System and method for robotic horizontal sorting

Abstract

The present invention provides a system and method for suitable robotic horizontal sorting. [Solution] A system and method for sorting articles may include an article sorting unit comprising an article selection unit with a robot pick-and-place machine positioned adjacent to a defined input article area, a horizontal multi-degree-of-freedom gantry system, and an article transport box array, wherein the horizontal gantry system is positioned above the article transport box array, and the article selection unit further comprises an article holding and placement system coupled to and operated by the gantry system. The system and method can separate articles from a collection of articles and sort them into one of a set of article transport boxes.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Application No. 63 / 075,046, filed on September 4, 2020, which is hereby incorporated by reference in its entirety.

[0002] (Rights of the Government) This invention was made with government support under Grant No. 2014689 awarded by the U.S. National Science Foundation. The government has certain rights in this invention.

[0003] The present invention generally relates to the field of automated item sorting, and more specifically, to a newly useful system and method for robotic horizontal sorting.

Background Art

[0004] Hundreds of billions of packages are shipped within the United States each year. Each of these packages must be guided into the shipping system and sorted to facilitate routing or regionalized shipping processes. Despite advances in automation, package sorting remains a difficult and labor - intensive problem.

[0005] ? (Linear sorters such as target - drop sorters, etc.) are effective, but as the number of desired outputs increases, the cost, size, and complexity of the system become unjustifiable.

[0006] A typical manual package sorting station has one input area for packages and approximately 50 output locations. A single facility can sort to over 1,000 destinations. However, a conveyor - based sorting method with 1,000 output sections would be huge and expensive. In many situations, the facility simply will not have the floor space to accommodate one of the available automated sorting solutions. Conversely, when a robot sorts items in its immediate vicinity, the robot's reach limits the number of outputs, which is not a practical solution for many high - scaling problems.

Summary of the Invention

Means for Solving the Problems

[0007] Therefore, in the field of automatic article sorting, there is a need to generate a new and useful system and method for robotic horizontal sorting. The present invention provides such a new and useful system and method. This specification also provides, for example, the following: (Item 1) It is a system, An item selection unit with a robot pick-and-place machine positioned adjacent to a defined input item area, An article sorting unit comprising a horizontal multi-degree-of-freedom gantry system and an article transport box array, wherein the horizontal gantry system is positioned above the article transport box array, The article sorting unit further comprises an article holding and placement system coupled to and operated by the gantry system. Item sorting unit, A control system comprising one or more processors and one or more non-transient computer-readable media, wherein the one or more non-transient computer-readable media store instructions, and when the instructions are executed by one or more computer processors, the control system causes the article selection unit to grasp an article, to orient the article in a transport position, to transport the article to the article sorting unit, to translate the article into a designated article transport box in the article transport box array, and to place the article in the article transport box. A system equipped with these features. (Item 2) The system according to item 1, wherein the reachable range of the pick-and-place machine overlaps with the reachable range of the article holding and placement system when operated by the gantry system. (Item 3) The system according to item 1, further comprising a transfer system positioned between the item selection unit and the item sorting unit. (Item 4) The transfer system comprises a slotted transfer tray, and the article holding and placement system is a slotted article tray, as described in item 3. (Item 5) The article holding and placement system is an article container that is rotatably operated, as described in item 1. (Item 6) The item holding and placement system is a sorting robot pick-and-place machine, as described in item 1. (Item 7) The system according to item 1, wherein the item sorting unit further comprises a transport box capacity sensor. (Item 8) It is a method, From a statically positioned robot system, picking items from the item input area, Using the robot system, the article is oriented within the transfer position. The process involves transferring the aforementioned items to the receiving mechanism of the item sorting unit, Using the item sorting unit, the items are translated to a designated item transport box in an array of item transport boxes. The aforementioned articles are placed inside the article transport box. Methods that include... (Item 9) The method of item 8, wherein oriented the article includes oriented it within the transfer position above the receiving mechanism, and transporting the article to the receiving mechanism includes, in the robot system, placing the article inside the receiving mechanism. (Item 10) The method according to item 8, wherein orienting the article includes orienting it within the transfer position in the transfer system, and transferring the article to the receiving mechanism includes, in the robot system, placing the article in the transfer system, and in the article sorting unit, removing the article from the transfer system. (Item 11) The method according to item 10, wherein the receiving mechanism is a slotted article tray, the transfer system is a slotted transfer tray, and removing the article from the transfer system includes moving the slotted article tray through the slotted transfer tray and collecting the article into the slotted transfer tray. (Item 12) The method of item 8, further comprising determining the dimensional properties of the article while oriented the article, wherein oriented the article comprises oriented the article in a transport position for controlled placement of the article in an article transport box based on the dimensional properties. (Item 13) The method of item 8, wherein the robot system is used to orient the article, an identifier for the article is determined, and the designated article transport box is determined based on the identifier. (Item 14) The method according to item 8, further comprising sensing the capacity of the array of item transport boxes and signaling a change in the item transport boxes when a capacity condition is met. (Item 15) The method according to item 8, further comprising dynamically assigning grouping locations within the array of item transport boxes. (Item 16) A non-transient computer-readable medium, the non-transient computer-readable medium storing instructions, the instructions being executed by a computer processor on one or more computing platforms, the computing platform From a statically positioned robot system, picking items from the item input area, Using the robot system, the article is oriented within the transfer position. <00,00126> Using the item sorting unit, the items are translated to a designated item transport box in an array of item transport boxes. The aforementioned articles are placed inside the article transport box. A non-transient, computer-readable medium that enables the execution of [the action]. (Item 17) The non-transient computer-readable medium according to item 16, wherein oriented the article includes oriented it within the transport position above the receiving mechanism, and transporting the article to the receiving mechanism includes, in the robotic system, placing the article inside the receiving mechanism. (Item 18) The non-transient computer-readable medium according to item 16, wherein oriented the article includes oriented it within the transport position in the transport system, and transporting the article to the receiving mechanism includes, in the robot system, placing the article in the transport system, and in the article sorting unit, removing the article from the transport system. (Item 19) <l Non-transient computer-readable media as described in item 18, wherein the receiving mechanism is a slotted article tray, the transfer system is a slotted transfer tray, and removing the article from the transfer system includes moving the slotted article tray through the slotted transfer tray and collecting the article into the slotted transfer tray. (Item 20) A non-transient computer-readable medium according to item 16, further comprising determining the dimensional properties of the article while oriented the article, wherein oriented the article comprises oriented the article in a transport position for controlled placement of the article in an article transport box based on the dimensional properties.

Brief Description of the Drawings

[0008] [Figure 1A] Figure 1A is a schematic diagram of a variant of the present system.

[0009] [Figure 1B] Figure 1B is a schematic diagram of a variant of the present system with an indication of the article flow when sorting.

[0010] [Figure 2] Figure 2 is a schematic diagram of a modified top view of this system.

[0011] [Figure 3] Figure 3 is a schematic top view of a modified version of this system, including a transport system.

[0012] [Figure 4] Figure 4 is a schematic top view of a modified system in which an item selection unit interfaces with multiple item sorting units.

[0013] [Figure 5] Figure 5 is a schematic top view of a modified system in which an item selection unit and multiple item sorting units are connected through a connecting conveyor system.

[0014] [Figure 6] Figure 6 is a schematic side view of a modified system, which includes a vertical conveyor for distributing items vertically to different item sorting units.

[0015] [Figure 7] Figure 7 is a schematic top view of a modified system with two operationally integrated item sorting units.

[0016] [Figure 8] Figure 8 is a schematic top view of a modified system, showing a shared item sorting unit and multiple operationally integrated item selection units.

[0017] [Figure 9] Figure 9 is a detailed schematic diagram of the first modified version of the system, which includes multiple selectable end effectors.

[0018] [Figure 10] Figure 10 is a detailed schematic diagram of a second modified version of the system, which includes multiple selectable end effectors.

[0019] [Figure 11] Figure 11 is a detailed schematic diagram of the modifiable end-effector system.

[0020] [Figure 12] Figure 12 is a schematic side view of a modified tray of the article holding and placement system in operation.

[0021] [Figure 13A] Figures 13A-13C are schematic diagrams of item trays, shown from the side, in different operating states. [Figure 13B] Figures 13A-13C are schematic diagrams of item trays, shown from the side, in different operating states. [Figure 13C] Figures 13A-13C are schematic diagrams of item trays, shown from the side, in different operating states.

[0022] [Figure 14] Figure 14 is a concrete side view of an article tray with shaded areas for potential rotation points.

[0023] [Figure 15] Figure 15 is a schematic side view of an item tray positioned above the item transport box.

[0024] [Figure 16A] Figure 16A is a schematic top view of an exemplary slotted article tray.

[0025] [Figure 16B] Figure 16B is a schematic side view of an exemplary slotted article tray.

[0026] [Figure 16C] Figure 16C is a schematic perspective view of an exemplary slotted goods tray.

[0027] [Figure 17A]Figure 17A is a schematic perspective view of an exemplary slotted transport tray.

[0028] [Figure 17B] Figure 17B is a schematic side view of an exemplary slotted transport tray.

[0029] [Figure 18A] Figure 18A is a schematic perspective view of an exemplary slotted article tray engaged with a slotted transport tray.

[0030] [Figure 18B] Figure 18B is a schematic side view of an exemplary slotted article tray engaged with a slotted transport tray.

[0031] [Figure 19] Figure 19 is a schematic diagram of the sequence of a slotted item tray collecting items from a slotted transport tray.

[0032] [Figure 20] Figure 20 is a schematic diagram of a modified version of the system in which the selected item transport box has been removed.

[0033] [Figure 21] Figure 21 is an illustrative image representation of an article transport box for holding mailbags using a feed pin extending from the base.

[0034] [Figure 22] Figure 22 is an image representation of the plate with a feed groove in the assembly of the item sorting unit.

[0035] [Figure 23] Figure 23 is a flowchart representation of the first method.

[0036] [Figure 24] Figure 24 is a flowchart of a modified example of a method involving the processing of articles.

[0037] [Figure 25] Figure 25 is a flowchart of a modified method involving item identification.

[0038] [Figure 26] Figure 26 is a flowchart of a modified method using item measurement.

[0039] [Figure 27] Figure 27 is a flowchart of a modified method involving direct transfer between an item selection unit and an item sorting unit.

[0040] [Figure 28] Figure 28 is a flowchart of a modified method involving indirect transfer between an item selection unit and an item sorting unit using a transfer system.

[0041] [Figure 29] Figure 29 is a flowchart of a modified method involving indirect transfer using a slotted transfer tray.

[0042] [Figure 30] Figures 30 and 31 are flowchart representations of this method. [Figure 31] Figures 30 and 31 are flowchart representations of this method.

[0043] [Figure 32] Figure 32 shows an exemplary system architecture that may be used when implementing the system and / or method. [Modes for carrying out the invention]

[0044] Description of the Embodiment The following description of embodiments of the present invention is not intended to limit the invention to these embodiments, but rather to enable those skilled in the art to construct and use the invention.

