable with respect to the induction height or induction level, a better ergonomics (efficient working environment) for the operator is provided. In one embodiment, the multi-level induction station 101 may include a button for adjusting the induction height or induction level, which allows the operator to set the height that is most comfortable for induction from the operator's perspective. For example, the induction height or induction level shown in FIG. 7 may be the position preferred by the first operator 139, but does not necessarily represent the position preferred by the second or third operator 139.

[0029] The multi-level induction station 101 includes frames 121, 123, and 125 disposed proximate to a plurality of sorting levels, and the frames extend to at least the same height as the highest sorting level of the plurality of sorting levels. Each frame is configured to support a lift as the lift moves vertically between the plurality of sorting levels. Each frame may include a plurality of support rails. The lift may be moved vertically by a belt, worm drive, pulley, rack and pinion, or other such mechanism. In various embodiments, the frames may form a square or rectangular shape, as shown, for example, in FIG. 1. The support rails of the frame may be engaged by the lift. Thereby, the support rails support the lift, and the support rails enable the lift to move vertically and optionally also laterally and horizontally. In one embodiment, each frame occupies a footprint that is slightly larger than the footprint occupied by the transport device. For example, in one embodiment, each frame may be 19’’ (width) × 19’’ (depth) × 82’’ (height). The height of the frame may be adjusted or customized depending on the height of the top platform and the ceiling, as well as other relevant features. In various embodiments, the multi-induction station includes a plurality of frames disposed proximate to each other.

[0030] In one embodiment, the multi-level guiding station 101 may further include a shielding panel (not shown in FIG. 1 for clarity) provided on one or more sides of the frame. In one embodiment, the shielding panel is configured on the side of the frame facing the operator such that the operator only has holes or openings provided on the shielding panel for guiding through the holes or openings. Thus, in various embodiments, the shield includes guiding openings or guiding holes for facilitating placement of an article on the article-carrying surface of the lift. In various embodiments, the shielding panel may function to protect the operator's hand from the moving parts of the lift. In various embodiments, the shield panel may be provided on a further side of the frame regardless of the presence or absence of an opening provided therein for purposes such as access to the lift, access for the operator, access for the transport vehicle, access for inspection, access for maintenance, and other similar purposes. In at least one embodiment, the shield panel may be formed of a transparent or translucent material. In some embodiments, the multi-level guiding station 101 may further include one or more sensors that operate such that the lift does not move unless the operator's arm is withdrawn from the opening that enables access to the lift and the tray. Thus, in at least one embodiment, the frame further includes a sensor that prevents the lift from moving before the operator's arm is withdrawn from the guiding opening.

[0031] The information acquisition devices 153, 155, and 157 of the multi-level induction station 101 are each arranged on the frame so that the information acquisition device reads information from an article placed on the article carrying surface of the lift. In one embodiment, as shown in FIG. 1, each information acquisition device is arranged on or near the back surface region of each frame (for example, the support rail) so as to read an identifier on the article below it. The information acquisition devices 153, 155, and 157 are configured to image or otherwise examine an image or other identifier of the article in order to determine the identification and / or destination of the article. In various embodiments, the information acquisition device may be a barcode reader, a QR code reader, a text reader, an RFID reader, or the like. The information acquisition device is configured to acquire article information of the article, and the article information may include the destination of the article. The information acquisition device interacts with an identifier on the article or the article itself.

