Material handling method and apparatus

Abstract

A method and apparatus for sorting items into multiple sorting containers are provided. After items have been sorted into sorting containers, the contents of the sorting containers may be automatically discharged into another container. Alternatively, the sorting containers may be discharged from the device and processed at a remote destination. The apparatus may include multiple transport vehicles for transporting items to sorting containers. Furthermore, the apparatus may include multiple acquisition vehicles that acquire sorting containers after all grouped items have been sorted into containers. The acquisition vehicle may be configured to move the acquired containers to one or more discharge points, where the items in the sorting containers may be discharged into other containers, such as item shipping boxes.

Description

Cross - reference to related applications

[0001] This application claims priority based on PCT / US Patent Application No. 24 / 16389, a PCT application filed on February 19, 2024, which claims priority based on U.S. Provisional Patent Application No. 63 / 590,647 filed on October 16, 2023, and which claims priority based on U.S. Provisional Patent Application No. 63 / 446,575 filed on February 17, 2023. The entire disclosure of each of the above applications is incorporated herein by reference.

Technical Field

[0002] The present invention generally relates to a material handling system, and more particularly to a system for storing items in a plurality of containers or other movable containers and sorting them. This material handling system may include an acquisition mechanism that acquires a container after sorting items into the container.

Background Art

[0003] The inventors have observed that stacking inventory items to form respective item groups for fulfilling orders to be shipped to customers or retailers and / or for processing item returns, etc., is laborious, time - consuming, inefficient, and error - prone. These and other disadvantages are most prominent when it is necessary to obtain a large quantity of inventory items from scattered locations within a warehouse or other large facilities and return them to inventory. For example, a single order fulfillment center may receive thousands of orders per day, and for each order, it is necessary to obtain one, multiple, or a large number of different items from inventory, pack them into one or more containers, and ship them to customers. The most inefficient method still in use today is to manually obtain inventory items from the storage area (e.g., by batch picking or wave picking) and directly put them into shipping containers, which requires processing inventory items in a single step. A slightly less efficient method involves first placing items in a temporary item stacking area or cell of a "put wall," and then transferring the stacked item group to a shipping package or carton. Once all items for the order have been stacked in the manner described above, the packing process is complete, and the parcels, cartons, or other containers may be shipped directly to the customer.

[0004] Patent Document 1 discloses a system that is more advanced than the conventional system described above. This patent is jointly owned by OPEX Corporation, the assignee of the present invention, and was granted to McVaugh et al. on March 21, 2023. McVaugh et al. disclose sorting items using vehicles that can move within aisles positioned between multiple rows and / or columns of sorting containers. Items are transported by vehicles in the order they arrive at the input location. In the embodiment disclosed by McVaugh et al., the transport system is implemented as a plurality of independently movable vehicles and is provided with a display device to notify a person in charge of events such as the completion of preparations to transfer sorting containers to a container that can be moved to another destination. While McVaugh et al.'s system represents a significant advancement over conventional technology, the inventors have observed that a considerable amount of manual work is still required even after items have been sorted into the sorting containers, and that the sorted items may be damaged during this process. Since there is a continuing demand for improved processing speed and reduced manual work in the sorting system, it is desirable to reduce the manual work required for order processing after items have been sorted. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] U.S. Patent No. 11,607,713 [Patent Document 2] U.S. Patent No. 7,861,844 [Overview of the project] [Problems that the invention aims to solve]

[0006] This summary provides a simplified introduction to some of the concepts that will be explained in more detail in the detailed description of the invention described below. This summary is not intended to identify the main or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0007] According to embodiments of the present invention, the drawbacks and problems associated with conventional warehouse automation methods, which involve sorting inventory items into multiple groups and performing operations related to the sorted item groups, are significantly mitigated or eliminated by a sorting system that can be configured to perform various tasks related to inventory management, distribution centers, and / or order fulfillment operations. [Means for solving the problem]

[0008] The present invention provides multiple embodiments that can form part of a material handling system. This material handling system may include one or more of the multiple embodiments of the present invention, as will be further described below.

[0009] According to one aspect of the present invention, a device for sorting multiple items is provided. In one embodiment, the apparatus for sorting multiple items includes a plurality of sorting containers, each having a defined internal volume and an inlet opening, and a rack configured to hold each sorting container at a plurality of positions that are spatially separated from other locations. The sorting containers, held by the racks, are arranged in rows and / or columns, and each container is maintained in a configuration and orientation that allows items to be stacked inside. Sorting containers are arranged along one or both sides of a passageway, and movable within the passageway are (1) an item sorting system that receives items arriving at the device's input and transports those items within the passageway to operate a first transport mechanism to transport the items one by one into one or more sorting containers, and (2) a sorting container acquisition mechanism that acquires sorting containers containing stacked groups of items and transports those sorting containers to a transport location located within the passageway and close to the device's discharge point.

[0010] According to one embodiment, the sorting container acquisition mechanism extends a second transfer mechanism at the transfer location to begin discharging the sorting containers of item groups that have been moved from the passageway and stacked in the containers at the discharge point. Furthermore, the sorting container acquisition mechanism extends the second transfer mechanism to move the sorting container out of the passageway along with the stacked item groups contained within it. In this embodiment, the discarded sorting container is replaced with an empty sorting container.

[0011] According to one embodiment of the present invention, a sorting system that can move within a passageway includes a plurality of independently movable vehicles, each capable of moving along a route section of a vertical annular path extending within the passageway. Each vehicle in at least a first group of independently movable vehicles is movable along a corresponding item transport path, which includes an input point on which items are transferred to one of the vehicles, and a transport location adjacent to a sorting container holding position on a rack. Each item transport route may include a series of horizontal and / or vertical sections of a vertical annular path within the passageway.

[0012] Furthermore, each vehicle in at least a second group of independently movable vehicles is capable of moving along a section of a vertical ring path extending within the passageway. Each vehicle of at least a second group of a plurality of independently movable vehicles is movable along a path section of an acquisition path of a corresponding sorting container. This path section includes a location within the passage where the sorting container is removed onto the vehicle and a location within the passage where the sorting container is transferred to a discharge location (which may be an area where the stacked items are discharged into a container that moves the items out of the passage) away from the passage from the vehicle. The acquisition path of the sorting container may include continuous horizontal and / or vertical sections of a vertical circular path within the passage.

[0013] According to another aspect of the present invention, the discharge location defines one or more discharge areas that are dimensioned and arranged to receive one of the plurality of sorting containers after the items have been stacked. Vehicles of at least a second group of the plurality of vehicles are movable along horizontal and / or vertical sections of a sorting container acquisition path that extends from a location adjacent to an acquisition location adjacent to a holding position of a sorting container of a rack structure to a location adjacent to at least one discharge area of the discharge location.

[0014] According to one aspect of the present invention, an apparatus for sorting a plurality of items is provided. This apparatus for sorting a plurality of items includes a plurality of sorting containers and a rack configured to support the plurality of sorting containers at a plurality of positions spaced apart spatially along at least a first side or a second side of the passage defining the passage. This apparatus for sorting a plurality of items further includes a transport mechanism operable within the passage for transporting items to the sorting containers and an acquisition mechanism operable within the passage for acquiring the sorting containers after the items have been sorted into the sorting containers.

[0015] According to one aspect, a first group of sorting containers of a device for sorting a plurality of items is supported by a rack along a first side of a passage, a second group of sorting containers is arranged along a second side of the passage, and an acquisition mechanism is operable to move a plurality of sorting containers from a storage location in the rack into the passage. According to another aspect, the acquisition mechanism is movable in a vertical direction and / or a horizontal direction within the passage.

[0016] The transport mechanism and / or the acquisition mechanism is implemented by a plurality of vehicles operable independently. All or some of the vehicles may perform a transport function, and all or some of the vehicles may perform an acquisition function. The plurality of vehicles (transport vehicles) performing the transport function includes a transfer mechanism, and this transfer mechanism is operable in a first direction to transfer an item from the plurality of transport vehicles to one of the plurality of sorting containers along the first side of the passage, and is operable in a second direction to transfer an item from the transport vehicle to one of the plurality of sorting containers along the second side of the passage. The plurality of transport vehicles may be controlled to move within the passage along a section of a vertical circular path including an input location for receiving an item from outside the passage and one or more sorting containers.

[0017] According to one aspect of an embodiment in which the transport mechanism and / or the acquisition mechanism includes vehicles, each vehicle includes an energy storage device for providing power for the operation of the vehicle, and a charging element is provided within the passage to charge the vehicle when the vehicle moves within the passage.