[0045] 1. Overview The system and method for robotic horizontal sorting serves as a modular and easily expandable item sorting solution using an item sorting unit that includes a robotic pick-and-place machine for automating the individualization and identification of items from an item input area, and an item sorting unit that includes a secondary sorting system for placing items in designated locations within an array of containers. In this system and method, the robotic pick-and-place machine operates in sync with the secondary sorting system to move the items to desired output locations. The system and method also functions to collect unorganized items and automatically sort them into multiple outputs.

[0046] In one modification, the robotic pick-and-place machine is a robotic arm, and the secondary sorting machine is a horizontal gantry system. The horizontal gantry system may include an actuated tray used to hold articles and place them within targeted output locations. The horizontal gantry system may, alternatively, include a second robotic pick-and-place machine or other type of component for holding and placing articles. As shown in Figures 1A and 1B, the horizontal gantry system may have a horizontal translation section along two dimensions. As described herein, the system and method may include numerous modifications and implementations of various forms. One possible modification may include the combination of multiple article sorting units (e.g., multiple horizontal gantry systems and / or vertical gantry systems). Another possible modification may involve multiple article selection units operating in cooperation with the same article sorting unit. Another possible modification may involve one article selection unit operating in cooperation with two article sorting units (e.g., one on each of two opposing sides of that article selection unit).

[0047] The system and method are preferably used to select unsorted articles from one or more input areas. The articles may be contained within input article containers within the input areas, and are described herein as such, but the form of representation of the input articles is not limited to any particular container type. A robotic pick-and-place machine separates the articles from the input areas by grasping or picking them.

[0048] Other components of the robotic pick-and-place machine and / or item selection unit may also collect information such as the dimensions and weight of the items. Individual item processing may also be performed, such as scanning the items, evaluating the items (e.g., classifying the quality, size, or type of the items), marking or otherwise modifying the items (e.g., stamping or applying labels), or performing any preferred form of processing. In some variations, scanning the items may be used in a step of planning the placement of the items to facilitate a more reliable handover to the item sorting unit and placement into containers.

[0049] The robotic pick-and-place machine then places the items into a secondary sorting system, which moves the items into the output area. Because these two functions are separated, the overall throughput of the system can be significantly higher. The size of the output system is designed to statistically match the speed of the input (picking / scanning system).

[0050] In this specification, the term "article" will refer to an object that is subject to sorting by a robotic system. An article can be any suitable type of object that requires sorting, such as packages, parcels, products, raw materials (e.g., manufactured parts), and / or any suitable type of object. In the case of shipping or other operational contexts, articles can have various properties. In a parcel processing center, an article may be, for example, boxed goods, bagged goods, and / or parcels. An article may have a destination property, indicating where it is to be shipped. An article may have an article type property, which may correspond to a minimum stock unit (SKU) identifier or an alternative product identifier.

[0051] In this specification, the term "article carrier" or simply "carrier" is also used to characterize a receiver used to hold articles once they have been sorted. Shape factors and various types of carriers can vary considerably, and this system and method can be adapted to different types of carriers such as boxes, containers, trays, bags, Gaylords, and equivalents.

[0052] In this specification, the term "article container" is also used to characterize the method by which articles are initially held or stored prior to picking and sorting into appropriate transport boxes. Similar to transport boxes, shape factors and various article containers can vary considerably, and the system and method may be adapted to different types of article containers, such as boxes, containers, trays, bags, and equivalents. Article containers may include any suitable variety of articles, but generally will require sorting into a number of different article transport boxes. Article transport boxes and containers may use any suitable shape factor, and in some cases, the same type of container may be used. In some modifications, shape factors may be customized for specific modifications and implementations of the system and method, as described herein.

[0053] This system and method can be used to provide efficient sorting of goods for various purposes.

[0054] In one exemplary application, the system and method can be used to consolidate parcels for dispatch. For example, a parcel processing facility may use the system and method to sort parcels by destination (e.g., postal code or delivery route) for subsequent dispatch processing. Unsorted letters and / or packages can be collected in a large article container, and the system and method can then facilitate sorting them into smaller article containers for different delivery routes / destinations.

[0055] There is a high need for compact and modular sorting of items other than parcels, and this system and method can be applied similarly to those applications.

[0056] In another exemplary application, the system and method may be used for cross-docking, where cases of the same or different articles are split across different outputs. When deployed within a cross-docking facility, the system and method can improve the operational efficiency of the supply network.

[0057] In another exemplary application, the system and method can be used for processing returned goods and / or for restocking. For example, mixed containers of returned goods can be appropriately sorted for redisplay, restocking, or other subsequent processing. In another embodiment, newly received goods orders can be sorted into appropriate containers for replenishing in-store stockpiles. The size and automated affordances of the system and method are such that they can be used in a variety of environments, such as the backroom of a retail store or in an order fulfillment center (e.g., for e-commerce returns).

[0058] In another exemplary application, the system and method may be used for order fulfillment, in which a collection of goods is sorted into individual goods containers, each of which may be associated with a specific order. In a similar manner, the system and method may also be used for dynamic or customized kitting of industrial goods or consumer goods.

[0059] This system and method may offer several potential benefits. This system and method are not necessarily limited to limiting such benefits, but are presented merely as illustrative examples of how this system and method may be used. The enumeration of benefits is not intended to be exhaustive, and other benefits may exist, either additionally or alternatively.

[0060] One potential benefit is that this system and method can be used with a wide variety of article types. In particular, in the case of parcels, there can be a wide variety of package types, such as letters, postcards, boxes, tubes, foam packaging, plastic bags, and equivalents. The system and method can potentially be used in combination with depth cameras and color cameras to facilitate the planning and execution of robotic grasping of unknown articles using discriminatory reasoning. In addition, the robotic planning of this system and method can address the problem of reaching articles in cluttered situations, as well as the problem of reaching articles in corners or hard-to-reach locations.

[0061] As another potential benefit, the system and method may provide a space-efficient solution for the automated sorting of goods. Thus, the system and method can enable sorting into a large number of different sorting groups. In some implementations, the number of sorting groups can range from 20 to 60. Those skilled in the art will understand that such a range may vary depending on the implementation. Several modifications can significantly expand the capacity depending on needs and space constraints. Similarly, the system and method can also be modified for fewer sorting groups.

[0062] As a related potential benefit, the system and method may provide a substantially modular solution that can be easy and rapid to deploy sorting solutions. Multiple examples of the sorting system may be deployed on a single site. Similarly, some variations may use coordinated operation between multiple item selection units, item sorting units, and / or auxiliary conveyors or transport systems (e.g., containers, transport boxes, or automated robots for moving items).

[0063] As another potential benefit, the system and method may be implemented in a way that allows for safe integration into an environment where workers can directly interact with the system. The system and method may include safety systems such that such normal interactions are safe and convenient. For example, output item containers may be easily removed from the system once filled with sorted items without having to stop the system's operation or endangering workers. Methods for safe interaction of human workers during the operation of the system and method thereby improve its flexibility and ease of use. For example, a human worker may manually remove a filled item container without stopping or altering the operation of the sorting system.

[0064] Another potential benefit is that the system and method can provide a convenient physical interface for further automation. This allows the system and method to be easily integrated into the operation of other automated systems, such as input and output conveyors or mobile robots, that move input item containers or output item transport boxes.

[0065] 2. System As shown in Figures 1A and 1B, a system for robotic horizontal sorting may include an item selection unit 110 with a robotic pick-and-place machine 111 and an input item area 112, an item sorting unit 120 including a horizontal translation system 121 with an item holding and placement system 122, and an output transport box array 123. As shown in Figure 1B, this system can enable sorting of items as they flow from the input item area 112 to the output transport boxes of the output transport box array 123.

[0066] The item selection unit 110 and the item sorting unit 120 are preferably arranged adjacent to the reachable areas of the robotic pick-and-place machine 111 and the secondary sorting mechanism 122, having partially overlapping reachable areas where objects can be transported between them, as shown in Figure 2. However, some modifications may use an active or passive transport system 130 for transporting items between the item selection unit 110 and the item sorting unit 120, as shown in Figure 3.

[0067] The system and method may include various different modular configurations. Figure 2-8 shows some exemplary variations of how the system may be configured.

[0068] As shown in Figure 4, the item selection unit 110 may be configured to have two or more reachable areas used to transport items to the item sorting unit 120. In one modification, this may include an item selection unit 110 that uses one of two reachable areas, where the first reachable area overlaps with the reachable area of ​​the first item sorting unit 120 and the second reachable area overlaps with the reachable area of ​​the second item sorting unit 120. These reachable areas may be defined around different locations around the robot pick-and-place machine 111, such as on opposite sides. In another modification, the system may include two transport systems 130 at different locations around the robot pick-and-place machine, as shown in Figure 4.

[0069] As shown in Figure 5, a transfer system 130, including an intermediate conveyor system, can facilitate the integration of the item selection unit 110 and the item sorting unit 120. This may be used so that one item selection unit 110 can interface with multiple item sorting units 120 in such a way that the reachable area of ​​the robot pick-and-place machine 111 does not directly overlap with the reachable area of ​​the item sorting unit 120, i.e., the transfer system 130 can actively bridge the gap in the reachable areas. More specifically, the transfer system 130 includes an intermediate conveyor system 132 with one or more conveyors for transporting items to one or more handover stations (i.e., transfer trays 131) of the set of item sorting units 120. The intermediate conveyor system may include an initial area that is reachable by the robot pick-and-place machine 111 and transports items to the handover station for transfer to one of the item sorting units 120.

[0070] As shown in Figure 6, in another variation, the multiple sorting units 120 may also be stacked vertically, in which case the transfer system includes a vertical intermediate conveyor system that moves the picked items to another level, which will be sorted by one of the set of item sorting units 120. More specifically, the transfer system 130 includes an intermediate vertical conveyor system 133 with one or more conveyors for transporting the items to one of the set of item sorting units 120. A handover station may be used. Alternatively, the vertical conveyor system 133 may hold the items in a suitable position for transfer.

[0071] As shown in Figure 7, multiple sorting units 120 can interface with each other to expand the number of sorting groups. The article sorting units 120 may include article holding and placement systems that can be positioned for the transfer of the articles to be held to adjacent article sorting units 120. More specifically, the first horizontal translation system 121 (of the first article sorting unit 120) may have a first article holding and placement system 122 that can be positioned at the sorting transfer position, and similarly, the second horizontal translation system 121 (of the second article sorting unit 120) may have a second article holding and placement system 122 that can be positioned at the sorting transfer position. Thus, the sorting transfer position can be an area reachable by the first article sorting unit 120 and the second article sorting unit 120, more specifically, an area where the articles held by the first article holding and placement system 122 can be placed into the second article holding and placement system 122.