[0032] The multi-level induction station 101 further includes a plurality of transport devices 109, 111, 113, 115, 117, and 119, and there is at least one transport device at each sorting level. In various embodiments, the transport devices 109, 111, 113, 115, 117, and 119 may include automated guided vehicles (AGVs), delivery robots, transport robots, loading / unloading robots, rail robots, bins on a rail system, bins on a conveyor system, bins on a truck-based system, truck and conveyor systems, or other types of mobile robots operable on a platform or on a rail system. The transport device may be self-powered and self-guided; the transport device may be part of a rail system to move along a predetermined path; the transport device may be driven by an external power source such as a worm gear mechanism. In at least one embodiment, the transport device is in wireless communication with a control system. In one embodiment, based on commands / signals received from the control system, the transport device can move in all directions across the platform to a destination area for further processing. The control system operates to manage the operation of the transport devices along the platform, including the movement of the movable transport devices, the avoidance of collisions between the movable transport devices, and all other related tasks. In other embodiments, the transport device moves to a destination on a rail system or a conveyor belt for further processing. In at least one embodiment, based on commands / signals received from the control system, the transport device can move in all directions across a first platform to a lift system, and then the lift system transports the transport device to a second platform above or below the first platform, and then the transport device moves in all directions across the second platform to a destination area for further processing.In at least one embodiment, the transport device can move omnidirectionally across the first platform to a robotic elevator system, and subsequently, the robotic elevator system transports the transport device, along with the article thereon, to a second platform above or below the first platform, and subsequently, the transport device moves omnidirectionally across the second platform to a destination area for further processing.

[0033] In some embodiments, the multi-level induction station further includes a plurality of transport systems, each system including a plurality of transport devices. The multi-level induction station may operate with other sorting systems and may therefore be used, for example, to direct items to a three-level bomb bay sorter stacked on top of each other.

[0034] The multi-level induction station 101 further includes a sorter control system (see FIGS. 11A and 11B) including a processor. The sorter control system and its processor are configured to receive article data that identifies articles placed on the article-carrying surface of the lift. The processor is further configured to determine the destinations of the articles placed on the article-carrying surface of the lift based on the article data. The processor is further configured to direct the lift to one of a plurality of sorting levels. Here, the transport device is an article receiving position proximate to the frame and is disposed at an article receiving position at one of the plurality of sorting levels. In one embodiment, the processor selects a particular transport device among a plurality of transport devices that is disposed at an article receiving position proximate to the frame and at an article receiving position at a particular one of the plurality of sorting levels. The processor is further configured to direct the lift in a state where an article is placed on the article-carrying surface of the lift so as to place the article onto the transport device disposed at the article receiving position by operating the article-carrying surface of the lift (for example, FIGS. 8 to 10 show that an article is placed by the lift). The processor is further configured to direct the transport device to the destination. The processor is further configured to direct the lift to an induction height or an induction level.

[0035] In one embodiment, as shown in FIGS. 1 to 7, the plurality of sorting levels may include a plurality of platforms, and the transport device may include an automatically movable transport device (for example, a robot) that moves on the platform. In one embodiment, the automatically movable transport device is disposed at or near an edge of the platform at an article receiving position that is position-adjusted with respect to the lift.

[0036] In at least one embodiment, the information acquisition device is optional. For example, in a sorting system where the same type of articles are always guided to a predetermined guiding station, or a certain amount of the same type of articles are guided, or the upstream system provides article information, there is no need to separately identify articles using the information acquisition device. In such an embodiment, the multi-level guiding station includes a plurality of sorting levels arranged in a vertical stacked configuration. The multi-level guiding station further includes a vertically movable automatic lift having an article carrying surface. The multi-level guiding station further includes a frame arranged adjacent to the plurality of sorting levels, and the frame extends to at least the same height as the highest sorting level among the plurality of sorting levels. The frame is configured to support the lift when the lift moves vertically between the plurality of sorting levels. The multi-level guiding station further includes a plurality of transport devices, and at least one transport device is arranged at each sorting level. The multi-level guiding station further includes a control system including a processor. The processor is configured to guide the lift to one of the plurality of sorting levels. Here, the transport device is an article receiving position adjacent to the frame and is at the article receiving position at one of the plurality of sorting levels. The processor is further configured to guide the lift to place the article arranged on the article carrying surface of the lift onto the transport device at the article receiving position by operating the article carrying surface of the lift. The processor is further configured to guide the transport device to the destination. The processor is further configured to guide the lift to the guiding height (again).

[0037] In various embodiments, the multi-level guiding station 101 may be portable. For example, the multi-level guiding station 101 may be provided with wheels 149. Thereby, the multi-level guiding station can be moved to the optimal position or place where it can be used most effectively within the material handling facility. Also, by providing wheels, an additional multi-level guiding station can be easily added during peak times such as holidays.