[0018] In any of the above-described embodiments using vehicles as the transport mechanism and / or the acquisition mechanism, the device may include a track for guiding the plurality of vehicles to the plurality of sorting containers. In such embodiments, both the acquisition mechanism and the transport mechanism are implemented as a plurality of vehicles movable within a passage positioned between first and second groups of sorting containers, each vehicle incorporating either or both a first transport mechanism operable to discharge items into sorting containers outside the passage, and a second transport mechanism extendable in a first direction, thereby holding and retracting the sorting containers into the passage from their support positions along the racks for movement within the passage. In this embodiment, the second transfer mechanism is further configured to extend from the passage to the discharge area.

[0019] According to another aspect of the present invention, a sorting apparatus for multiple items comprises one or more discharge points configured to receive one of a plurality of sorting containers after the items have been sorted into that sorting container. In one embodiment, the sorting containers include movable walls, and the discharge area is configured to facilitate the movement of the movable walls so that items can be discharged from the sorting containers when one of the sorting containers is transported to the discharge area.

[0020] A method for sorting multiple items into multiple groups includes the steps of loading multiple items one by one onto a transport mechanism that is movable within a passageway at a loading area; operating the transport mechanism within the passageway to transport the items to each of several sorting containers arranged along the passageway; transporting each loaded item along a vertical circular path within the passageway, wherein the vertical circular path includes the loading location and each destination adjacent to one of the several sorting containers; and operating the transport mechanism of the transport mechanism to place the items into each of the several sorting containers and stack the item groups within the several sorting containers. The process includes the steps of: operating a transport mechanism in a passage, including a step of; determining that a group of items assigned to a sorting container has been stacked in a first sorting container; acquiring the first sorting container, which includes the steps of: moving the acquisition mechanism in the passage to a position adjacent to the first sorting container; moving the first sorting container and the stacked items in the passage while holding the first sorting container; transporting the first sorting container to a first discharge point in the passage; discharging the stacked items from the first sorting container to a first container located away from the passage at the first discharge point; and moving the first container from the first discharge point. [Brief explanation of the drawing]

[0021] The above summary and the following detailed description of embodiments of the present invention will be best understood in conjunction with the accompanying drawings. In the drawings, the same reference numeral is used throughout the drawing for identical or similar parts.

[0022] [Figure 1] This is a plan view of the material handling apparatus of the present invention.

[0023] [Figure 2] Figure 1 is a partial perspective view of the material handling apparatus shown.

[0024] [Figure 3] Figure 1 is a side view of the material handling apparatus shown.

[0025] [Figure 4] Figure 1 is an end view of the material handling apparatus shown.

[0026] [Figure 5] Figure 1 is a partial side view showing a portion of the track of the material handling device.

[0027] [Figure 6] Figure 1 is a plan view of the transport vehicle for the material handling equipment shown.

[0028] [Figure 7] Figure 6 is an end view of the transport vehicle.

[0029] [Figure 8] Figure 1 is a perspective view of the vehicle acquiring the material handling system shown.

[0030] [Figure 9] Figure 8 is a perspective view of the acquisition vehicle, with the acquisition assembly in the extended position.

[0031] [Figure 10] Figure 9 is a perspective view of the acquisition vehicle, with the acquisition latch in a protruding position.

[0032] [Figure 11A] This is a perspective view of the acquisition vehicle shown in Figure 8, which is located adjacent to the sorting area of ​​the material handling equipment shown in Figure 1.

[0033] [Figure 11B] Figure 11A is a perspective view of the acquisition vehicle, where the sorting container holding mechanism is in the retracted position.

[0034] [Figure 11C] Figure 11A is a perspective view of the vehicle used for acquisition, showing that sorting containers have been partially acquired from the sorting area.

[0035] [Figure 11D] Figure 11A is a perspective view of the acquisition vehicle, with the containers loaded onto the vehicle.

[0036] [Figure 12A] Figure 11A is a perspective view of the discharge site of the acquired vehicle, with the discharge site partially cut out.

[0037] [Figure 12B] Figure 12A is a perspective view of the vehicle being acquired at the discharge point.

[0038] [Figure 12C] Figure 12A is a downward perspective view of the acquisition vehicle, showing the container extending above the discharge station.

[0039] [Figure 13A] This is an enlarged end view of a sorting container located in the sorting area of ​​the material handling device shown in Figure 1.

[0040] [Figure 13B] Figure 13A is an enlarged end view of the container, where the holding mechanism for the sorting container is in the retracted position.

[0041] [Figure 14] Figure 13A is an enlarged perspective view of another embodiment of the sorting container shown.

[0042] [Figure 15] Figure 1 is an enlarged perspective view of the discharge area of ​​the material handling system shown in Figure 1.

[0043] [Figure 16] Figure 15 is an enlarged perspective view of the conveyor belt at the discharge point.

[0044] [Figure 17] Figure 16 is a plan view of the conveyor.

[0045] [Figure 18] Figure 17 is an end view of the conveyor.

[0046] [Figure 19] Figure 15 is a side view of the discharge site.

[0047] [Figure 20] Figure 19 is a side view of the discharge station, with the carton holding mechanism in the operating position.

[0048] [Figure 21] Figure 19 is an end view of the discharge station.

[0049] [Figure 22A] This is a perspective view of alternative emission sites.

[0050] [Figure 22B] Figure 22A is a perspective view of the discharge area, where the sorting containers are placed on top of empty cartons.

[0051] [Figure 22C] Figure 22A is a perspective view of the discharge area, where the sorting container is located after the items have been discharged into empty cartons.

[0052] [Figure 23A] This is a perspective view of the second alternative discharge site.

[0053] [Figure 23B] Figure 23A is a perspective view of the discharge area, where the sorting container is positioned on top of an empty carton.

[0054] [Figure 23C]Figure 23A is a perspective view of the discharge area, where the sorting container is located after the items have been discharged into empty cartons.

[0055] [Figure 24A] This is a block diagram showing a warehouse operation or distribution center configuration that utilizes a warehouse management system and incorporates a material handling device configuration.

[0056] [Figure 24B] This block diagram provides a more detailed view of a warehouse management system utilizing a material handling device configured to incorporate the item sorting function in an embodiment of the present invention into the sorting of sorting containers, as well as the acquisition, discharge, and / or replacement of sorting containers.

[0057] [Figure 25A] This is a block diagram illustrating in more detail the sorting and container acquisition / discharge / exchange (SBRE) system constructed according to the present invention.

[0058] [Figure 25B] This is a block diagram showing the functional components of an item guide station that can form part of the system shown in Figure 25A according to the present invention.

[0059] [Figure 25C] This is a plan view showing the components of the input area for the item in Figure 25B in the present invention.

[0060] [Figure 26] This graph illustrates the exchange of messages and / or commands between multiple logical control elements of a sorting and container acquisition / discharge / exchange (SBRE) system.

[0061] [Figure 27]This flowchart shows an automated process where a stacked group of items is sorted into sorting containers, a vehicle is used to retrieve the sorting containers containing the stacked group of items, the vehicle is used in a passageway to transfer the contents of the sorting containers to another container, and / or the sorting containers containing the stacked group of items are replaced with empty containers, or the containers containing parts of the item group to be combined with other items are replaced with containers containing those parts.

[0062] [Figure 28] This flowchart shows the process of assigning item groups or item subgroups to the locations of sorting containers.

[0063] [Figure 29] This flowchart shows the process of controlling the movement of transport vehicles while items are being sorted.

[0064] [Figure 30] This flowchart shows the sorting and container acquisition vehicle traffic control process, which adjusts the movement of the vehicle acquiring the sorting containers while sorting and container acquisition are being performed simultaneously within the passageway.

[0065] [Figure 31A] This is a flowchart showing a sorting container ordering process according to the present invention, which combines the contents of multiple sorting containers within the same container.

[0066] [Figure 31B] This is a flowchart showing the discharge and / or replacement process of sorting containers according to the present invention.

[0067] [Figure 32] This flowchart shows a modified sorting container sequencing process according to the present invention, which uses determined information regarding the characteristics of one or more items or groups of items to determine the order in which the contents of multiple sorting containers are combined within the same container.

[0068] [Figure 33] This is a detailed block diagram of a computer system that can be used for implementing the computer and / or display device according to the present invention.