[0072] As shown in Figure 8, in another configuration variation, multiple item selection units 110 may be used in combination with one item sorting unit 120. In one variation, each item selection unit may have an reachable area that overlaps with the reachable area of ​​the item sorting unit 120. The item selection units 110 may be adjacent to the same side of the item sorting unit 120. Alternatively, the item selection units 110 may be located on different parts of the item sorting unit 120, which can be adapted for the item holding and placement system 122 to retrieve from different sides. In another variation, the transport system 130 may use a conveyor system or other means for transporting items between two areas (e.g., a chute or inclined section) to bridge the reachable area of ​​one or more of the item selection units 110 to the item sorting unit 120.

[0073] In this specification, the system will be implemented primarily when one article selection unit 110 interfaces with one article sorting unit 120. One variation includes an article selection unit 110 that directly interfaces with one article sorting unit 120. Another variation includes an article selection unit 110 that indirectly interfaces with the article sorting unit 120 through a transfer system 130 (for example, the article selection unit 110 places articles into the transfer system 130, and the article sorting unit collects articles from the transfer system 130). The variations described herein are not limited in any way to such configurations, and as can be understood by those skilled in the art, the variations may also be applicable to other configurations and implementations of the system.

[0074] The item selection unit 110 functions as a modular system for selecting items from an unorganized collection. As described, item selection may include one or more robotic pick-and-place machines 111 that select from one or more input item areas 112, which are preferably implemented as item containers. The item selection unit 110 preferably includes, or communicates with, a control system 140, which comprises one or more computer processors and one or more computer-readable media (e.g., non-transient computer-readable media) that, when executed by the one or more computer processors, stores commands causing the item selection unit 110 to grasp an item, optionally perform any item processing (e.g., scanning a barcode), and translate and orient the grasped item into a position for transport to the item sorting unit 120.

[0075] The robotic pick-and-place machine 111 functions as an automated system used to interact with items and move them from the input item area 112 to an area for transfer to the item sorting unit 120.

[0076] The robotic pick-and-place machine 111 preferably includes an actuation system and an end effector, which are used to temporarily physically connect to (e.g., grasp or attach to) an article and to perform some operation on that article. The actuation system is used to move the end effector and connect to one or more articles (e.g., grasp an article), and to move and orient the article in space. Preferably, the robotic pick-and-place machine 111 is used to capture an article, manipulate the article (move the article, and / or re-orient the article), and then, upon completion, to place the article. The placement of the article may also include orienting the article to a specific position and orientation for proper positioning within the article holding and placement system 122, and then placing it. In another variation, the placement of the article may include the step of orienting and placing the article within the transfer system 130 for proper positioning when it is transferred to the article holding and placement system 122.

[0077] The robotic pick-and-place machine 111 may also facilitate other item-related tasks, such as scanning barcodes or identifiers on items or performing any preferred tasks. In one variation, the robotic pick-and-place machine 111 can scan a grasped item to identify it. The detected item identifier may be used in a step to determine the final output carrier box in which the item can be placed by the item holding and placement system 122. As an additional or alternative variation, the robotic pick-and-place machine 111 may use a dimensional camera or other sensor system to measure the item. Measuring may include a step to determine the spatial characteristics of the item (i.e., item dimensions). In one implementation, the item dimensions may include a step to define the boundary volume of the item (e.g., width, height, and depth of the item). The item dimensions may be used, at least in part, in a step to plan the placement orientation when placing the item in the transport system 130 and / or the item holding and placement system 122. This may include modeling, with satisfactory modeling results, in which the item is placed in the item carrier box based on the item dimensions and the transport position is selected.

[0078] In this specification, the robotic pick-and-place machine 111 may be more concisely referred to as the robotic system 111. Various robotic systems 111 may be used. In one preferred implementation, the robotic system 111 is an articulated arm using a pressure-based suction cup end effector. The robotic system 111 may include various features or designs.

[0079] The actuation system functions to translate the end effector through space. Preferably, the actuation system will move the end effector to various locations for interaction with various articles. In addition, or alternatively, the actuation system may be used to move the end effector and the article being grasped along a specific path, to orient the end effector and / or the article being grasped, and / or to provide any preferred operation of the end effector. Generally, the actuation system is used for the overall movement of the end effector.

[0080] The actuation system may be one of various types of machines used to facilitate the movement of the end effector. In one preferred modification, the actuation system is a robotic articulated arm having multiple acting degrees of freedom coupled through interconnected arm compartments. One preferred modification of the actuated robotic arm is a 6-axis robotic arm having 6 degrees of freedom. Alternatively, the actuation system may be a robotic arm with fewer degrees of freedom, such as a 4-axis or 5-axis robotic arm, or with additional articulated degrees of freedom, such as a 7-axis robotic arm.

[0081] In other variations, the actuation system may be any various robotic system 111 such as Cartesian coordinate robots, cylindrical coordinate robots, polar coordinate robots, horizontal articulated robots, delta robots, and other parallel robots, and / or any other variation of the robotic system 111 for controlled actuation.

[0082] The actuation system preferably includes an end arm section. The end arm section is preferably a rigid structure extending from the final operating degree of freedom portion of the actuation system. In an articulated robotic arm, the final arm section is coupled to an end effector. As described below, the end of the end arm section may include a head selector, which is part of a modifiable end effector system.

[0083] In one modification, the end arm compartment may also include, or be connected to, at least one flexible joint, which may improve the gripping and dexterity of the robot system 111.

[0084] The flexible joint preferably functions as at least one additional degree of freedom, located near the end effector. The flexible joint is preferably located at the distal end of the end arm section of the actuation system, and the flexible joint can function as a “wrist” joint. The flexible joint preferably provides an auxiliary amount of dexterity near where the end effector interacts with the article, which can be useful in various situations when interacting with the article.

[0085] In the multi-device modification of this system, the flexible joint preferably precedes the head selector component so that each mountable end effector head can be used in conjunction with controllable flexibility. Alternatively, one or more end effectors may have flexible joints.

[0086] In variations of the multi-head device, the flexible joint may be integrated into a shared mounting point of the multi-head end effector. Thus, the use of connected end effectors allows for the sharing of common degrees of freedom in the flexible joint. Alternatively, one or more end effectors of the multi-head end effector may include the flexible joint. In this way, each individual end effector can have independent flexibility.

[0087] A flexible joint is preferably a controllable flexible joint, which can be selectively manufactured so that the joint moves in at least partially flexible mode. When moving in flexible mode, the flexible joint can preferably act in response to an external force. Preferably, the flexible joint has a controllable degree of rotational freedom so that the flexible joint can rotate in response to an external force. The flexible joint can also preferably be selectively manufactured to act in a controlled mode. In one preferred modification, the controllable flexible joint has a single degree of rotational freedom, which, when engaged in flexible mode, can rotate freely (at least within a certain angular range), and when engaged in controlled mode, can be actuated to rotate in a controlled mode. Linear flexible action may be designed in addition to, or alternatively, in the flexible joint. The flexible joint may also be controlled for variable or partially flexible forms of action, which the flexible joint can actuate but is flexible to forces above a certain threshold.

[0088] The end effector functions to facilitate direct interaction with the article. Preferably, the system is used to grip the article, and gripping describes the step of physically bonding with the article for physical operation. Controllable gripping preferably allows the end effector to selectively connect / bond ("gripping" or "picking") to the article and selectively disconnect / disconnect ("dropping" or "installing") from the article. The end effector may controllly "gripping" the article through suction force, pinching the article, applying a magnetic field, and / or through any suitable force. In this specification, the system is described primarily in relation to gripping an article on a suction base, but the modifications described herein are not necessarily limited to suction-based end effectors.

[0089] In one preferred modification, the end effector includes a suction end effector head (which may be more simply referred to as a suction head) connected to a pressure system. The suction head preferably includes one or more suction cups. The suction cups can be stocked in various sizes, rigidities, shapes, and other configurations. Several embodiments of the suction head configuration may include a single suction cup configuration, a four-suction cup configuration, and / or other modifications. The size, material, and geometry of the suction head can also be modified to target different applications. The pressure system will generally include at least one vacuum pump connected to the suction head through one or more hoses.

[0090] In one preferred modification, the end effector of the system includes a multi-head end effector fixture including a plurality of selectable end effector heads, as shown in the exemplary modifications of Figures 9 and 10. Each end effector head can be connected to an individually controlled pressure system. The system may selectively activate one or more pressure systems and grip using one or more end effectors of the multi-head end effector fixture. The end effector heads may be selected and used based on dynamic control inputs from a grip planning model. The pressure system may alternatively use a controllable valve for redirecting the airflow. Alternatively, all or a subset of the end effector heads may be connected to a shared pressure system. Two or more end effector heads may be activated simultaneously, and an article may be gripped by one or more of the end effector heads. Different end effectors are preferably spaced apart. They may be angled substantially in the same direction, but the end effectors may, alternatively, be directed outward in a non-parallel direction from the end arm section.

[0091] As shown in the cross-sectional view of Figure 9, one exemplary modification of a multi-head end-effector device can be a two-head gripper. This modification may be specialized to reach into the corners of deep containers or vessels and to grasp small items (e.g., small items such as pencils) as well as larger items (e.g., boxes). In one modification, each gripping head end-effector may be able to slide linearly on a spring mechanism. The end-effector heads may be coupled to a hose that connects to a pressure system. The hose is spirally coiled around a central shaft and can allow the suction head to be connected to (and moved to) a vacuum generator.

[0092] As shown in Figure 10, another exemplary modification of the multi-head end effector device can be a multi-four-head gripper. As shown in this modification, various sensors, such as cameras or barcode readers, can be integrated into the multi-head end effector device, shown here in the palm. Suction cup end effector heads can be selected to have a wide range of applications collectively (e.g., one for small boxes, one for large boxes, one for loose poly bags, one for more rigid poly bags). Multiple gripper combinations can be used to pick items of different sizes. In some modifications, this multi-head end effector device may be connected to a robot by a spring plunger to allow for positioning errors.

[0093] Another preferred modification of the system includes a changeable end-effector system that functions to allow the end-effector to be changed. The changeable end-effector system preferably includes a head selector integrated into the distal end of the actuation system (e.g., an end-arm compartment), a set of end-effector heads, and a head holding device. The end-effector heads are preferably selected and used based on dynamic control inputs from a grip planning model. The head selector and end-effector heads are preferably mounted together to the selector and the mounting portion of the heads. One or more end-effector heads may be stored in the head holding device when not in use and when in use. The head holding device may also be able to orient the stored end-effector heads for easier selection during storage. The head holding device may also partially restrict the movement of the end-effector heads in at least one direction to facilitate mounting to or removal from the head selector.

[0094] The head selector system functions to selectively attach and detach multiple end effector heads. The end effector heads function as physical parts for engaging with an article. The end effectors can be configured specifically for different situations. In some modifications, the head selector system may be used in combination with a multi-head end effector fixture. For example, one or more end effector heads may be removable and changeable through the head selector system.