[0038] In various embodiments, the multi-level guidance station 101 may be modular. For example, each of the plurality of sorting levels or sorting platforms may be something that parts are assembled to, thereby making the multi-level guidance station 101 easily reconfigurable to fit any material handling facility. Also, in various embodiments, the multi-level guidance station 101 may be reconfigurable to various dimensions, whereby the length, width, area, and other attributes of each sorting level or sorting platform can be reconfigured.

[0039] FIG. 2 is a side perspective view of an exemplary embodiment of a multi-level guidance station. FIG. 2 shows many of the same components as shown in FIG. 1 from a different perspective. FIG. 3 is a side view of an exemplary embodiment of a multi-level guidance station. FIG. 3 shows many of the same components as shown in FIG. 1 from a different perspective. FIG. 4 is a top perspective view of an exemplary embodiment of a multi-level guidance station. FIG. 4 shows many of the same components as shown in FIG. 1 from a different perspective. FIG. 5 is a top perspective view of an exemplary embodiment of a multi-level guidance station. FIG. 5 shows many of the same components as shown in FIG. 1 from a different perspective. FIG. 6 is a top view of an exemplary embodiment of a multi-level guidance station. FIG. 6 shows many of the same components as shown in FIG. 1 from a different perspective. FIG. 7 is a side perspective view of an exemplary embodiment of a multi-level guidance station. FIG. 7 shows many of the same components as shown in FIG. 1 from a different perspective. In FIG. 7, the lift 143 is in a guidance position set based on the preference of a particular operator 139.

[0040] FIG. 8 is a side perspective view of an automatic lift according to an embodiment of a multi-level induction station. Referring to FIG. 8, the automatic lift 131 moves along or around support rails that form part of a frame such as frames 121, 123, 125. The motor 167 causes the lift 131 to move (e.g., ascend or descend) along the support rails of the frame. The tilt mechanism 169 tilts the tray forward (e.g., to the position where an article is placed) and / or backward (e.g., back to the article-carrying position) by rotating the arm 171. In the embodiment shown in FIG. 8, the tray rotates to place (lower) the carried article onto the transport device at the article receiving position. In at least one embodiment, an additional motor such as motor 167 may be provided to move the lift in all three directions: vertically, horizontally, and in the direction of movement, along additional support rails of the frame. In some embodiments, the arm 171 may be configured to move within the three-dimensional space relative to the lift 131 by providing a suitable servo drive mechanism similar to that used, for example, in a 3D printer. In various embodiments, the lift is configured to move within the three-dimensional space.

[0041] FIG. 9 is a side perspective view showing an automatic lift according to an embodiment of the first position of the multi-level induction station. On the other hand, FIG. 10 is a side perspective view showing an automatic lift according to the same embodiment of the second position of the multi-level induction station. Referring to FIGS. 9 and 10, the motor 167 moves the frame of the lift 131 to a position close to the transport device or to a position close to the induction height or induction level (e.g., the height shown in FIG. 3 or FIG. 7) (e.g., rising or falling vertically). The tilting mechanism 169 tilts the tray forward (e.g., toward the position where the article is placed) and / or backward (e.g., back to the article-carrying position) by rotating, extending, and / or retracting the arm 171. In at least one embodiment, as the arm 171 extends, the tray slides forward or moves forward along the track 173. Thereby, first, the tray slides forward or moves forward (e.g., moves forward toward the transport device), and then the tray rotates to a downward angle, so that the article 145 slides off the tray onto the transport device arranged at the article receiving position of one of the plurality of sorting levels (as shown in FIG. 10).

[0042] FIG. 11A is an exemplary block diagram of an exemplary embodiment of the multi-level induction station described herein. Referring to FIG. 11A, the multi-level induction system 1101 includes a sorter control server 1102, an information acquisition device 1104, a lift 1106, and a transport device 1108, a wireless access point 1110, and a host management system server 1112. These are typically shown as blocks representing general descriptors of the technology.

[0043] FIG. 11B is an exemplary block diagram of an exemplary embodiment of a multi-level guidance station described herein. Referring to FIG. 11B, a multi-level guidance system 1151 includes a sorter control server 1152, an information acquisition device 1154, a lift 1156, a transport device 1158, a wireless access point 1160, a host management system server 1162, an execution system 1164, and a cloud server 1166. These are typically shown as blocks representing general descriptors of the art.