[0069] Some of the detailed explanations below are presented in terms of operations on binary digital signals stored in the memory of a specific device, a dedicated computing device, or a platform. In the context of this specification, terms such as “specific device” include general-purpose computers programmed to perform specific functions in accordance with instructions from program software. In this context, the operation or processing involves the physical manipulation of a physical quantity. Typically, such physical quantities may take the form of electrical or magnetic signals that can be stored, transferred, combined, compared, or otherwise manipulated. For reasons of general use, it has proven convenient to refer to such signals as bits, data, values, elements, symbols, characters, terms, numbers, and numerical values. However, it should be understood that these terms, or similar terms, should all be associated with appropriate physical quantities and are merely labels for convenience. As will be evident from the following explanation, unless otherwise specified, any use of terms such as “processing,” “calculation,” “calculation,” and “decision” throughout this specification shall be understood to refer to the operation or processing of a specific device, such as a dedicated computer or similar dedicated electronic computing device. Therefore, in the context of this specification, a dedicated computer or similar dedicated electronic computing device is capable of manipulating or converting signals that are typically represented as physical electronic or magnetic quantities within the memory, registers, or other information storage devices, transmission devices, or display devices of the dedicated computer or similar dedicated electronic computing device. [Modes for carrying out the invention]

[0070] This document describes systems and technologies that automatically stack one or more items at their respective sorting locations to form corresponding item groups (for example, for shipping to customers or stores to fulfill orders at a distribution center, or conversely, for replenishing returned items in inventory). The items are then automatically identified at the scanning station as they are transported along or between multiple conveyor stages of the guidance module. In other embodiments, items are scanned individually and transported to a transport mechanism. Optionally, one or more characteristics (e.g., weight, length, height, or width) are determined by referencing the data associated with the identification. Furthermore, or alternatively, one or more sensors in the induction module may be activated to determine one or more characteristics. Each item thus identified and / or characterized is transferred from the transport conveyor of the guidance module to an item transport system, such as an item transport vehicle that is movable along the horizontal and / or vertical sections of the item transport path and is individually movable.

[0071] The components of the transport system are movable within passages that extend parallel to the horizontal or vertical arrangement of the storage area. Each transport vehicle is self-propelled and includes a discharge mechanism that receives items from the guidance module, transports them to the sorting destination, and then transfers them to the sorting area positioned on each transport vehicle. The discharge mechanism is a conveyor configured to move items along a discharge path perpendicular to the direction of the vehicle's movement.

[0072] According to one embodiment, a device is provided for sorting multiple items into individually movable locations such as sorting containers. The apparatus comprises a plurality of sorting containers, each having a defined internal volume and an inlet opening; a rack structure, the rack structure including a support frame configured to hold each sorting container at a position spatially separated from other positions, thereby organizing the sorting containers into a plurality of rows and / or columns and maintaining them in a stackable configuration; and a plurality of independently movable vehicles, the plurality of vehicles being movable along horizontal and / or vertical sections of an item transport path extending from an input point where items are transferred onto one of the plurality of vehicles to an end position adjacent to the holding position of the sorting containers of the rack structure, with a minimum number of vehicles being movable. The apparatus comprises a plurality of independently movable vehicles, at least one of which is configured to transport items received at an input station to sorting containers temporarily associated with a group of items to be sorted, and a discharge station, the discharge station defining at least one discharge area having dimensions and arrangements to receive one of the plurality of sorting containers after items have been stacked, wherein vehicles of at least a second group of vehicles are movable along horizontal and / or vertical sections of a sorting container acquisition path that extends from an acquisition position adjacent to a holding position of a rack-structured sorting container to a terminal position adjacent to at least one discharge area of ​​the discharge station.

[0073] The vehicles of the second vehicle group are components of the acquisition system, and each vehicle of the second vehicle group includes a first transfer mechanism, which is configured to take a sorting container containing an item group from a sorting container holding position in a rack structure, and to reinsert the sorting container from which the item group has been discharged into the sorting container holding position in the rack structure, so that the reinserted sorting container may be temporarily associated with another item group to be sorted.

[0074] The first vehicle group is a component of the sorting system, and each vehicle in the first vehicle group includes a second transfer mechanism, which is configured to transfer items received at the input point to one of several sorting containers.

[0075] The support frame of the rack structure includes two compartments separated by a passage, and the first and second vehicle groups are free to move vertically and / or horizontally through this passage. In one embodiment, sorting containers are arranged in first and second groups, each group arranged in rows and columns, and each vehicle in the first and second vehicle groups is movable within a passage along horizontal and vertical path sections.

[0076] In one embodiment, the sorting container includes a gravity-operated trapdoor mechanism, the opening of which is initiated by extending the acquired sorting container containing the sorted items in a first direction. This first direction is the direction from the terminal position toward a first position on the discharge area of ​​the discharge site. The closing operation of the trapdoor mechanism is initiated by retracting the sorting container from its position on the discharge area of ​​the discharge station onto the vehicles of the second group of vehicles.

[0077] The discharge area further includes a slope that defines an item receiving surface located directly below the first discharge area of ​​the discharge area, so that items discharged from the sorting container and falling onto the slope slide down toward a movable container located in the second discharge area of ​​the discharge area. Furthermore, the discharge station may further include a discharge auxiliary conveyor system having a first conveyor. The item receiving surface of the first conveyor is positioned directly below the first (or possibly third) discharge area, thereby configuring the first conveyor to transport items discharged from the sorting container toward and / or toward a movable container located in the second (or possibly fourth) discharge area of ​​the discharge station.

[0078] The discharge assist conveyor system further includes a second conveyor defining an item engagement surface which is dimensionally configured and positioned to impart frictional force to discharged items moving in the transport direction on a first conveyor, the second conveyor being dimensionally configured and positioned along a first side surface of the transport receiving surface of the first conveyor, and a third conveyor defining an item engagement surface which is dimensionally configured and positioned to impart frictional force to discharged items moving in the transport direction on the first conveyor, the third conveyor being dimensionally configured and positioned along a second side surface of the transport receiving surface of the first conveyor. The item engagement surfaces of the second and third conveyors flank each other upward, and each item engagement surface of the second and third conveyors forms an obtuse angle with respect to the transfer receiving surface of the first conveyor.

[0079] The discharge assist conveyor system further includes one or more sensors dimensionally configured and positioned to determine that the discharge assist conveyor system cannot move an item toward the container of interest, and a control device operationally associated with second and third conveyors, which, in response to one or more of the sensors, facilitates clearing the blockage by applying opposite frictional forces to the second and third conveyors toward the jammed item that cannot move toward the container of interest.

[0080] Furthermore, the control device, in response to one or more of its sensors, causes the first, second, and third conveyors to apply a common directional frictional force to the items when the items are able to move toward the target container (i.e., when the container is not loaded with items).

[0081] In addition to the incorporation of the slope and / or discharge transport system according to the embodiments described above, or instead, the apparatus of the present invention may further include a delivery conveyor configured to move a movable container received from the discharge area of ​​a discharge site toward another destination.

[0082] In addition to incorporating the inclined section and / or discharge mechanism according to the embodiments described above, or alternatively, the discharge station of the apparatus of the present invention defines an input / output (I / O) passage area which is dimensionally configured and positioned to receive one sorting container from a plurality of sorting containers on which items are stacked, and at least vehicles of a second group of vehicles are movable along horizontal and / or vertical sections of the sorting container acquisition path which extends from an acquisition position adjacent to the holding position of the sorting container in a rack structure to an end position adjacent to the I / O passage area, and the discharge station further includes an I / O conveyor system. This I / O conveyor system is configured to receive acquired sorting containers transported to the I / O passage area by vehicles of a second vehicle group, transport the received acquired sorting containers to a distant destination, receive sorting containers arriving from the distant destination, and transfer the sorting containers arriving from the distant destination to the I / O passage area. As a result, sorting containers containing items retrieved from sorting container locations in a rack structure may exit the I / O passage area via the I / O conveyor system, and empty sorting containers and / or sorting containers containing fewer items than all the items required for an order group may be returned to sorting container locations in a rack structure via the I / O passage area.

[0083] Furthermore, the sections of the item transport route, where multiple vehicles move, form a vertical circular path within passages defined by a rack structure. Each transport vehicle may include an energy storage device that provides power for the operation of the transport vehicle. The system may also include charging elements within the passageway to charge the transport vehicles as they move along it. In one embodiment, a track for guiding a first group of vehicles to a sorting container is arranged within the passageway. Furthermore, this track may be configured to guide the acquired vehicles to sorting containers.

[0084] Embodiments of the present invention will be described in detail below. These embodiments are shown in the attached drawings. Wherever possible, identical or similar parts are referred to by the same reference numeral throughout the drawings.

[0085] Referring to Figures 1 to 4, the material handling system is generally indicated by reference numeral 10. This material handling system 10 includes a sorting system 15 that sorts items into multiple sorting locations, such as sorting containers 20. Once an item is sorted into sorting container 20, sorting container 20 is acquired and transported to discharge location 400. At the discharge point 400, items are either discharged from the sorting container 20 into a container, or the entire sorting container 20 is discharged from the sorting system 15 onto the output conveyor 700 so that the sorting container 20 can be transported to another area.

[0086] The sorting system 15 may include a plurality of sorting containers 20 arranged in a series of columns or rows, forming a first container group 30. The second container group 35 may be positioned spaced apart from the first container group 30 so that a passage 100 is formed between the first container group 30 and the second container group 35. Multiple transport vehicles 200 may travel within the passage 100 and transport items to different sorting containers 20.