[0095] The changeable end effector system may employ various designs to allow the end effector to be changed. In one variation, the changeable end effector is a passive variation in which the end effector head is attached to and removed from the robot system 111 without the use of a controlled mechanism. In the passive variation, the actuation and / or pneumatic control capability of the robot system 111 may be used to engage and disengage different end effector heads. Static magnets, physical fasteners (threads, feed / matching structures, friction mating, or snap-fit ​​fasteners), and / or other static mechanisms may also be used to temporarily attach the end effector head and head selector.

[0096] In another modification, the changeable end effector is an active system that uses an activated mechanism (e.g., mechanical, electromechanical, electromagnetic, etc.) to engage with and disengage a selected end effector head. While passive modifications are primarily used in this specification, modifications of the system and method may also be used in conjunction with active or alternative modifications.

[0097] One preferred modification of the modifiable end effector system is designed for use with a robotic system 111, using a pressure system with a suction head end effector. A head selector can further function to direct pressure to the end effector head. The head selector may include defined internal through-holes so that the pressure system is coupled to the end effector head. The end effector head will generally be a suction head. A set of suction end effector heads can have various designs, as shown in Figure 11.

[0098] The head selector and / or end effector head may include a sealing element that circumstantializes the defined through-hole. The seal can allow the pressure system to reinforce the mounting of the head selector and end effector head. This force is activated when the end effector captures an article and should help ensure that the end effector head remains mounted when the outer article is loaded.

[0099] The robot system 111 preferably includes a grip planning and control system for managing the robot control of the robot system 111. A machine learning model can be used in planned gripping, which is used in the step of selecting a gripping location for an article in the input article area 112, which maps to locations with higher reliability of successful gripping, higher reliability of successful article translation and orientation (e.g., minimizing the moment arm of the article when gripped), not gripping in locations that interfere with article identification (e.g., not gripping within an area of ​​the article that obstructs the barcode), higher reliability, and / or other aspects that affect the success of the article selection unit 110 in completing its task.

[0100] The input article area 112 functions to hold articles prior to sorting. In a preferred modification, the input article area 112 includes one or more input article containers containing unsorted articles. The article containers can be installed adjacent to the robot system 111, preferably within the reachability of the robot system 111. In one implementation, the input article area 112 is a defined space into which article containers can be inserted and removed. Thus, an operator, conveyor system, or robot system may move the article containers to a designated position and, as desired, remove empty (or otherwise completed) article containers.

[0101] Articles and / or article containers may be moved through or added to the input article area using conveyors, chutes, autonomous mobile robots, or any suitable mechanism. In one variation, the system is coupled to an article processing system, thereby causing an article input conveyor to move articles from a source into the input article area 112. In another variation, the input articles may be supplied without article identification, so the system can facilitate the step of determining an article identifier (or some other property) which can be used in the step of selecting a destination output carrier for the articles. In yet another variation, the input articles may be configured such that the article identifier (or property) becomes known when one or more articles are grasped by the robot system 111, so that a destination output carrier can be supplied so that it can be associated with the articles prior to grasping. In such a variation, the order of article selection by the article selection unit 110 may take into account the capacity levels of the output carriers so that articles are grasped for selection when the destination output carrier has the capacity to receive the articles.

[0102] The item selection unit 110 preferably includes a sensing system 113. The sensing system 113 functions to collect data on objects and the environment. The sensing system 113 preferably includes an imaging system that functions to collect image data. The imaging system may preferably include at least one imaging device with a field of view of a region of interest that covers an input item area 112 and optionally a region to which the items are transported to the item sorting unit 120. The imaging system may also include a plurality of imaging devices used to collect image data from a plurality of viewpoints of distinctly different regions, overlapping regions, and / or distinctly different non-overlapping regions. The set of imaging devices (e.g., one or more imaging devices) may include visual imaging devices (e.g., cameras). The set of imaging devices may also include, or alternatively, other types of imaging devices such as depth cameras. Other suitable types of imaging devices may also be used, or alternatively.

[0103] The sensing system 113 may communicate with the control system 140 and collect data to facilitate the planning of gripping items. For example, image data of a set within the input item area 112 may be processed by an analytical model that outputs one or more gripping plans (e.g., points for item selection, or motion plans for approaching, gripping, and picking items).

[0104] The sensing system 113 may also include, or alternatively, one or more sensors for item identification. This may include sensors and / or RFID tag readers for scanning barcodes. In one exemplary implementation, the system may include four barcode scanners, namely two side scanners, one top scanner, and one bottom scanner. The two side barcode scanners can capture barcodes on the sides of items while the item is rotating. The top scanner can capture barcodes from above, such as after an item has been placed in a transport tray or item tray. The bottom scanner can capture barcodes from below as an item is removed from the item container. A transparent shield can be positioned above the bottom scanner such that an item will deflect away from the shield if dropped. Any suitable sensing system may be used to collect information about the item, which may be used to determine the destination output transport box.

[0105] The sensing system 113 may, in addition or alternatively, include one or more sensors for measuring the dimensions of the article. The sensing system 113 may include one or more dimensional cameras (e.g., depth sensors) or other sensor systems for measuring the dimensions of the article. Measuring may include the step of determining the spatial characteristics of the article (i.e., article dimensions). In one implementation, article dimensions may include the step of defining the boundary volume of the article (e.g., width, height, and depth of the article). Article dimensions may be used at least in part in the step of planning the installation orientation when placing the article in the transport system 130 and / or the article holding and placement system 122.

[0106] Other sensors, such as load cells, proximity sensors, RFID tracking systems, and equivalents, may also be used to monitor the status of various aspects of the system.

[0107] The item selection unit 110 may also include other supplementary systems that can be used to facilitate other forms of item processing. For example, the item selection unit 110 may include a label printer and a label affixer that function to enable labels to be produced and applied to items prior to sorting.

[0108] The item sorting unit 120 receives items selected from the item selection unit 110 and translates them to one of the array of item transport boxes. The item sorting unit collects items directly or indirectly from the item selection unit 110. The sorting unit converts the dynamic and adaptive item individualization and gripping capabilities of the item selection unit 110 into scalable sorting into many output groupings. The item sorting unit 120 operates in cooperation with one or more item selection units 110. In some cases, a transport system 130 is used as an intermediate component to temporarily hold items after placement by the item selection unit 110 and collection by the item sorting unit 120, and to transport them as needed.

[0109] In a preferred variation, the article sorting unit 120 includes a gantry system 121 with an article holding and placement system 122 that performs grouping across a horizontally distributed array of output transport boxes 123. As will be discussed, several configuration variations may allow for a vertical distribution of the output transport box array 123.

[0110] The item sorting unit 120 preferably includes, or communicates with, a control system 130 which, when executed by one or more computer processors, causes the item sorting unit 120 to position the item holding and placement system 122 in a position for receiving items transferred from the item selection unit 110, to move the item holding and placement system 122 in a position above the targeted output item transport box, and to place the items in the targeted output item transport box. An output transport box capacity sensor 124 may also sense the current capacity level of one or more output item transport boxes.

[0111] In a single modified item sorting unit 120, all output item transport boxes (defining the number of item groupings) are accessible by the item sorting unit 120.

[0112] In some applications, the decision to add an item sorting unit may be based on the desired number of output groupings and the item handling speed of both the item selection unit and the item sorting unit. In one optimized implementation, the item selection processing time of the item selection unit (e.g., the time for item processing steps such as gripping the item, scanning barcodes, etc., and the step of oriented the item for transport) and the item sorting processing time of the item sorting unit (e.g., the time for receiving the item, moving it to a designated position, and positioning the item) are substantially equal. Variations in item type, size, and weight may affect the gripping success rate and the speed at which the item can be moved, and therefore, processing time may vary between different items.

[0113] In some modifications, multiple item sorting units may be combined to expand the number of groupings. This may be used to keep the item sorting processing time close to the item selection processing time and to reduce the waiting time of any one unit. In one modification, vertical degrees of freedom may be used to translate selected items between different vertically arranged item sorting units 120. In another modification, the item selection units 120 may be combined so that items can be transferred between them.

[0114] The gantry system 121 functions as an actuation system used for sorting. The gantry system 121 can be a horizontal gantry system actuated with at least two degrees of freedom (linear). Thus, the horizontal gantry system can translate the article holding and placement system 122 (and the articles held thereby) across a 2D area. In one implementation, the horizontal gantry system is a two-axis linear actuator consisting of two coupled linear actuators arranged at right angles, as shown in Figures 1A and 1B. Various other approaches to actuation may be used as alternatives. In some modifications, the horizontal gantry system 121 may actuate along one degree of freedom if the output bin array is a linear array of article bins.

[0115] In this specification, the gantry system 121 is described as a horizontal gantry system, but the gantry system 121 may also be a vertical gantry system. A vertical gantry system may function to sort items across the walls of the output transport box. In yet another variation, the gantry system 121 may include three degrees of freedom (linear) to enable sorting into a 3D array of output transport boxes 123.

[0116] The gantry system 121 preferably includes an article holding and placement system 122 coupled to the actuation system of the gantry system 121 so that it can be moved to different positions. The article holding and placement system 122 also serves as a mechanism for holding articles during positioning and then placing the articles into targeted article transport boxes. The article holding and placement system 122 can be implemented through various approaches, namely two variations, which include an actuated article tray and a second robotic pick-and-place machine.

[0117] A variation of the article holding and placement system 122 may be an actuated article tray, as shown in Figure 12, which functions as an actuated surface or container that holds articles when receiving / collecting them and when moving them. In addition, the article holding and placement system 122 may function to controllably position articles within a targeted area.

[0118] An actuated article tray preferably includes at least a partial container and a placement mechanism. In one preferred modification, the actuated article tray includes a rotary articulated container. The container may include two intersecting surfaces, one defining the periphery surface and a second defining the back surface. The two intersecting surfaces may form a valley on which an object can be seated. The two surfaces may be perpendicular or at any preferred angle. The container may also include other lateral structures, such as two side walls or two adjacent corners of the tray, as shown in Figure 12. A box, letter, or other type of article may be placed inside the container and rotated so that it remains inside the container during translation, and the container may then be rotated to position the article. During motion, the container may rotate upward to reduce the amount of room for the article to slide out of the container when stopping, starting, or changing direction.

[0119] The article tray may have defined receiving ends oriented toward the article selection unit 110. The article carrier preferably has an opening defined for storing items to be placed from the article tray. For example, the article carrier has an opening with a width wider than the width of the article tray and a height sufficient to receive the expected articles. These dimensions may be configured within the system to indicate the placement orientation of the articles when installed by the article selection unit 110.