[0044] Referring to FIGS. 11A and 11B, the wireless access points 1110 / 1160 communicate wirelessly with the transport devices 1108 / 1158. The sorter control servers 1102 / 1152 are configured to communicate with one or more components of the multi-level induction stations 1101 / 1151 described herein and shown, for example, in FIG. 1. In one embodiment, the sorter control servers 1102 / 1152, the host management system servers 1112 / 1162, the execution system 1164, and / or the cloud server 1166 include memory, a processor, and / or one or more communication interfaces. The network may form part of the multi-level induction stations 1101 / 1151. The network may take any suitable form. Any suitable form includes wireless networks (e.g., WiFi, cellular, or other frequency bands for private use), or hard-wired networks (e.g., LAN, WAN, Internet, etc.), and combinations thereof. In one embodiment, the sorter control servers 1102 / 1152 communicate with the cloud (e.g., cloud server 1166) and / or resources accessible via the cloud over the network. In some embodiments, one or more components of the sorter control servers 1102 / 1152 may be located within the cloud. Similarly, some of the components (e.g., transport devices 1108 / 1158, lifts 1106 / 1156, and information acquisition devices 1104 / 1154, sorter control servers 1102 / 1152, and / or host management servers 1112 / 1162, etc.) may communicate with the cloud over the network. In some embodiments, one or more components of the multi-level induction stations 1101 / 1151 may be located within the cloud. For example, in one embodiment, the sorter control servers 1102 / 1152 and / or the execution system 1164 may be located within the cloud. In one embodiment, the sorter control servers 1102 / 1152 and one or more other components of the multi-level induction stations 1101 / 1151 may be communicating with the cloud.

[0045] As used herein, the term "cloud" refers to a plurality of Internet-connected servers that can be leased as part of software or application services. Cloud-based services can include web hosting, data hosting and sharing, and the use of software or applications. The term "cloud" also refers to cloud computing. In cloud computing, multiple servers are coordinated to share the load. This means that complex processing can be distributed across multiple smaller computers instead of using a single powerful machine. In various embodiments, the sorter control servers 1102 / 1152, the host management servers 1112 / 1162, and the cloud server 1166 may be servers in which the term "server" is understood in its broadest sense, or may include servers in which the term "server" is understood in its broadest sense in other ways. As used herein, the term "server" includes any computer that provides data to other computers. It can provide data to a system on a local area network (LAN) or a system on a wide area network (WAN) via the Internet. In various embodiments, the sorter control servers 1102 / 1152 can be, or can include, cloud servers (e.g., cloud server 1166). As used herein, the term "cloud server" includes any pooled and centralized server resource that is hosted and delivered via a network (usually the Internet) and is accessed on demand by multiple users. A cloud server can be located remotely (e.g., can exist in a remote cloud server configuration). A cloud server can be a virtual server that operates in a cloud computing environment (rather than a physical server). A cloud server can be built, hosted, and delivered via the Internet through a cloud computing platform and accessed remotely. A cloud server can include all the software necessary for execution and can function as an independent unit.A cloud server can perform all the same functions as a conventional physical server, including processing power, storage, and application provision. One of the advantages of cloud storage is that there are many distributed resources that act as one. This is often referred to as a federated storage cloud. As a result, the cloud is highly resilient to failures because the data is distributed. By using the cloud, access to documents, files, and data is shared, so the creation of various versions of files can be reduced.

[0046] Furthermore, each of the components shown in FIGS. 1-11B may be in a state of communicating with one or more other components through a wired network and / or a wireless network. For example, the cloud and the sorter control servers 1102 / 1152 may further communicate with the transport devices 1108 / 1158, the lifts 1106 / 1156, and the information acquisition devices 1104 / 1154 via the network.

[0047] In various embodiments, the sorter control servers 1102 / 1152 operate to guide articles through a multi-level induction station and deliver the guided articles to the transport devices 1108 / 1158. The transport devices 1108 / 1158 then transport the articles across sorting levels (e.g., platforms) to a destination for further processing.