[0087] The item group may be transported to one of the multiple sorting containers 20. When the last item in the item group is transported to sorting container 20, the item is acquired and sent out for transport. For example, the acquiring vehicle may acquire the sorting container 20 after the item group has been transported to the sorting container 20. The vehicle may be configured to transport items to the sorting container 20, and to be able to acquire the sorting container 20 once the item group has been transported to the sorting container 20. Furthermore, as will be described later, the sorting system 15 may include a first type of vehicle called a transport vehicle 200 that transports items to a sorting container 20, and a second type of vehicle called an acquisition vehicle 300 that acquires items after the item group has been transported to the sorting container 20.

[0088] The transport vehicles 200 may be configured such that multiple transport vehicles 200 operate independently and simultaneously to transport multiple items. Furthermore, the transport vehicle 200 may travel within the passage 100 to transport items to the sorting containers 30 and 35. Optionally, transport vehicle 200 may move from loading area 145 to one of the sorting containers, and then return to loading area 145 to transport another item to one of the sorting containers.

[0089] As described above, multiple transport vehicles 200 may transport multiple item groups into one of multiple sorting containers 20. The sorting container 20 may be considered full when it has received a certain amount of items, or when all items in a group (such as an order) have been sorted into the sorting container 20. When the sorting container 20 becomes full, the sorting system 15 may automatically retrieve the sorting container 20 in order to empty the items inside it. In one embodiment, the sorting system 15 automatically acquires the sorting containers 20 using an acquisition vehicle 300 that operates within the passage 100.

[0090] The acquisition vehicle 300 may move within the passage 100 to a position adjacent to the full sorting container 20. Subsequently, the acquisition vehicle 300 may transfer the full sorting container 20 to the acquisition vehicle 300. The acquired vehicle 300 moves through the passage 100 carrying the full sorting container 20, and moves to a location where the item groups inside the sorting container 20 can be transferred outside the passage 100.

[0091] For example, a group of items in a full sorting container 20 may be discharged at the discharge point 400. Specifically, items are discharged from the full sorting container 20 onto a conveyor belt operating outside the passage 100. Alternatively, the item group may be discharged into a box or other container located outside the aisle 100, away from the front rack 30 and rear rack 35 of the sorting container 20.

[0092] Furthermore, instead of emptying the full sorting container 20 at the discharge point 400, the full sorting container 20 may be transferred to a device such as a conveyor that can move outside the passage 100. For example, the acquisition vehicle 300 may move the full sorting container 20 to the output location. At the output location, the acquisition vehicle 300 may transfer the full sorting container 20 outside the passage 100 to a device such as a conveyor operating outside the passage 100. For example, as shown in Figure 22A, the acquisition vehicle 300 may transfer the full sorting containers 20 onto the output conveyor 700 that transfers the full sorting containers 20 from the sorting system 15.

[0093] The material handling system 10 may also incorporate a device for supplying empty sorting containers 20 that receive contents from full sorting containers 20. For example, the material handling system 10 may include equipment for manufacturing containers such as cardboard boxes, as shown in Figure 1, numbers 600-1 to 600-4. The box assembly devices 600-1, 2, 3, and 4 are configured to produce multiple boxes. Each box assembly device 600-1, 2, 3, and 4 may be configured to assemble containers or boxes of different sizes. The empty containers are automatically transported to the discharge point 400 to receive the contents of the full sorting containers 20. The boxes may then be optionally transported from the discharge point 400 by a conveyor 660 or the like.

[0094] The box assembly devices 600-1, 2, 3, and 4 shown in Figure 1 manufacture boxes of different sizes and supply the boxes to different discharge points 400 of the sorting system 15. In this way, the material handling system 10 can determine the appropriate discharge station 400 based on the volume of items sorted into the sorting container 20 and the volume of empty boxes in each discharge station 400. Once a suitable disposal site 400 is identified, the acquisition vehicle 300 transports the full sorting container 20 to the appropriate disposal site 400, and at the disposal site 400, it discharges the items from the full sorting container 20 into boxes.

[0095] As will be further explained below, instead of a series of box assembly devices 600-1, 2, 3, and 4 supplying empty containers to a single sorting system 15, the material handling system 10 may include a series of sorting systems similar to the sorting system 15, and the box assembly devices 600-1, 2, 3, and 4 may send a series of empty containers from the box assembly devices 600-1, 2, 3, and 4 to each sorting system 15.

[0096] The material handling system 10 may include a central control unit 800 that controls various operations of the material handling system 10 and provides control signals to various components of the material handling system 10. The central control unit 800 may include one or more microprocessors. Furthermore, the central control unit 800 may be connected to a warehouse management system (WMS) that provides signals to the material handling system 10 regarding the grouping of items for sorting. For example, the WMS may form an order by specifying which items to group together. Thus, the WMS may provide the central control unit 800 with information regarding the grouping of items, and the central control unit 800 sorts the items by controlling the operation of various components such as transport vehicles 200, gates, and scanners according to the information received from the WMS. <About the sorting system>

[0097] The sorting system 15 of the material handling device 10 will be described in detail with reference to Figures 1 to 5. The material handling system 10 may incorporate any of the various systems for sorting items into a series of sorting containers 20. In the embodiments shown in Figures 1 to 5, the sorting system 15 employs a passage-based system in which the sorting device operates within a passage 100 located between the front rack 30 and rear rack 35 of opposing sorting containers 20. Various aisle-based sorting systems can be used. In this embodiment, the sorting system 15 incorporates multiple transport vehicles 200 that operate independently within the passage 100.

[0098] The sorting system 15 shown in Figure 1 includes a front rack 30 of a sorting area on one side of the aisle 100 and a rear rack 35 of a sorting area on a second side of the aisle 100. The sorting containers 20 in the front rack 30 and rear rack 35 may be arranged in a series of columns or a series of rows. Please note that the term "rack" refers to any structure that supports multiple sorting containers 20.

[0099] As described above, the sorting system 15 may include a plurality of transport vehicles 200 that operate within the passage 100 and sort items into sorting containers 20. The transport vehicle 200 may be configured to move horizontally and / or vertically within the passage 100 to transport items to a sorting location. For example, the sorting system 15 may include multiple rows spaced apart from each other in a vertical direction, and the transport vehicles 200 may move independently along horizontal guide devices or tracks provided in each row within the passage 100. Furthermore, the sorting system 15 may include a mechanism for moving the transport vehicle 200 vertically within the passage 100. For example, an elevator or lifting mechanism can be used to move the transport vehicles 200 up and down between multiple rows. The elevator / lifting mechanism can be placed at various points within the passageway 100. For example, one embodiment may involve a first elevator or lifting mechanism located at one end of the passageway 100, which lifts the transport vehicle 200 from the lower row to the upper row, and a second elevator or lifting mechanism located at the second end of the passageway 100, which lowers the transport vehicle 200 from the upper row to the lower row.

[0100] In the sorting system 15 shown in Figures 1 to 5, multiple independently operating vehicles are used that can climb vertically within the front rack 30 and rear rack 35 without using elevators or lifting mechanisms.

[0101] The sorting system 15 may also use a guidance system 105, such as a track, to guide the transport vehicle 200 as it moves within the passage 100. The term "track" refers to any structure configured to support or guide a transport vehicle 200 as it moves. For example, the guidance system 105 may include a forward track 110 extending along a passage 100 adjacent to the forward rack 30, and a rear track 120 extending along a passage 100 adjacent to the rear rack 35. In this manner, the forward track 110 supports and / or guides the first side of the transport vehicle 200, and the rear track 120 supports and / or guides the second side of the transport vehicle 200. For example, as shown in Figures 6 to 7, the transport vehicle 200 may include a drive system that includes two pairs of wheels, namely a pair of front wheels generally indicated as 220a and 220c and a pair of rear wheels generally indicated as 220b and 220d. Wheels 220a and 220b are connected to axle 215 and rotate together, while wheels 220c and 220d are connected to axle 216 and rotate together. The front wheels 220a and 220c are on the forward track 110, while the rear wheels 220b and 220d are on the rear track 120.

[0102] At loading dock 145, the items are loaded onto transport vehicle 200. Each transport vehicle (200 units) may carry multiple items. Alternatively, as will be described later, each transport vehicle 200 may carry a single item. After the items are loaded into one of the transport vehicles 200, the transport vehicle 200 moves along the route to one of the sorting containers 20. The transport vehicle 200 transfers the items to the sorting container 20, and returns to the loading area 145 along the route to receive other items.

[0103] Each transport vehicle 200 may take a different route from the loading area 145 to one of the sorting locations. The track 105 may include multiple vertical and horizontal track sections that guide the transport vehicle 200 as it moves from the loading area 145 to the sorting container 20 and back to the loading area 145.