[0120] A rotary articulated container may have a first operating state in which the container is in a holding position, and a second operating state in which the container is angled into a placement position. During transport, the article tray may preferably be in a holding position, and a concave portion of the article tray (defined by the wall surface of the article tray) may be provided at the lower point (lower than the edge of the highest wall surface) so that the held article is seated within the article tray. The sides may prevent the article from sliding out during transport. In one exemplary modification shown in Figures 13A, 13B, and 13C, the rotary articulated container may have a first operating state that functions as an insertion state for receiving or removing an article from an article selection unit 110, as shown in the embodiment of Figure 13A; a second operating state that functions as a transport state for holding an article by a gantry system 121 during transport, as shown in the embodiment of Figure 13B; and a third operating state that functions as a placement state for placing an article in a targeted article transport box, as shown in the embodiment of Figure 13C.

[0121] A rotary articulated container may have a pivot point defined to facilitate the sliding of an article outward in a controlled manner to a targeted output location. Preferably, the pivot point is defined within a central region on the side of the container. More specifically, the pivot point may be located within the central region but closer to the back wall compared to the front (where the article slides outward), as shown in the exemplary concrete image of Figure 14, where a shaded area is used in some implementations to indicate the potential location of the pivot point. As an alternative to a pivot point, the rotary articulated container may rotate within its positional location by rotating while the container is moved along a track or path.

[0122] As shown in Figure 15, the rotation point of the articles tray may be configured and adjusted for the expected size of the articles container. The length of the articles tray's extension arm (i.e., surface) can be configured to have sufficient clearance when positioned. In this embodiment, an 8-inch clearance can be configured for the longest objects handled by the system. Similarly, the inclination angle can be configured for reliable transfer from the articles tray into the articles container. In this embodiment, 70 degrees is shown as in the embodiment of Figure 15.

[0123] In certain modifications, the article tray may be a slotted article tray, wherein the tray includes a set of protruding structures that define the stationary surface of the article tray and mesh or engage with a complementary transfer system 130. As shown in Figures 16A-16C, the slotted article tray 1621 may have slotted extension arms 1622 that connect to a center-holding tray 1623 with a rear stop 1624. The extension arms 1622 may be tapered to accommodate slight misalignment when engaging to collect articles. In the complementary transfer system 130, the transfer system 130 may include a slotted transfer tray as shown in Figures 17A and 17B. The slotted transfer tray 1731 may include a slotted surface with a set of extension arms 1732. In one modification, the slotted transfer tray may also include a slotted inclined section 1733. The slotted inclined section may allow the extension arms of the article tray to pass through it, facilitating the secure transfer of articles. The inclined section can also facilitate the smooth transport of articles by reducing the amount of room for large, fixed-size articles to get caught when pushed forward during transport. In addition, one or more of the extension arms 1732 may be adjusted in length to allow clearance from the carrier arm or other parts of the slotted article tray. The set of extension arms 1732 can complement the slotted extension arm 1622 of the article tray (e.g., the protruding structure of the article tray) so that articles can pass through defined slots in the slotted article holder when collecting them, as shown in Figures 18A and 18B. In such a modification, the article tray may be inserted into position so that the extension arm 1622 rises from below the articles resting on the transport system 130, and the articles can then be removed by pulling out the article tray in a rotated transport state, as shown in Figure 19.

[0124] The activated goods tray may use alternative design configurations. For example, the activated goods tray may be a container with a target-drop door, hatch, or other opening mechanism so that the goods contained within the container can be positioned when the mechanism is opened.

[0125] Another variation of the article holding and placement system 122 may be a sorting robot pick-and-place machine. This may be a robot system such as the one in the robot system 111 or one of its variations described above. In this variation, articles are grasped or held by the machine and then dropped into a suitable article transport box. In this variation, the base of the sorting robot pick-and-place machine may be coupled to an actuated part of the gantry system 121 so that it can move around the transport box array 123. In one variation, where the sorting robot pick-and-place machine provides a range of motion, the sorting robot pick-and-place machine may increase the reachability of the gantry system 121. In one implementation, the gantry system may provide actuation along a single axis extending outward from the article selection unit 110, and the sorting robot pick-and-place machine is an articulated arm that can be oriented to position articles perpendicular to this axis. In another variation, the sorting robot pick-and-place machine may be a robotic system with a more limited range of motion, and in some cases may be nothing more than an end effector. For example, the gantry system 121 may have a rigidly fixed end effector, such as those described above, capable of gripping and dropping items.

[0126] The output transport box array 123 functions as an array of transport boxes for receiving articles. The output transport box array 123 preferably includes a plurality of transport boxes arranged within the reachable area of ​​the article sorting unit 120. The transport boxes are preferably arranged in a grid manner directly below the gantry system 121. The plurality of transport boxes 123 may include transport boxes that are boxes, containers, trays, bags, Gaylords, containers, chutes to other containers, and / or other receivers for articles. The plurality of transport boxes 123 will generally include one type of transport box, but the plurality of transport boxes 123 may include multiple types of transport boxes that are similarly standardized or have various sizes.

[0127] The output transport box array 123 is preferably a two-dimensional array of multiple item transport boxes. In one variation, the item transport boxes are arranged in a grid, and in another variation, the item sorting unit 120 has an output transport box array 123 configured and arranged so that the item transport boxes are accessible for maintenance from one or more sides. For example, the array may have a rectangular grid from which item transport boxes are added to or removed from one or more sides of the item sorting unit 120. In one implementation, the output transport box array 123 includes 4 to 6 item transport boxes arranged along n rows. The item transport boxes may be on a cart that can be slid from the side. In one implementation, the cart can be slid in from two opposing sides. In one embodiment, 4 or 6 transport boxes are arranged along 10 or more rows. The number of rows (and columns) in the output transport box array 123 may be configured for different use cases.

[0128] In some alternative implementations, the item transport boxes may be located in various arrangements. In one embodiment, the item transport boxes may be placed in any preferred arrangement within a defined area reachable by the item sorting unit 120. The location of the item transport boxes is detected and then used as output transport boxes.

[0129] In one variation, the output transport box array 123 may be a defined empty space where item transport boxes can be positioned. In some variations, the system may dynamically detect item transport boxes and assign the detected item transport boxes to item output groupings. In another variation, the item transport boxes may have an organized array. In some cases, the placement of associated groupings for item transport boxes may be substantially statically associated with their position in the array. For example, item transport boxes in the second row and fourth column may always be assigned for parcels destined for a particular route. In yet another variation, the grouping associations of item transport boxes may be dynamically assigned. This assignment may be automatically adjusted based on past trends and predictions of expected item sorting. For example, more common groupings may be assigned to positions closer to the item selection unit 110 to reduce sorting processing time. This assignment may also be dynamically assigned based on the identification of items from the input item area 112. This functions to adapt to the current items requiring sorting.

[0130] Preferably, the article carrier array 123 includes an assembly with defined cavities into which a plurality of article carriers are fitted. The assembly may be a structure that functions to hold and / or guide the positioning of the article carriers. The assembly of the article carrier array may include, at least in part, a set of alignment mechanisms for defining the position of the article carriers within the article carrier array.

[0131] The item transport boxes can preferably be selectively added to and removed from the transport box array 123, as shown in Figure 20. In some variations, the item transport box array 123 includes at least a semi-automatic actuation system for adding and / or removing item transport boxes. In other variations, an automated system may facilitate the steps of removing, adding, or otherwise replacing item transport boxes. In one variation, an item transport box or collection of item transport boxes may be positioned within and retrieved from an automated robotic system. For example, a robotic transport device may move directly beneath one or more item transport boxes, engage with one or more item transport boxes, and remove one or more item transport boxes. Similarly, a robotic transport device may move a new item transport box to a fixed position within the output transport box array 123.

[0132] In one variation, the item transport box may be a wheeled container. The item transport box may also be a container on a conveyor system of the type in which filled item transport boxes can be moved out of the transport box array 123 and new item transport boxes can be moved into the transport box array 123.

[0133] In one modified example shown in Figure 21, the goods transport cart may include a rigid assembly on which bags can be positioned. The wheeled cart may have two outwardly extending jaws that can be adjusted and opened so that bags of different widths can be securely fitted across them and held in place.

[0134] The container array 123 may include container array alignment equipment that functions to structurally guide and restrict the arrangement of the containers. Various equipment or mechanisms may be implemented to mechanically restrict the positioning of the containers. In one modification, the alignment equipment may be a set of guide rails that extend parallel to and across the container array 123, thereby defining distinctly different rows (or columns) into which the containers can be inserted. In one modification, the containers include a base with a feeding mechanism such that they are aligned when inserted. As shown in Figure 21, the cart holding the containers may have a downward-extending pin that can enter into a defined feeding groove formed by a plate that is internally positioned within the container selection unit assembly as shown in Figure 22. This functions to feed the cart to a defined reference point or reference line. In one implementation, the front wheels of the cart may rise over rails or raised sections on the floor, providing two additional reference lines to restrict the cart's position in space relative to the assembly with respect to the gantry system 121. In addition, such matching equipment may include sensors for detecting when the goods transport box or cart is in a fixed position. For example, an instantaneous switch or proximity sensor may detect when the cart is placed inside the matching equipment.

[0135] The output container volume sensor 124 functions to measure the volume level of the goods container and / or to detect when the goods container is in close proximity. Various sensor mechanisms may be used. In one implementation, a depth sensor or imaging system can be mounted downward to the gantry system 121. The depth sensor can detect or collect image data used in the step of predicting the volume level of the goods container as it passes through the goods container. The volume of the goods container may be measured each time an item is placed in it.

[0136] In one modified example, the output container capacity sensor 124 is coupled to the gantry system 121 so that the output container capacity sensor 124 can move across the output container array 123. The capacity of the containers may be measured as the capacity sensor moves across the containers during use, such as when the gantry system 121 is in transition and / or while placing items.

[0137] In another variation, each item carrier may include a capacity sensor system for individually reporting its capacity. For example, load cells, proximity sensors, optical or mechanical switches, and / or other sensor systems may be employed as alternatives. In a related variation, an array or sensor of capacity sensors may be used that can monitor multiple item carriers from a displaced fixed location. For example, a camera mounted above the output carrier array 123 may monitor at least a sub-assembly of item carriers.

[0138] In some variations, the system may include a transfer system 130 that functions to facilitate the transfer of articles between the article selection unit 110 and the article sorting unit 120. The transfer system is preferably an intermediate component that receives articles from one or more article selection units 110 and has articles to be transferred to the article sorting unit 120. In particular, a robotic system 111 places articles into the article transfer system 130, and the articles are then transferred into an article holding and placement system 122 (for example, into article trays).

[0139] The transfer system 130 may be a component used each time an item is transferred between the item selection unit 110 and the item sorting unit 120. Alternatively, the transfer system 130 may be a component that can be used dynamically to select items for different scenarios. For example, the transfer system 130 may be used to transfer an item to one of the set of item sorting units 120 when the item selection unit 110 and the item sorting unit 120 do not have directly overlapping reachable areas. In another embodiment, the transfer system 130 may be used to transfer an item when the item sorting unit 120 is not currently ready to collect another item (for example, still sorting previously collected items).