[0048] In one embodiment, the sorter control servers 1102 / 1152 include a controller. The sorter control servers 1102 / 1152 are configured to determine the destination for a particular article identified by an information acquisition device from among a plurality of possible destinations based on the interaction with an identifier and the determined destination for the article. The sorter control servers 1102 / 1152 are further configured to direct the lift to transport the article to a transport device at an article receiving location.

[0049] In various embodiments, the sorter control server 1102 / 1152 may coordinate the delivery of multiple items to various destinations, either alone or in combination with the host management server 1112 / 1162 and / or the execution system 1164. The sorter control server 1102 / 1152 may be further configured to coordinate the delivery of multiple items by one or more of a human process, a mechanical process, and a robotic process. The lift and transport devices cooperate to transport multiple items to their respective destinations determined and directed by the sorter control server 1102 / 1152 and / or the execution system 1164.

[0050] The control server 1102 / 1152 may operate to complete the analysis of the acquired item information for all items to be sorted, thereby obtaining the destination information for each item. The sorter control server 1102 / 1152, and / or the execution system 1164, communicate with the information acquisition device, obtain the item information acquired by the information acquisition device, and as a result, obtain the destination of each item.

[0051] In operation, the operator receives one or more articles at the multi-level guidance station. The one or more articles may be transported to the operator by an article delivery device. The operator takes out one of the articles from the article delivery device and places the article on the article-carrying surface (e.g., a tray) of the lift waiting at the guidance height or guidance level. As can be seen from FIG. 1, for example, the operator loads the lift tray from the back surface of the tray (i.e., the surface of the tray facing the operator). In at least one embodiment, the lift tray can be rotated at least 90 degrees or 180 degrees. As a result, since the front or side surface of the tray faces the operator, the operator can load the lift tray from the front surface of the tray. Thereafter, before the next step of the process is started, the tray rotates back to its original position so that the back surface of the tray faces the operator. The information acquisition device reads the identifier on the article on the article-carrying surface of the lift (e.g., from above the lift, from the side, or in the vicinity of the lift). The information acquisition device transmits the identifier information to the control system. The control system identifies the article and the destination of the article. Next, the control system assigns the article on the lift tray to a specific transport device and transmits the position of the selected transport device to the lift. Thereafter, the lift moves (e.g., ascends or descends) the frame as appropriate to the appropriate height with respect to the selected transport device. When the lift reaches the appropriate height, the lift places the article on the assigned transport device at the article receiving position. In one embodiment, the tray on the lift tilts forward, and as a result, the article slides off from the front surface of the tray onto the assigned transport device. The tilting movement of the lift tray may include a forward movement simultaneous with the tilting movement such that the front edge of the lift tray covers the transport device during tilting so that the article can be delivered more smoothly from the lift tray to the transport device (see FIGS. 9 and 10). After delivering the article to the assigned transport device, the lift returns to the guidance height or guidance level so that the operator is ready to receive the next article.

[0052] It should be understood that various configurations of the frame are possible based on the number of operators and the reach of each operator. For example, in a state where two frames are arranged side by side at a three-level station, a single operator can ergonomically (efficiently) load items onto six different robot positions. Similarly, in a state where two frames are arranged side by side at a four-level station, a single operator can ergonomically load items onto eight different robot positions.

[0053] Furthermore, for example, as shown in FIG. 1, in a state where three frames are placed at the corner in a three-level system, the operator can ergonomically load items onto nine different robot positions.

[0054] The above are merely specific embodiments of the present invention. However, the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the disclosed technical scope of the present invention should belong to the protection scope of the present invention. That is, the protection scope of the present invention should be determined by the protection scope of the appended claims.