[0104] The vertical and horizontal track sections may form a path in the form of a vertical annular path in the passage 100. For example, referring to Figures 1 and 5, the track 105 may include a forward track 110 and a backward track 120. Figure 5 shows the forward orbit 110, but please understand that the backward orbit 120 is substantially the same as the forward orbit 110, and that the backward orbit 120 is a mirror image of the forward orbit 110.

[0105] The forward track 110 may have an upper track section 125 and a lower track section 130 parallel to the upper track section 125. Multiple vertical tracks 132 may connect the upper track section 125 and the lower track section 130. As shown in Figure 5, the vertical track 132 may divide the track 105 into a series of columns, and the transport vehicle 200 may move up and down along these columns toward one of the sorting containers 20. Alternatively, as described above, the track 105 may include a number of horizontal tracks that divide the track 105 into a series of rows, and the transport vehicle 200 can move along these rows to one of the sorting containers 20.

[0106] In the track 105 shown in Figure 5, the track 105 includes multiple vertical columns. Each row is defined by a pair of vertical tracks. The transport vehicle 200 may move vertically up and down within the row. For example, vertical tracks 132a and 132b define a first lane for guiding transport vehicles 200. This first row may be a loading row 140 having a loading area 145 that receives the items that each transport vehicle 200 will transport to one of the sorting containers 20.

[0107] The track 105 may include rows that share a vertical track 132 and rows that have independent vertical tracks 132. For example, as shown in Figure 5, the second row is defined by vertical tracks 132c and 132d, and the transport vehicle 200 is able to move vertically up and down within this second row. The second column does not share vertical orbit 132 with the first column. In contrast, the third row is formed by vertical orbits 132e and 132f, and the fourth row is formed by vertical orbits 132f and 132g. In this way, the third and fourth columns share vertical track 132f.

[0108] Multiple gates 135 may be arranged along the track 105 to guide the transport vehicle 200 along the track 105. For example, the transport vehicle 200 may move horizontally along the upper track section 125 until it arrives at a row having a sorting container 20 to which the items are to be transported. When a transport vehicle 200 arrives in the appropriate lane, the gate 135 operates, instructing the transport vehicle 200 to descend its lane from the upper rail. The transport vehicle 200 may have an actuator that selectively operates the gate 135. Alternatively, each gate 135 may have an actuator that automatically moves the gate 135 from a first position in which the transport vehicle 200 is facing horizontally to a second position in which the transport vehicle 200 is facing vertically. For example, each gate 135 may be controlled by a solenoid or other element configured to move the gate 135 in response to a signal from a control device.

[0109] The flow of transport vehicles 200 along track 105 may move along any of the various routes. In one embodiment, the transport vehicle 200 moves along a path that forms a vertical annular path, and generally moves forward along the vertical annular path.

[0110] For example, from the viewpoint shown in Figure 5, the transport vehicle 200 may move clockwise along a vertical annular path as indicated by arrow T1. Specifically, from loading area 145, transport vehicle 200 moves upward along the first row until it arrives at upper track section 125. In the upper track section 125, the transport vehicle 200 transitions from vertical to horizontal movement. The transport vehicle 200 moves along the upper track section 125 in the direction of T1 until it reaches the row where the sorting container 20 that the transport vehicle 200 will transport items is located. For example, if the target sorting container 20 is in the fourth column, the transport vehicle 200 moves along the upper rail until it reaches the vertical tracks 132f and 132g. Gate 135 operates so that the transport vehicles 200 face downwards in the fourth row. The transport vehicle 200 continues to move downwards until it reaches the target sorting container 20.

[0111] At the target sorting container 20, the transport vehicle 200 discharges the items into the target sorting container 20. Subsequently, the transport vehicle 200 continues to descend the line until it reaches the lower track section 130. Upon arriving at the lower track section 130, the transport vehicle 200 switches from vertical to horizontal movement. Subsequently, the transport vehicle 200 moves to the left (from the perspective of Figure 5) and returns to the loading line 140.

[0112] As described above, the transport vehicle 200 moves along a path that forms a vertical annular route within the passage 100. Specifically, the transport vehicle 200 moves clockwise from the loading area along the upper rail, one of the rows, and then the lower rail, returning to the loading row 140. Each transport vehicle 200 moves along a path that forms a vertical ring path, but the path of each transport vehicle 200 may differ depending on which sorting container 20 the transport vehicle 200 is heading towards.

[0113] The transport vehicles 200 may be controlled to continue moving in a common direction, such as clockwise as described above. However, while the transport vehicles 200 generally move in a common direction (such as clockwise), please understand that when multiple transport vehicles 200 are circling a vertical ring path, one transport vehicle 200 may move in the opposite direction. For example, after moving downward along the fourth column, it may be desirable to move the transport vehicle 200 upward within the fourth column before driving it downward to the lower track section 130. In this case, the general flow of the transport vehicle 200 is the same, proceeding from the loading area 145 to one of the sorting containers 20 in a clockwise direction along a vertical ring path, and then returning to the loading area 145 along a different return path.

[0114] Track 105 is generally configured to work in conjunction with transport vehicle 200. Specifically, the transport vehicle 200 may include a drive element having teeth. Such a track 105 may include teeth that mesh with the teeth of the drive element of the transport vehicle 200. Similarly, the transport vehicle 200 may include drive elements, such as drive wheels, that frictionally engage with the track 105. In this embodiment, the raceway 105 does not need to have teeth. Therefore, the transport vehicle 200 may be equipped with various known drive mechanisms. The track 105 is configured to work in cooperation with the drive mechanism of the transport vehicle 200 to guide the transport vehicle 200 within the passage 100.

[0115] As described above, the configuration of the track 105 may vary depending on the configuration of the transport vehicle 200. For example, it may be similar to the trajectory described in Patent Document 2. The entire disclosure of Patent Document 2 is incorporated herein by reference. <About the input field>

[0116] The material handling system 10 may be configured such that items are loaded directly onto the transport vehicle 200 at the loading area 145. For example, the operator may load the items directly onto the transport vehicle 200 at the loading area 145. Furthermore, a scanner may be provided to scan the items before they are loaded onto the transport vehicle 200. It should be understood that the term "operator" may include human operators or mechanical operators such as robotic arms.

[0117] Alternatively, the material handling system 10 may include an input area for loading items onto the transport vehicle 200. The input area may include an input conveyor 55 that transports items toward the loading area 145. The input conveyor 55 may include a first end that forms a drop area on which items can be dropped or placed. The second end of the conveyor 55 may be adjacent to the loading area 145, thereby allowing the input conveyor 55 to transport items from the drop area to the loading area 145. At loading dock 145, the items are loaded onto transport vehicle 200.

[0118] Various elements may be detected, and a method for processing the items may be determined. For example, items typically need to be identified so that the material handling system 10 can determine the location or sorting container 20 where the items will be transported. This is usually done by determining a unique product code for each item. The material handling system 10 may include a scanning element that scans product identification marks on the product. For example, an item may have one or more marks, including but not limited to barcodes (such as QR codes or UPC codes), printed alphanumeric characters, or machine-readable optical labels such as unique graphic identifiers. Scanning station 60 may include a scanner or reader that reads such marks. For example, a barcode reader, optical reader, or RFID reader may be provided to scan items and read identification marks.

[0119] Therefore, the input area 50 may include a scanner 60 that scans the items before they are placed on the input conveyor 55. Alternatively, the input area 50 may include a scanner 60 that scans items as they move along the input conveyor 55.

[0120] Once a product identification mark is determined (manually or automatically), the material handling system 10 retrieves information about the product and controls further processing of the item based on the information stored in the central database.

[0121] At input station 50, items are sequentially loaded onto transport vehicles 200, which then guide the items to material handling system 10. In one embodiment, each item is manually scanned at the entry point, and one or more features of the item are detected. These features are used to verify the identification of the item. Once an item is identified, various characteristics of the item may be retrieved from a central database, and the item may then be processed based on these known characteristics. For example, the input station 50 may include a scanning station 60 for scanning product codes such as barcodes. Once the product code is determined, the material handling system 10 retrieves information about the product from the central database. This information is used to control further processing of the item.

[0122] The input conveyor 55 may be configured so that an operator can select items from an item supply source located adjacent to the input conveyor 55. For example, another supply conveyor may transport items to the guidance station 50 in a constant flow. The operator may continuously select items from the supply conveyor and drop the items onto the input conveyor 55. Alternatively, a large container for items, such as a container or other type of container, may be placed adjacent to the input conveyor 55. The operator may select items one by one from the supply container and place each item on the input conveyor 55. Furthermore, the input conveyor 55 may cooperate with a supply assembly that continuously supplies items to the input conveyor 55. For example, the supply conveyor may transport a continuous flow of items toward the input conveyor 55. The input conveyor 55 may include a sensor that detects when an item is being transported from the input conveyor 55. Accordingly, the material handling system 10 may control the operation of both the supply conveyor and the input conveyor 55, driving items forward from the supply conveyor to the input conveyor 55. In this way, the items may be sent to the input conveyor 55 manually by an operator or automatically by another feeding mechanism that is capable of sending the items to the input conveyor 55.