[0140] In some modifications, the transfer system 130 makes the articles substantially static so that the placement of the articles by the robot system 111 is substantially the same as when the articles are collected by the article holding and placement system 122. In alternative modifications, the transfer system 130 moves the articles from an input area to an output area, the robot system places the articles within the input area, the transfer system 130 facilitates the movement of the articles from the input area to the output area, and the articles are collected within the output area by the article holding and placement system 122.

[0141] In one modification, the transfer system 130 includes a substantially static transfer tray that serves as a surface or container on which articles can be placed and held during the transfer between the article selection unit 110 and the article sorting unit. In one modification, the transfer tray may have a substantially flat surface (e.g., solid, gridded, slotted, or otherwise). Alternatively, the transfer tray may be a container with side walls and / or surfaces defined along a non-horizontal plane (here, “horizontal” is used to mean a plane parallel to the ground).

[0142] A static transport tray is preferably located between or adjacent to the article selection unit 110 and the article sorting unit 120. In one variation, the transport tray is intended to receive and hold a single article at any given time. Alternatively, multiple articles may be placed on the transport tray. For example, a wide transport tray may hold multiple articles side by side. The control system 140 can store the locations of different articles so that the article sorting unit 120 can be controlled to collect one of the sets of articles on the transport tray and sort it into a targeted transport box for that particular article.

[0143] In one modification, the transfer system 130 may include a slotted transfer tray that receives and holds articles, similar to a static transfer tray, but functions such that the article holding and placement system 122 can actively remove articles from the slotted transfer tray. As described herein, such modifications would generally involve an article holding and placement system 122 that includes a slotted article tray. The slotted transfer tray would generally be a static transfer tray as described above, but the slotted tray may be used in conjunction with other modifications of the transfer system 130. For example, a slotted conveyor system could function similarly, in which articles are not only transported along the path of the conveyor system but can also be actively removed by the slotted article tray.

[0144] The slotted transfer tray may have the advantage that articles are collected by the article holding and placement system 122 while substantially maintaining the orientation of the objects when installed by the robotic system 111.

[0145] Similar to the static trays described above, a slotted transport tray may be used to hold a single item at any given time. Alternatively, multiple items may be placed on the transport tray. For example, a wide transport tray may hold multiple items side by side. The item sorting unit 120 may dynamically collect one of the multiple items.

[0146] In another variation, the transfer system 130 may include an actuated transfer tray that functions to actuate a transfer tray to facilitate the transfer of articles to the article holding and placement system 122. The actuated transfer tray may be translated and / or rotated. In one embodiment, the actuated transfer tray may rotate to place the held articles into the article trays of the article holding and placement system 122.

[0147] In another variation, the transfer system 130 is or may include a passive conduit such as a chute or inclined section, allowing the placed articles to slide, fall, or otherwise move from the input area to the output area.

[0148] In another variation, the transfer system 130 is or may include a conveyor system that functions to move articles along a path.

[0149] In one variation, the transfer system 130 may be equipped with sensors or other elements that can act on the articles while they are present in the transfer system. In particular, the transfer system 130 may include a weight sensor so that the articles can be weighed prior to being transferred to the article sorting unit 120. In one embodiment, the weight sensor may be a load cell (or other type of pressure sensor, strain sensor, digital scale, or equivalent for estimating / measuring weight) integrated into the transfer tray.

[0150] The control system 140 functions to manage the coordinated operation of the item selection unit 110, the item sorting unit 120, and optionally the transport system 130.

[0151] The control system 140 may include one or more computer processors and one or more computer-readable media (e.g., non-transient computer-readable media) that store commands, when executed by one or more computer processors, to cause the item selection unit 110 to grasp an item, optionally perform any item processing (e.g., scanning a barcode), translate and orient the grasped item to a fixed position for transfer to the item sorting unit 120, and further cause the item sorting unit 120 to position the item holding and placement system 122 to receive or collect the item transferred from the item selection unit 110, move the item holding and placement system 122 to a fixed position above a targeted output item transport box, and place the item in the targeted output item transport box. In a similar manner, the control system 140 may manage the control of the transport system 130 if the transport system 130 includes active components that need to be controlled.

[0152] The control system 140 may be a centrally located computing device that is communicatively connected to the item selection unit 110, the item sorting unit 120, and optionally the transport system 130. Alternatively, the control system 140 may consist of two or more computing devices, accompanied by control subsystems that can work together to facilitate the sorting of items from the input item area 112 to the final output item transport box. In some modifications, some components or functionalities of the system may operate automatically without the need for external control.

[0153] The control system 140 may be communicatively connected to one or more sensors of the system to facilitate the use of collected data in the operation of the system. For example, the output container capacity sensor 124 may sense the current capacity level of one or more output containers, which may be used in steps of controlling the selection of articles, assigning output containers for articles, and signaling changes to article containers in the output container array 123.

[0154] In one modified example, the item selection unit 110 and the item sorting unit 120 include separate internal control systems used in steps that manage some of their own operations. The control system 140 may facilitate the coordinated operation of such systems.

[0155] In one implementation, the item selection unit 110 and the item sorting unit 120 operate in such a manner that the state of one or both affects the operation of the other. In one embodiment, the state of the item sorting unit 120 (e.g., the current status of item sorting and / or the capacity of the output item transport box) may affect item selection, while the state of item selection may modify the way the item sorting unit 120 plans and allocates.

[0156] In alternative implementations, the two systems may be controlled substantially independently of each other. Independent operation can preferably result in coordinated operation of the systems. In one embodiment, the article selection unit 110 independently picks, retrieves, and places an article in the output area when the output area is capable of receiving an article, and at that time (for example, when no other articles are present in the output area, and / or when the article holding and placement system 122 is in position to receive an article). Article identification may be communicated to the article sorting unit, which can then be used to set a targeted output for the current article. The article sorting unit 110 can sort the article to the targeted output when the article is identified and available in the retrieval area, and at that time.

[0157] Other alternative approaches to coordinating actions may be used.

[0158] The system may also include a user management system that functions to enable the collection of user input and / or output information regarding the status of the system. The management system may include a dashboard on which the operational configuration and settings of the system can be configured. The management system may, alternatively, include one or more input or output UI elements, which may be terminals, buttons or other forms of user input, displays, lights, audio systems (for audio alerts), and equivalents.

[0159] The user management system may include one or more user interfaces for outputting the status of the system. In one embodiment, identifiers for item groupings for multiple item containers may be communicated through one or more user interfaces so that a human operator can identify the item containers during or after sorting.

[0160] The user interface output may also be used in a step to signal changes to the item containers in the output container array 123. An operator and / or automated system may use the output signals to know when and how to replace an item container from the output container array 123.

[0161] 3. Method A method for robotic sorting of articles functions to appropriately sort an unsorted collection of articles into groups to be held in article transport boxes, and in an article selection unit, may include the steps of: separating articles from input articles; transporting the separated articles from the article selection unit to an article sorting unit; translating the articles in the article sorting unit into targeted article transport boxes in an array of article transport boxes; and placing the articles into the targeted article transport boxes. In one preferred variation, the separation preferably includes the step of picking using a robotic arm with an end effector such as those described above with respect to a robotic pick-and-place system, and the translation step preferably includes the step of translating the articles horizontally using a two-dimensional gantry system.

[0162] This method can enable collaborative operation between item sorting units. This method can divide the task from sorting to picking items into a number of possible exits (for example, "a number" could be 30 or more).

[0163] As shown in Figure 23, the method S100 for robotic sorting of articles may include the steps of: picking articles from an article input area using a statically positioned robotic system S110; oriented the articles in a transfer position using the robotic system S112; transporting the articles from the transfer position to a receiving mechanism of an article sorting unit S120; translating the articles to a designated article transport box in an array of article transport boxes using the article sorting unit S130; and placing the articles in an article transport box S140.

[0164] This method can be implemented in various ways, and therefore, different variations of this method may be possible, such as processing the articles prior to the sorting step, dynamically identifying the articles using detected attributes of the articles in the step of determining how to place the articles for more successful placement of the articles into the article transport box, and instructing the transfer of articles between the article selection unit and the article sorting unit using a transfer system as an intermediate component for article transfer.

[0165] As shown in Figure 24, one modified method for enabling the processing of articles may include the steps of: picking an article from an article input area using a statically positioned robotic system S110; processing the article while it is being held by the robotic system S111; oriented the article in a transfer position using the robotic system S112; transporting the article to a receiving mechanism of an article sorting unit S120; translating the article above a designated article transport box in an array of article transport boxes using the article sorting unit S130; and placing the article inside an article transport box S140. The steps for processing the article may include variations of processing such as identifying the article, scanning the article for measurement, applying a label, or performing any preferred task with the article.

[0166] As shown in Figure 25, one modified method that uses an identification process to determine a method for sorting includes the steps of: picking an item from an item input area using a statically positioned robotic system (S110); determining an identifier for the item and determining a targeted item transport box (S111); oriented the item in a transport position using the robotic system (S112); transporting the item to a receiving mechanism of an item sorting unit (S120); translating the item above a targeted item transport box in an array of item transport boxes using the item sorting unit (S130); and placing the item inside an item transport box (S140).

[0167] As shown in Figure 26, in addition, or as an alternative, one modification of the method involves using a process for using articles in a form that allows the articles to be more optimally positioned within the article transport box for better placement. This modification may include the steps of: picking an article from an article input area using a statically positioned robotic system (S110); determining the dimensional properties of the article (S111); oriented the article in a transport position using the robotic system based on the dimensional properties (S112); transporting the article to a receiving mechanism of an article sorting unit (S120); translating the article to an article transport box in an array of article transport boxes using the article sorting unit (S130); and placing the article inside the article transport box (S140). Preferably, the article can be oriented so that it can slide better inside the article transport box and avoid being trapped inside the article transport box entrance or entering the article transport box in an unpredictable manner. More specifically, the step of orienting the articles may include oriented the articles within the transport position for controlled placement of the articles in the article transport box, based on their dimensional properties. This method may employ modeling of object behavior using article dimensions. Alternatively, a heuristic method may be used in the step of determining the preferred orientation.

[0168] As shown in Figure 27, one modified method for directly transferring items between an item selection unit and an item sorting unit may include the steps of: picking an item from an item input area using a statically positioned robot system (S110); oriented the item within the transfer position of the receiving mechanism of the item sorting unit using the robot system (S112); placing the item within the receiving mechanism of the item sorting unit using the robot system (S120); translating the item to the top of an item transport box in an array of item transport boxes using the item sorting unit (S130); and placing the item within an item transport box (S140).

[0169] As shown in Figure 28, one modified method using a transfer system for indirectly transferring articles between an article selection unit and an article sorting unit may include the steps of: picking an article from an article input area using a statically positioned robot system (S110); oriented the article within a transfer position in the transfer system using the robot system (S112); placing the article in the transfer system using the robot system and removing the article from the transfer system in the article sorting unit (S120); translating the article to the top of an article transport box in an array of article transport boxes using the article sorting unit (S130); and placing the article inside an article transport box (S140).