Brief Description of the Drawings

[0055]

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Claims

1. A multi-level induction station, comprising: a plurality of sorting levels arranged in a vertical stacked configuration; a vertically movable automatic lift having an article carrying surface; a frame arranged adjacent to the plurality of sorting levels, the frame extending to at least the same height as the highest sorting level among the plurality of sorting levels, the frame being configured to support the lift when the lift moves between the plurality of sorting levels; a plurality of transport devices, with at least one transport device at each sorting level; a control system including a processor; and wherein: the processor is configured to: receive article data for identifying an article placed on the article carrying surface of the lift; determine a destination of the article placed on the article carrying surface of the lift based on the article data; guide the lift to one of the sorting levels where there is a transport device at an article receiving position adjacent to the frame at that one sorting level; guide the lift to place the article placed on the article carrying surface of the lift onto the transport device at the article receiving position by operating the article carrying surface of the lift; guide the transport device to the destination; guide the lift to a guiding height. A multi-level induction station configured as such.

2. The multi-level induction station further includes an information acquisition device arranged to read information from the article placed on the article carrying surface of the lift, wherein the article data is received from the information acquisition device. The multi-level induction station according to Claim 1.

3. The multi-level induction station according to Claim 1, wherein the multi-level induction station is portable.

4. The multi-level induction station according to Claim 3, wherein the multi-level induction station has wheels.

5. The multi-level induction station according to Claim 1, wherein the multi-level induction station is modular.

6. The multi-level induction station according to Claim 1, wherein the multi-level induction station is reconfigurable.

7. The multi-level induction station according to Claim 1, wherein the article carrying surface is an inclined tray.

8. The multi-level guiding station according to claim 7, wherein the inclined tray is configured to move in a forward direction toward the transport device while being inclined so as to cover the transport device.

9. The multi-level guiding station according to claim 1, wherein the article carrying surface includes a cross belt, an article pushing mechanism, or an article deflecting mechanism.

10. The multi-level guiding station according to claim 1, wherein the lift is configured to move within a three-dimensional space.

11. The multi-level guiding station according to claim 1, wherein the guiding height is set to a predetermined height determined by the processor.

12. The multi-level guiding station according to claim 1, wherein the guiding height is set to a user-specified height.

13. The multi-level guiding station according to claim 1, wherein the multi-level guiding station includes at least two sorting levels arranged vertically.

14. The multi-level guiding station according to claim 1, wherein the multi-level guiding station includes a plurality of frames arranged in proximity to each other.

15. The frame includes a shield for protecting an operator of the multi-level guiding station. The multi-level guiding station according to claim 1, wherein the shield includes a guiding opening for facilitating placement of the article on the article carrying surface of the lift.

16. The multi-level guiding station according to claim 15, wherein the frame further includes a sensor for preventing the lift from moving before an operator's arm is withdrawn from the guiding opening.

17. A control system for a multi-level guiding station, receiving article data for identifying an article placed on an article carrying surface of an automatic lift that moves a frame of the multi-level guiding station, determining a destination of the article placed on the article carrying surface of the lift based on the article data, guiding the lift to one of the sorting levels where a movable transport device is waiting at an article receiving position proximate to the frame at one of the plurality of sorting levels of the multi-level guiding station. By operating the article-carrying surface of the lift, guide the lift so as to place the article placed on the article-carrying surface of the lift onto the movable transport device at the article receiving position. Guide the movable transport device to the destination. Guide the lift to the guiding height of the multi-level guiding station. A control system having a processor configured as described above.

18. The control system according to claim 17, wherein the article data is received from an information acquisition device arranged on the frame of the multi-level guiding station.

19. The control system according to claim 17, wherein the processor is further configured to guide the transport device to the article receiving position.

20. A multi-level guiding station, comprising: A plurality of sorting levels arranged in a vertical stacked configuration; A mobile automatic lift having an article-carrying surface; A frame arranged adjacent to the plurality of sorting levels, the frame extending to at least the same height as the highest sorting level among the plurality of sorting levels, the frame being configured to support the lift when the lift moves between the plurality of sorting levels; A plurality of transport devices, with at least one transport device at each sorting level; A control system including a processor; Including: The processor is configured to: Guide the lift to one of the plurality of sorting levels where there is a transport device at an article receiving position close to the frame at that one sorting level; By operating the article-carrying surface of the lift, guide the lift so as to place the article placed on the article-carrying surface of the lift onto the transport device at the article receiving position; Guide the transport device to the destination; Guide the lift to the guiding height. A multi-level guiding station configured as described above.

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