[0123] Furthermore, in the above description, the material handling system 10 is described as having a single input port 50. However, it may be desirable to incorporate multiple guide stations 50 arranged along the material handling system 10. By using multiple guide stations 50, the item delivery speed can be improved. Furthermore, the guidance station 50 may be configured to process different types of items.

[0124] Referring to Figures 1 and 5, the input area 50 includes an input conveyor 55 that continuously transports items to the loading area 145. Loading point 145 is located along track 105 and provides an entry point for loading items onto transport vehicles 200. At the loading area 145, the transport vehicles 200 are positioned along the input conveyor 55, and items discharged from this input conveyor 55 are received by the transport vehicles 200 located at the loading area 145. Once the items are loaded onto transport vehicle 200, transport vehicle 200 moves away from loading area 145. Next, another transport vehicle 200 moves into loading area 145 and receives the following item.

[0125] The material handling system 10 may include an optional return conveyor 70 for returning items to the input conveyor 55. The return conveyor 70 may facilitate the rescanning of items that cannot be transported for any reason. For example, if the material handling system 10 cannot identify the product code scanned for each item, it cannot identify the sorting container 20 to which that item should be transported.

[0126] The return conveyor 70 extends from the track 105 toward the drop area of ​​the input conveyor 55. If the transport vehicle 200 is unable to transport the items, it may drive along the track 105 to the return conveyor 70 and deposit the items on the return conveyor 70 instead of transporting them to one of the sorting containers 20. The return conveyor 70 then returns the items to the input conveyor 55 so that they can be rescanned and loaded again into one of the transport vehicles 200. <Regarding transport vehicles>

[0127] As described above, the sorting system 15 may include a plurality of transport vehicles 200 that can operate independently. Each transport vehicle 200 is configured to transport one or more items into one of the sorting containers 20. The details of the transport vehicle 200 are described below. However, it should be understood that the sorting system 15 is not limited to one that uses multiple transport vehicles 200. Furthermore, the configuration of the transport vehicle 200 may vary depending on various factors. Therefore, please understand that the following description provides details of the transport vehicle 200, and the sorting system 15 is not limited to the use of the transport vehicle 200 having the detailed configuration described below.

[0128] Referring to Figures 6 and 7, a semi-autonomous transport vehicle 200 is shown. This transport vehicle 200 has an on-board drive system that includes an on-board power supply. The transport vehicle 200 includes a mechanism for loading and unloading items to be transported. One embodiment of a transport vehicle 200 that can operate in conjunction with a sorting system 15 is illustrated and described in Patent Document 2.

[0129] Furthermore, the transport vehicle 200 may incorporate any of the various mechanisms for loading items onto the transport vehicle 200 and discharging items from the transport vehicle 200 into one of the sorting containers 20. Furthermore, the loading / unloading (or transport) mechanism 210 may be specially tailored to a particular application. However, in this embodiment, the loading / unloading mechanism 210 is one or more conveyor belts extending along the top surface of the transport vehicle 200. This conveyor belt can rotate in reverse. By driving the conveyor belt in a first direction, the items are moved toward the rear end of the transport vehicle 200, and by driving the conveyor belt in a second direction, the items are moved toward the front end of the transport vehicle 200.

[0130] One or more conveyor motors, such as motors 240a and 240b (Figure 6), mounted on the underside of the transport vehicle 200, drive the conveyor belt. Specifically, the conveyor belt is placed over the front roller at the front end of the transport vehicle 200 and the rear roller at the rear end of the transport vehicle 200. One or more conveyor motors 240a and / or 240b are connected to the front rollers, which drive the front rollers to operate the conveyor belt.

[0131] The transport vehicle 200 includes four wheels, which are used to transport the transport vehicle 200 along the track 105. These wheels are mounted on two parallel, spaced-apart axles 215 and 216, with two of the wheels positioned along the front end of the transport vehicle 200 and the other two wheels positioned along the rear end of the transport vehicle 200.

[0132] Each wheel, designated as wheel 220a, 220b, 220c, and 220d, includes a corresponding external gear, indicated by 222a, 222b, 222c, and 222d, respectively, which cooperate with the drive surface of the track 105. The external gear 222 is fixed to the axles 215 and 216 to which the external gear 222 is attached. In this way, when axle 215 or 216 is rotated, the corresponding external gear 222 rotates. Therefore, when the transport vehicle 200 is moving vertically, these external gears 222 cooperate with the drive surface of the track 105 to drive the transport vehicle 200 along the track 105.

[0133] The transport vehicle 200 includes an on-board drive motor 250 that drives the wheels. More specifically, the on-board drive motor 250 is operably connected to the axles 215 and 216, thereby rotating the axles 215 and 216, and the external gears 222a to 222d of the wheels.

[0134] The transport vehicle 200 may be powered by an external power source, such as a contact along a rail, which supplies the power necessary to drive the transport vehicle 200. However, in this embodiment, the transport vehicle 200 includes an onboard power supply that provides the necessary power for both the onboard drive motor 250 and the conveyor motors 240a and 240b. Furthermore, in this embodiment, the power supply is rechargeable. The power supply may include a rechargeable battery or the like, but in this embodiment, the power supply consists of one or more ultracapacitors.

[0135] As will be further explained below, the transport vehicle 200 further includes a processor that controls the operation of the transport vehicle 200 in response to signals received from the central processor 800. Furthermore, the transport vehicle 200 also includes a wireless transceiver, enabling continuous communication with the central processor 800 while the transport vehicle 200 is moving along the track 105. Alternatively, for some applications, it may be desirable to incorporate multiple sensors or indicators positioned along the track 105. In addition to providing a central processor 800 that controls the operation of the transport vehicle 200 in response to sensors or indicators, the transport vehicle 200 may also include a reader that senses sensor signals and / or indicators.

[0136] If the material handling system 10 includes a large number of transport vehicles 200, the positions of the transport vehicles 200 are controlled to prevent collisions between different transport vehicles 200. In one embodiment, the central control unit 800 tracks the position of each transport vehicle 200 and provides control signals to each transport vehicle 200 to control the movement of the transport vehicles 200 along the route. Furthermore, this central control device 800 may also control the operation of various elements along the track 105, such as the gate 135. Gate 135 changes the direction of travel of the transport vehicle 200 from horizontal to vertical, or vice versa. <Regarding acquired vehicles>

[0137] The material handling system 10 may include one or more acquisition vehicles 300 for acquiring sorting containers 20. A transport vehicle 200 used to transport items to the sorting container 20 may be configured to acquire the sorting container 20. Alternatively, as will be described later, the material handling system 10 may include one or more acquisition vehicles 300 having a different configuration from the transport vehicle 200.

[0138] The acquisition vehicle 300 is configured to be movable in both the vertical and horizontal directions. For example, the acquisition vehicle 300 may be configured to be movable so as to align with the sorting container 20.

[0139] In the embodiments shown in Figures 8 to 10, the acquisition vehicle 300 is configured to travel within the passage 100. Furthermore, the acquisition vehicle 300 may move along a separate track 105 or a guide mechanism 430, but in this embodiment, the acquisition vehicle 300 is operable within the track 105. In particular, the acquisition vehicle 300 may have a drive system 310 that is substantially the same as the drive system 220 of the transport vehicle 200.

[0140] Referring to Figures 8 to 10, the acquisition vehicle 300 may include a plurality of drive wheels 310 that drive the acquisition vehicle 300 within the passage 100. The drive wheel 310 may include teeth that mesh with the track 105. Similarly, if the track 105 is configured to cooperate with the friction wheel, the drive wheel 310 may include the friction wheel.

[0141] The acquired vehicle 300 may include two pairs of synchronously driven drive wheels 310. For example, the first pair of drive wheels 310 may be mounted on the first axle, and the second pair of drive wheels 310 may be mounted on the second axle. Furthermore, the axles may be driven independently. However, in this embodiment, the axles are interconnected so that the two axles are driven synchronously.

[0142] The acquired vehicle 300 includes a support surface 320 that supports one or more items. For example, the support surface 320 may include a substantially horizontal surface that supports the thort 20.

[0143] Acquired vehicle 300 may include one or more walls for holding items on acquired vehicle 300. For example, as shown in Figure 8, the acquisition vehicle 300 may include a pair of side walls 330 that are spaced apart from each other. As shown in Figure 8, the side wall 330 may be positioned to sandwich the support surface 320, thereby preventing the item from being ejected from the front or rear edge of the acquisition vehicle 300.