[0170] As shown in Figure 29, one modified method using a modified slotted transfer tray of the transfer system may include the steps of: picking an item from an item input area using a statically positioned robot system (S110); oriented the item in a transfer position on the slotted transfer tray using the robot system (S112); placing the item on the slotted transfer tray in the robot system and moving the slotted item tray through the slotted transfer tray in the item sorting unit to collect the item in the slotted item tray (120); translating the item to the top of an item transport box in an array of item transport boxes using the item sorting unit (S130); and placing the item in an item transport box (S140).

[0171] In some implementations, the method may also facilitate the management of item containers such that they can be removed when they become full and are replaced with item containers that have more capacity for more items. Therefore, the method may include step S150, as shown in Figure 30, which senses the capacity of an item container and signals a change in the item container when the capacity condition is met.

[0172] In some implementations, the method may also facilitate automated management of grouping assignments, which may be a method for sorting systems to automatically improve efficiency or dynamically adjust new groupings. Thus, the method may include step S160 of dynamically assigning grouping locations within an array of item transport boxes, as shown in Figure 31.

[0173] This method is preferably implemented in combination with a robotic horizontal sorting system such as those described above, but it may also be used in combination with any suitable robot or automation system.

[0174] Block S110, which includes the step of picking articles from an article input area from a statically positioned robotic system, functions to separate articles from a collection of articles. The collection of articles can be an unsorted collection. For example, the articles may be a collection of articles in a Gaylord or container. Alternatively, the articles may be supplied in a more organized manner and may be further fed through a conveyor system.

[0175] The step of picking an item preferably includes the step of grasping the item using a robotic pick-and-place machine, as described above. Thus, the robotic system may be a robotic articulated arm with an end effector. Any suitable robotic system may be used, as an alternative, in the step of selecting an item. The robotic system is generally static in that it is in a fixed position. In some modifications, the robotic system may be mobile, with a limited range of motion across a floor area. In some other modifications, the robotic system may be a mobile robot.

[0176] One potential benefit of this method is its ability to handle a wide variety of item types. Therefore, this method can be implemented in combination with an intelligent robotic system that dynamically picks items according to customized, planned gripping trials for unsorted items. In one implementation, the item-picking step may include steps of generating and selecting a gripping plan, executing the selected gripping plan, and proceeding with the subsequent handling of the item (e.g., S111 or S112).

[0177] One variation of the steps for generating and selecting a grip plan may include collecting image data from an input item area, segmenting the image data into a focus area mask, evaluating the image data through a trained grip quality model to generate a set of candidate grip plans, processing the candidate grip plans, and selecting a grip plan. This may be used in the steps of determining which item to pick next and selecting grip points or target grip areas to avoid in terms of important features (e.g., barcodes or address labels) and / or other aspects related to the steps of picking an item from a group of items, including the end effector to use, the motion path for gripping and extraction, and picking an item from a group of items. Any alternative approach for picking items may be used as an alternative.

[0178] As one variation, the item picking step may include a step of determining the item for selection based on the expected item processing time of the item sorting unit for the items currently being sorted by the item sorting unit. For example, if an item is heavier (requiring slower movement), located in an item transport box at the far end of the output transport box array, resulting in a longer expected item processing time, the item from the input item area may be picked, which will take longer than other input items, thereby allowing for a longer item processing time window. Conversely, if an item is lighter, located in an item transport box at the near end of the output transport box array, resulting in a shorter expected item sorting processing time, the item from the input item area may be picked, which can be grasped and processed quickly to avoid the item sorting unit remaining idle for a similarly long time compared to items that may take longer to pick.

[0179] In another variation, the item picking step may include a step of determining the item for selection based on the expected carrier array status. For example, items that are expected or anticipated to be for a carrier that is full, needs to be changed, or is being changed because it has reached capacity may be avoided. In some cases, the grouping of items may be unknown until the item is processed by scanning its barcode. In these situations, if a grasped item is identified as an item designated with an unavailable item carrier, the method may proceed to a step of abandoning item processing for that item and proceeding to a step of processing a new item. An item carrier may be unavailable because it has reached capacity, or it may be changed to an unfilled item carrier, or perhaps no existing item carrier is associated with its output grouping. The step of abandoning item processing may include a step of dropping the item. The step of abandoning an item may also include a step of placing the item within an item input area or holding area, which may enable item grasping processing to avoid rescanning and / or increase the probability of successful grasping during subsequent attempts.

[0180] An optional process in block S111, which includes a step of processing the article while it is being grasped (i.e., picked) by the robotic system, functions to perform one or more actions with the article while it is being grasped. This may include a process for processing the article to identify it, characterizing the article, modifying the article, or performing any preferred action with the article. In some implementations, multiple processes may be used simultaneously and / or sequentially.

[0181] In one variation, the step of handling the articles while they are being held may include a step of determining the identifier of the articles. This may be used when information regarding the identification of the articles is unknown prior to the step of picking the articles. Thus, the articles may be scanned or imaged to determine a designated grouping. For example, with respect to a parcel, the address may be scanned and used to determine a route group for use for the parcel. The step of determining the identifier of the articles may include scanning a barcode (or other preferred type of machine-readable code or information), reading an RFID tag, or reading another type of radio identifier signal, visually classifying the articles using computer vision analysis, and / or using some other identification or classification method.

[0182] After determining the identifier of an article, in some variations, the method may then include the step of determining the targeted article bin for the article based on the article identifier. In other words, an article can be picked, scanned, and its identification determined, and then, based on the identification, a database can be queried to determine one or more targeted article bins. The article sorting unit can then facilitate the step of sorting the article into the targeted article bin when translating the article to the article bin for placement (e.g., S130).

[0183] In another variation, the step of handling the article while it is being held may include a step of determining the dimensional properties of the article, which functions to sense or detect one or more dimensions of the article. In one variation, the step of determining the dimensional properties of the article may include a step of determining the boundary volume of the article (e.g., height, width, and depth). In yet another variation, the step of determining the dimensional properties of the article may include a step of collecting a full or partial 3D scan of the surface of the article. The step of determining the dimensional properties may include a step of sensing one or more dimensional metrics of the article. This may involve a step of moving the article within the range of a dimensional camera or other sensing system. This may also involve a step of manipulating the article within the field of view of the sensor to scan different views of the article. In addition to the step of sensing dimensions, the image data may be used to predict the dimensions and / or morphology of the object using an AI classifier model or other technique.

[0184] While dimensional properties can be used for any preferred purpose, in certain modifications, they can also be used in the step of predicting the placement orientation of an article for placement in an article carrier. In other words, the dimensions and / or shape of an article can be used to understand how the article can be best positioned in the article tray of an article sorting unit so that there is high reliability for successful placement when the article is placed in the article carrier. This can avoid situations where articles with more irregular shapes may flip over and miss the article carrier. In one embodiment, the dimensional properties of an article can be used in the step of determining whether the article is larger than the container opening on one or more axes, and then orienting the article so that, when placed, the object enters the article carrier with sides having dimensions that fit into the defined opening of the article carrier.

[0185] A variation that includes the step of determining the dimensional properties of an article may also include a variation S112 in which a robotic system is used to orient the article into a transfer position, the transfer position being based on the dimensional properties.

[0186] Block S112, which includes the step of orienting an article into a transfer location using a robotic system, functions to move the position of an article using a robotic system in order to carry out or prepare for the transfer of an article. The step of orienting an article preferably includes the step of translating the article from one position in the article input area to another location for the transfer of the article using a robotic system.

[0187] As discussed above, the step of orienting articles may also involve inferring and proactively orienting the articles based on their dimensional properties. These dimensional properties may be detected during processing, as discussed above, or alternatively, determined through other sources, such as when article dimensions are available using article identifiers. Orientation may also take into account the current level and surface properties of the articles within the targeted article crate. For example, articles may be positioned to better fit within a collection of articles within the targeted article crate.

[0188] As an additional or alternative use of the dimensional properties of an article, these properties may be used to determine whether an article can be stored in a targeted article carrier. This can function to avoid placing an article in an article carrier in such a way that the carrier becomes overfilled. As discussed herein, the capacity level of the article carrier may be sensed or otherwise tracked. An article can be placed in a targeted article carrier if its expected static orientation (after placement in the carrier) will fit (e.g., not exceeding the capacity). If an article is not expected to fit in the targeted article carrier, the system can dynamically switch to sorting a new article. This can also signal the removal of the full carrier and / or loading of a new carrier so that the article can be placed thereafter.

[0189] In a modified direct transfer, step S112, which involves using a robotic system to orient the articles into a transfer position, includes a step of using a robotic system to orient the articles into a transfer position in the receiving mechanism of an article sorting unit, which functions to transfer the articles directly from the article selection unit into the article sorting unit. Preferably, the receiving mechanism is an article tray or other suitable type of receiving mechanism. With respect to an article tray receiving mechanism, the articles are moved and oriented to a transfer position above the article tray, and then placed, dropped, or otherwise positioned within the article tray. Thus, block S120 may include step S120 in the robotic system for placing the articles into the receiving mechanism of an article sorting unit.

[0190] In a variant of the sorting robot pick-and-place machine with a receiving mechanism, the articles may be moved and oriented into a transfer position within the reachable range of the sorting robot pick-and-place machine. The method may include a step of grasping the articles from the robot system when the articles are in a transfer position in the sorting robot pick-and-place machine.

[0191] In the indirect transfer modification, the transfer system may be used as an intermediate conduit between the item selection unit and the item sorting system. In the indirect transfer modification, step S112 of orienting the item into the transfer position using the robotic system includes the step of orienting the item into the transfer position in the transfer system using the robotic system. This functions to move the item to the transfer system. This modification may also include a step of placing the item on the transfer system in the robotic system. In other words, the robotic system may release or free the item so that it is temporarily transferred to the transfer system. As discussed above, this may involve a step of lowering it so that the item is in a predicted orientation that facilitates better placement into the item transport box. The item may be held in the transfer system until it can be handed over to the item sorting unit during block S120.

[0192] Various forms of transfer systems may be used as discussed herein, and may include static transfer trays, slotted transfer trays, conveyor systems, and / or other component variations. In one exemplary implementation, the transfer system may be a slotted transfer tray. Thus, the method may include the step of using a robotic system to orient an article into a transfer position on the slotted transfer tray, and the robotic system to place the article on the slotted transfer tray.

[0193] Block S120, which includes the step of transferring articles from a transfer position to a receiving mechanism of an article sorting unit, functions to transfer articles to an article sorting unit. Preferably, the articles are placed in article trays that are movable by the gantry system of the article sorting unit. The implementation of the article transfer step may depend on the form of transfer. In some modifications, the method can use direct transfer of articles, and in other modifications, the method can use indirect transfer.