[0144] The acquisition vehicle 300 may be configured to facilitate loading and unloading of items onto the acquisition vehicle 300. For example, the acquisition vehicle 300 may have a front opening between a plurality of side walls 330 adjacent to the front end of the acquisition vehicle 300, and a rear opening between a plurality of side walls 330 adjacent to the rear end of the acquisition vehicle 300. The front and rear openings provide pathways for loading items onto and from the support surface 320.

[0145] The material handling system 10 includes one or more mechanisms for transferring sorting containers 20 between the front rack 30 and the rear rack 35 and the acquisition vehicle 300. In one embodiment, the storage location may be configured to transport the sorting container 20 onto the acquisition vehicle 300. For example, each sorting location may include a transfer mechanism such as a conveyor belt. Alternatively, as shown in Figures 8 to 10, the acquisition vehicle 300 may include a transfer mechanism for transporting items between the acquisition vehicle 300 and the storage location.

[0146] Figures 8 to 10 show the transfer mechanism, which extends outward from the acquisition vehicle 300 and engages with one of the sorting containers 20 among the sorting racks 30 and 35. In Figure 8, the acquisition mechanism 350 is shown in the retracted position. In Figure 9, the acquisition mechanism 350 is shown in its extended position. In Figure 10, multiple optional latch elements 355 and 357 are shown in their protruding positions.

[0147] The acquisition mechanism 350 may include one or more retractable arms. For example, as shown in Figures 10 and 11A to 11D, the acquisition mechanism 350 may include a pair of retractable arms 352 positioned to grip the sorting container 20. Optionally, the telescopic arm 352 may be composed of multiple sections such that it extends retractably from the acquiring vehicle 300.

[0148] The retractable arm 352 may include a latch or other element for securely engaging with the sorting container 20. For example, each telescopic arm 352 may include a front container latch 355 and a rear container latch 357 positioned spaced apart from the front container latch 355. The front container latch 355 is positioned to engage with the front end of the sorting container 20, and the rear container latch 357 is positioned to engage with the rear end of the sorting container 20. Furthermore, the rear container latch 357 may be movable between the retracted position shown in Figure 9 and the protruding position shown in Figure 10. In this retracted position, the container latches 355 and 357 are not engaged with the sorting container 20. Furthermore, in the protruding position, the container latches 355 and 357 engage with the sorting container 20 such that the sorting container 20 also moves when the telescopic arm 352 is moved. Optionally, container latches 355 and 357 rotate from a retracted position to an extended position around a pivot axis, as shown in Figures 9 and 10.

[0149] Actuators on the acquisition vehicle 300, such as solenoids or motors, operate to drive the acquisition mechanism 350 between an extended position and a retracted position. For example, as shown in Figures 9 to 10, the telescopic arm 352 is connected to one or more drive elements, such as gears, that work together to extend the telescopic arm 352. Similarly, the container latches 355 and 357 are connected to one or more drive elements, which move the container latches 355 and 357 between an extended position and a retracted position. Both the retractable arm 352 and the container latches 355 and 357 may be connected to a common actuator such as a motor.

[0150] The acquisition vehicle 300 may include an internal power supply similar to that of the transport vehicle 200 described above. For example, the acquired vehicle 300 may include a rechargeable power source that can be charged while moving within the passage 100. Specifically, the acquiring vehicle 300 may include one or more contacts that electrically contact a power source located within or adjacent to the passage 100.

[0151] The acquisition vehicle 300 may also include a control device that controls the operation of the acquisition vehicle 300, similar to the transport vehicle 200. For example, the acquisition vehicle 300 may include a control device configured to receive signals from the central control unit 800 and control the operation of various functions of the acquisition vehicle 300. The control signal may include a signal that controls the drive wheels 310 to control the movement of the acquired vehicle 300 within the passage 100. Furthermore, the control signal may include signals that control the operation of the acquisition mechanism 350.

[0152] Referring to Figures 11A to 11D, the acquisition vehicle 300 is configured to acquire the sorting container 20 from one of the storage locations, either the front rack 30 or the rear rack 35, after one or more items have been sorted into the sorting container 20. In particular, the acquisition vehicle 300 may be configured to pull the sorting container 20 onto the acquisition vehicle 300 from one of the storage locations while the acquisition vehicle 300 is located in the passageway 100.

[0153] The material handling system 10 may be configured such that the sorting container 20 is held in a removable location in a storage area while one or more items are being sorted into the sorting container 20. When the acquisition vehicle 300 acquires the sorting container 20, the acquisition vehicle 300 activates a release mechanism to release the sorting container 20 from its storage location. After releasing the sorting container 20, the acquiring vehicle 300 retrieves the sorting container 20 from the storage location.

[0154] The sorting container 20 may be held in the storage location by engaging it with any of the various holding mechanisms. Figures 11A to 11D and 13A to 13B show the holding mechanism 42. The holding mechanism 42 for the sorting container 20 is a displaceable latch that acts as a stopper capable of preventing the sorting container 20 from moving from the storage area toward the passage 100. In the first position, the holding mechanism 42 contacts the sorting container 20, preventing the sorting container 20 from moving toward the passage 100 (see Figure 13A). In the second position, the holding mechanism 42 disengages from the sorting container 20 so that the sorting container 20 can move toward the passage 100.

[0155] The material handling system 10 may include an element that automatically moves the holding mechanism 42 from a first position to a second position in response to a control signal. For example, the holding mechanism 42 may be connected to a solenoid, other linear actuator, or rotary actuator that displaces the holding mechanism 42 in accordance with a control signal. Alternatively, in this embodiment, the material handling system 10 includes an actuator 44 connected to a holding mechanism 42, which is operated by an acquisition vehicle 300 to release the holding mechanism 42.

[0156] The actuator 44 has an operating surface configured to cooperate with the acquiring vehicle 300. In this embodiment, the actuator 44 is displaceable in the vertical direction. Specifically, the actuator 44 includes a roller that is rotatable around a horizontal axis, and this roller is displaceable vertically between an upper position and a lower position.

[0157] The actuator 44 may be directly connected to the holding mechanism 42, but as shown in Figures 11A to 11D, the actuator 44 and the holding mechanism 42 are connected by a link mechanism such as a rotatable connecting link 45. In this configuration, when the actuator 44 is displaced, the holding mechanism 42 is also displaced.

[0158] The material handling system 10 may also include an element that automatically returns the holding mechanism 42 from the retracted position to the operating position. For example, the material handling system 10 may include a biasing element that biases the actuator 44 and / or the connecting link 45, thereby biasing the holding mechanism 42 from the released position shown in Figure 13B to the holding position shown in Figure 13A. The biasing element may include a spring that biases the actuator 44 upward, or a spring that biases the connecting link 45 clockwise (as viewed from the viewpoint in Figure 11B).

[0159] The acquiring vehicle 300 may have a separate operating element configured to engage with the actuator 44 to release the holding mechanism 42. However, in this embodiment, the acquisition mechanism 350 is configured to engage with the actuator 44. For example, the telescopic arm 352 may engage with the actuator 44 to displace the actuator 44 downward as the telescopic arm 352 extends to the storage location.

[0160] The actuator 44 may be configured to limit the resistance acting on the telescopic arm 352 when the telescopic arm 352 is engaged with the actuator 44. For example, the actuator 44 may be angled or tapered, such as having a wedge shape or a similar shape. However, in this embodiment, as shown in Figure 13B, the actuator 44 may be a roller 44 having a surface that allows the telescopic arm 352 to rotate while maintaining the actuator 44 in the operating position.

[0161] The actuator 44 may be configured such that the holding mechanism 42 is kept in the released position until the entire length of the sorting container 20 has passed through the holding mechanism 42. In this way, when the sorting container 20 is transferred from the storage location to the acquisition vehicle 300, the holding mechanism 42 does not apply any force to the sorting container 20. For example, in this embodiment, the actuator 44 is positioned and configured such that the retractable arm 352 maintains engagement with the actuator 44 throughout or substantially throughout the transfer process of the sorting container 20. Specifically, the retractable arm 352 may engage with the actuator 44 and push down the actuator 44 while the sorting container 20 is being transferred onto the acquisition vehicle 300. When the telescopic arm 352 is released from engagement with the actuator 44, the entire length (or substantially the entire length) of the sorting container 20 is moved onto the acquisition vehicle 300. Therefore, once the actuator 44 is released, the holding mechanism 42 will not move toward the upward position until at least substantially the entire length of the sorting container 20 has been transferred onto the acquisition vehicle 300. In this way, when the sorting container 20 is transferred onto the acquisition vehicle 300, the holding mechanism 42 does not engage with the sorting container 20 or impede the movement of the sorting container 20.