[0194] As discussed above, in a direct transfer modification, articles may be transferred directly from an article selection unit (e.g., a robotic system) to the receiving mechanism of an article sorting unit. In one preferred implementation, articles are moved to a specific position, and an actuated article tray of a gantry system is moved below the articles. This step also includes positioning the gantry system in the transfer position and transfer state. The receiving mechanism is set in the receiving position and may facilitate the holding of articles. For example, the actuated article tray may be rotated to act as a container for articles. The robotic system may also dynamically orient articles for a preferred arrangement within the actuated article tray. For example, elongated articles may be oriented in a particular way so that they are best held by the actuated article tray. Once in position, the robotic system can drop the articles, thereby transferring them to the gantry system.

[0195] In indirect transfer, articles may be transferred from a transfer system in which they are held to a receiving mechanism in an article sorting unit. Since the articles are held in the transfer system, the mechanism can be used to transfer the articles.

[0196] With respect to modifications using a slotted transfer tray, the article tray may be a slotted article tray. A modification of the slotted article tray may include the step (120) of moving the slotted article tray through the slotted transfer tray to collect articles into the slotted transfer section in the article sorting unit. The “teeth” (i.e., extended protrusions) of the slotted article tray and the slotted transfer tray can interlock so that the slotted article tray can rise and / or rotate through the slotted transfer tray, thereby collecting articles from the transfer tray. In some modifications, articles will substantially maintain their orientation when such transfer occurs using the slotted article tray.

[0197] Block S130, which includes the step of translating articles (using an article sorting unit) to a designated article container in an array of article containers, functions to move articles to a position for placement in the designated article container. The articles are preferably moved to a fixed position above the designated article container. The position is preferably determined based on a designated grouping of articles. As discussed above, the grouping may be determined in any preferred manner, or detected when processing the articles. The step of translating articles may include the movement of a gantry system to move a receiving mechanism (e.g., an article tray) to the area of ​​the article container array.

[0198] Block S140 functions to place articles into an article transport box, including the step of placing articles into the article transport box. The article holding and placement system used in conjunction with the gantry system may use a variety of different mechanisms. In embodiments of the actuated article tray, the article tray may tilt or otherwise actuate to slide articles into the article transport box. The precise positioning of the gantry system may be adjusted based on a modeled arrangement of articles into the transport box, which is partly based on the shape of the articles. Thus, the method may include the steps of modeling the arrangement of articles from the actuated article tray using the dimensional properties of the articles, and adjusting the positioning of the article tray based on the modeled arrangement.

[0199] An additional block S150, which includes the step of sensing the capacity of the item containers and signaling a change in the item containers when the capacity conditions are met, functions to manage the exchange of item containers. This process enables the step of exchanging item containers. In a preferred implementation, a subset of the item container array is exchanged at once. Selection of items can continue with respect to the item containers that are available.

[0200] The step of sensing the capacity of the item containers can be performed using a container capacity sensing system. In one variation, the step of sensing the capacity of the item containers includes sensing the capacity of at least a subset of item containers while the items are translating to a designated item container. The container capacity sensor can be positioned in or near the item tray (i.e., the receiving mechanism) so that it can pass through the item containers while performing the sensing. The container capacity sensor may be a depth sensor that reads the level of items in the item containers and determines the capacity of each individual container.

[0201] This method may use a fully autonomous or semi-automatic process for removing item transport boxes that have reached their capacity and / or loading item transport boxes with item capacity.

[0202] In a fully autonomous system, the item containers may be mounted on an automated conveyor system or other translational device so that the item containers can be removed. Similarly, empty (or at least not full) item containers may be loaded into the unfilled area of ​​the item container array. In one implementation, an autonomous robot, pallet jack, or tag may engage with the item containers when they reach capacity and remove them from the item container array. Similarly, new item containers may be automatically inserted into the unfilled item container space.

[0203] In a semi-automatic system, the step of signaling changes in item containers may include a step of triggering an alert indicating the item container to be removed. The alert may also indicate the next task relating to the assigned grouping and item containers. This may alert a human worker to remove an item container manually or with the assistance of some mechanism, and / or load an item container.

[0204] In general, when an item container meets a capacity requirement, it is signaled for discharge (using an autonomous or semi-autonomous approach). The capacity requirement may be based on the degree to which the item container is full. However, the method can also model the expected time and availability for replacing item containers. For example, an item container may be removed before reaching its capacity limit, avoiding the need for simultaneous replacement of too many item containers. Alternatively, an item container may be discharged when the method determines that it would benefit from having a different mixture of groupings allocated within the container array. For example, a sparse item container may be discharged when it has few items such that a new item container placed in its place can be reassigned to a different grouping through block S160.

[0205] Block S160, which includes the step of dynamically assigning grouping locations within an array of item containers, functions to determine the mapping of groupings for placement within the array of item containers. The step of assigning grouping locations would involve a step of tracking the assigned item containers until the item containers are discharged from the sorting system. This process can be used to dynamically assign groupings. For example, the method may not need to have all prior knowledge of the groupings to be assigned. Instead, the method may dynamically assign groupings to item container locations based on groupings resulting from the step of processing input items. Historical data, analysis of input items, provided item data, and / or other information may be used to infer grouping locations based on expected item sorting requirements. Various factors may be considered. For example, heavier items that are expected to have corresponding grouping locations assigned closer to the transport locations, minimizing the distance for placement within the item containers. In another embodiment, groupings that are expected to be more common may be assigned closer to the transport locations. In another embodiment, a grouping expected to be more common may be assigned to multiple article carriers in overlapping locations, and then used when one reaches capacity, while the other article carriers are used so that the articles of that grouping can still be processed even while the article carriers are being replaced. In yet another embodiment, a less common grouping may be assigned to a location at the far end of the carrier array.

[0206] 4. System Architecture Other systems and methods of this embodiment may be embodied and / or implemented as machines configured to accept a computer-readable medium storing computer-readable instructions. Instructions may be executed by computer-executable components integrated with applications, applets, hosts, servers, networks, websites, communication services, communication interfaces, hardware / firmware / software elements of user computers or mobile devices, wristbands, smartphones, or any suitable combination thereof. Other systems and methods of this embodiment may be embodied and / or implemented as machines configured to accept a computer-readable medium storing computer-readable instructions. Instructions may be executed by computer-executable components integrated with the types of devices and networks described above. The computer-readable medium may be stored on any suitable computer-readable medium such as RAM, ROM, flash memory, EEPROM, optical devices (CD or DVD), hard drives, floppy disk drives, or any suitable device. The computer-executable component may be a processor, but any suitable dedicated hardware device may also execute instructions (alternatively or in addition).

[0207] In one variation, the system, when executed by one or more computer processors, includes one or more computer-readable media (e.g., non-transient computer-readable media) that store commands causing the system or method described herein to perform actions such as: picking an article from an article input area from a statically positioned robotic system; optionally processing the article while it is being grasped by the robotic system; using the robotic system to orient the article into a transport position above the receiving mechanism of an article sorting unit and transporting the article to the receiving mechanism of the article sorting unit; using the article sorting unit to translate the article above a designated article transport box in an array of article transport boxes; placing the article into an article transport box; optionally sensing the capacity of an article transport box and signaling a change in the article transport box when a capacity condition is met; and optionally dynamically assigning a grouping location within the article transport box array.

[0208] Figure 32 is an exemplary computer architecture diagram of one implementation of the system. In some implementations, the system is implemented within multiple devices that communicate via communication channels and / or networks. In some implementations, the elements of the system are implemented within separate computing devices. In some implementations, two or more of the system elements are implemented within the same device. The system and parts of the system may be integrated into computing devices or systems that perform, or are within the scope of, the role of the system.

[0209] Communication channel 1001 interfaces with processors 1002A-1002N, memory (e.g., random access memory (RAM)) 1003, read-only memory (ROM) 1004, processor-readable storage medium 1005, display device 1006, user input device 1007, and network device 1008. As shown, the computer infrastructure may be used to connect the item selection unit 1101, the item sorting unit 1102, and / or other suitable computing devices.

[0210] Processor 1002A-1002N may take many forms, such as a CPU (Central Processing Unit), GPU (Graphical Processing Unit), microprocessor, ML / DL (Machine Learning / Deep Learning) processing unit such as a tensor processing unit, FPGA (Field Programmable Gate Array), custom processor, and / or any suitable type of processor.

[0211] Processors 1002A-1002N and main memory 1003 (or some secondary combination) can form a processing unit 1010. In some embodiments, the processing unit includes one or more processors communicatively coupled to one or more of RAM, ROM, and machine-readable storage media, one or more processors of the processing unit receiving instructions via a bus stored by one or more of RAM, ROM, and machine-readable storage media, and one or more processors executing the received instructions. In some embodiments, the processing unit is an ASIC (Application-Specific Integrated Circuit). In some embodiments, the processing unit is a SoC (System on a Chip). In some embodiments, the processing unit includes one or more of the elements of the System.

[0212] The network device 1008 may provide one or more wired or wireless interfaces for exchanging data and commands between this system and / or other devices such as devices in external systems. Such wired and wireless interfaces include, for example, a Universal Serial Bus (USB) interface, a Bluetooth® interface, a Wi-Fi interface, an Ethernet® interface, a Near Field Communication (NFC) interface, and equivalents.

[0213] Computer and / or machine-readable executable instructions, comprising a configuration for software programs (such as an operating system, application programs, and device drivers), can be stored in memory 1003 from a processor-readable storage medium 1005, ROM 1004, or any other data storage system.

[0214] When executed by one or more computer processors, individual machine-executable instructions may be accessed via communication channel 1001 by at least one of processors 1002A-1002N (of processing unit 1010) and then executed by at least one of processors 1001A-1001N. Databases, data records, or other stored forms of data generated or used by software programs may also be stored in memory 1003, and such data may be accessed by at least one of processors 1002A-1002N during the execution of machine-executable instructions of the software program.

[0215] The processor-readable storage medium 1005 is one of the following: a hard drive, a flash drive, a DVD, a CD, an optical disc, a floppy disk, a flash memory device, a solid-state drive, a ROM, an EEPROM, an electronic circuit, a semiconductor memory device, and equivalents (or a combination of two or more of these). The processor-readable storage medium 1005 may include an operating system, a software program, a device driver, and / or other suitable subsystem or software.

[0216] As used herein, “first,” “second,” “third,” etc., are used to characterize and distinguish various elements, components, regions, layers, and / or divisions. These elements, components, regions, layers, and / or divisions should not be limited by these terms. The use of numerical terms may be used to distinguish one element, component, region, layer, and / or division from another element, component, region, layer, and / or division. The use of such numerical terms does not imply a sequence or order unless explicitly indicated by the context. Such numerical references may be used synonymously without departing from the teachings of embodiments and modifications herein.

[0217] Those skilled in the art will recognize from the above detailed description, as well as from the figures and claims, that modifications and changes can be made to embodiments of the present invention without departing from the scope of the invention as defined in the following claims.

Claims

[Claim 1] The invention described herein.

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