[0162] As shown in FIG. 11D, the sorting container 20 may be supported by a shelf 40 that supports the sorting container 20 at storage locations within the front rack 30 and the rear rack 35. As shown in FIG. 13A, the holding mechanism 42 may project upward through the shelf 40. Furthermore, as shown in FIG. 11D, the shelf 40 may also include a fixing element such as a flange or wall 43 that prevents the sorting container 20 from moving outward from the passage 100. This outer stopper 43 prevents or inhibits the sorting container 20 from inadvertently moving from the front rack 30 and the rear rack 35. For example, when the transfer mechanism 350 moves the sorting container 20 into a storage location (e.g., one of a plurality of container supports 40), the outer stopper 43 prevents the transfer mechanism 350 from pushing the sorting container 20 out of the front rack 30 and the rear rack 35.

[0163] In one embodiment, as shown in FIG. 11A, the track 105 may be arranged in a plurality of columns such that when moving the sorting container 20 onto the acquisition vehicle 300, the acquisition vehicle 300 moves the sorting container 20 between a pair of vertical track sections 132. The drive system 310 of the acquisition vehicle 300 engages with the vertical track section 132 when the acquisition mechanism 350 pulls the sorting container 20 onto the acquisition vehicle 300. However, as described above, the track 105 may be formed in a plurality of horizontal rows instead of a plurality of vertical columns. When the track 105 is formed in a plurality of rows, when pulling the sorting container 20 onto the acquisition vehicle 300, the sorting container 20 does not necessarily need to move between a plurality of vertical track sections.

[0164] As described above, the material handling system 10 is configured to sort items into sorting containers 20, and to retrieve the sorting containers 20 after they are full or after all items within a particular group (such as an order) have been sorted into the sorting containers 20. In one embodiment, a vehicle such as an acquisition vehicle 300 acquires the sorting container 20. After acquiring the sorting container 20, the sorting container 20 is transported to the discharge location 400.

[0165] At the discharge point 400, items are discharged from the sorting container 20, or the sorting container 20 is moved outside the sorting system 15. For example, items in the sorting container 20 may be discharged from the sorting container 20 to another container outside the sorting system 15, or the sorting container 20 may be discharged onto a conveying mechanism that operates separately from the sorting system 15. Examples of such transport mechanisms include, but are not limited to, conveyors or vehicles such as autonomous vehicles.

[0166] The sorting container 20 may be transported to the discharge area 400 by being moved from the storage area to the discharge area 400 within the passage 100. For example, the sorting container 20 may be drawn from the storage area into the passage 100 and moved vertically and / or horizontally to be aligned with the discharge area 400.

[0167] In this embodiment, the sorting container 20 is moved within the passage 100 by the acquisition vehicle 300. After acquiring the sorting container 20, the acquisition vehicle 300 moves along the track 105 to the discharge location 400. For example, the acquisition vehicle 300 may move vertically and / or horizontally along the track 105. While one or more transport vehicles 200 transport items to the sorting containers 20 in the front racks 30 and rear racks 35, the acquisition vehicle 300 may move along the track 105 together with the sorting containers 20.

[0168] The acquired vehicles 300 may be controlled to flow in a common direction. For example, the acquisition vehicle 300 may flow in roughly the same direction as the transport vehicle 200, as described above. In one embodiment, as described above, the transport vehicle 200 and the acquisition vehicle 300 may generally flow in a clockwise direction.

[0169] While the acquired vehicles 300 generally move in a common direction (for example, clockwise), please understand that when moving along a vertical ring path, one of the acquired vehicles 300 may move in the opposite direction. For example, after moving downward along the fourth column, it may be desirable to move the acquisition vehicle 300 upward within the fourth column before driving the acquisition vehicle 300 downward to the lower track section 130. In such cases, the overall flow of the acquisition vehicle 300 or the transport vehicle 200 is the same, following a clockwise route along a vertical ring path that moves forward from the starting position.

[0170] Furthermore, while the acquisition vehicle 300 may generally move in the same direction as the transport vehicle 200, there are cases where it is desirable to reverse the direction of movement of the acquisition vehicle 300. For example, when moving from the sorting container 20 to the discharge point 400, it may be desirable to move the acquisition vehicle 300 along the first route. After transporting the sorting container 20 to the discharge point 400, the acquisition vehicle 300 may follow a route that moves in the same direction as the first route (for example, generally clockwise). Alternatively, it may be desirable to reverse the direction of movement of the acquisition vehicle 300 when it returns to one of the locations of the sorting container 20. For example, the acquired vehicle 300 may move in a second direction, which is in the opposite direction, along the same path as the first path.

[0171] The discharge location 400 may be one of several transfer locations for discharging items from the sorting system 15 after sorting the item groups into the sorting containers 20. Specifically, sorted item groups may be discharged from the sorting container 20 into which the items have been sorted.

[0172] The sorting container 20 may include one or more openings for discharging the sorted items to the discharge location 400. For example, each sorting container 20 may have a movable wall that selectively covers the opening of the sorting container 20. In the first position, the movable wall covers the opening, preventing items from passing through it. In the second position, the movable wall facilitates the discharge of items from the sorting container 20 without covering the opening.

[0173] An example of a sorting container 20 having a movable wall for discharging items is shown in Figure 12C. Furthermore, the bottom wall or base of this sorting container 20 is configured to open like a trapdoor or bomb drop door, allowing items to fall out of the sorting container 20. A trapdoor may consist of one or more sections. For example, as shown in Figure 12C, the trapdoor consists of two sections 25. Each of these compartments 25 may be opened individually, but in this embodiment, two compartments 25 open almost simultaneously, so all items in the sorting container 20 are discharged almost simultaneously.

[0174] In some cases, it may be desirable for movable walls to be configured to dispense items sequentially rather than all at once. By discharging items sequentially, the items in the sorting container 20 are not discharged as a single group, but rather as one or more groups, each containing one or more items, in succession.

[0175] FIG. 14 shows a sorting container 20 configured to facilitate sequentially discharging items from the sorting container 20. This sorting container 20 may have a trap door composed of a plurality of compartments 25 formed along the length direction of the sorting container 20. By sequentially opening the plurality of door compartments 25, the items in the sorting container​​​​​​​​​​​​​​​​​​​​​​​​​

[0178] Optionally, the guide track 420 may include one or more elements that improve the movement of the sorting container 20 along the guide track 420. As shown in Figure 12B, multiple rotatable elements, such as rollers, within the guide track 420 may provide a surface of rotation for the edge 27 of the sorting container 20 to move when the sorting container 20 is unloaded from the acquisition vehicle 300 at the discharge point 400.

[0179] The discharge location 400 may also include one or more elements that guide the items discharged from the sorting container 20. As shown in Figure 12C, when items are discharged from the sorting container 20, the inclined wall 425 may guide the items away from the passage 100. Furthermore, the inclined wall 425 may be curved to allow the trap door 25 to be easily closed when the sorting container 20 is pulled onto the acquisition vehicle 300.

[0180] The discharge location 400 may also include a wall 415 that forms a slope that directs the item in a desired direction when the item is discharged from the acquiring vehicle 300. The guide wall 415 may extend outward from the vertical support or vertical track 132, as shown in Figures 12A and 12B. Optionally, the guide track 420 may be permanently connected to the side wall 415.

[0181] At the discharge location 400, items in the sorting container 20 may be discharged from the sorting container 20, as described above. Items may be placed directly into a container such as a box or another container. For example, referring to Figure 2, the items in sorting container 20-1 are discharged onto a guide mechanism 430 that guides the items into a container. If the sorting container 20-1 includes a movable wall (such as the trap door 25 shown in Figure 12C), a gap may be created between the bottom of the sorting container 20-1 and the top surface of the guide mechanism 430 by supporting the sorting container 20-1 above the guide mechanism 430. In this way, when the sorting container 20-1 is pulled out from the passage 100 onto the guide mechanism 430, the trap door 25 may open.

[0182] The guidance mechanism 430 may be formed in various configurations. In one example shown in Figure 2, the guidance mechanism 430 is a slope that is inclined downwards and away from the passageway 100. Furthermore, the guidance mechanism 430 may include a housing 435 or enclosure that functions as a funnel for guiding items into an empty container. The housing 435 may have a side wall 415 and an end wall facing the inclined slide 430. The lower end of the housing 435 may be positioned spaced above the container input conveyor 650 through which the containers are transported, so that empty containers can pass beneath the housing 435.

[0183] As described above, the items may be discharged directly into the container via a guide mechanism 430 such as a funnel or a slope. Alternatively, the items may be discharged onto a movable element that guides or transfers the items from the sorting container 20 to an empty container. Such movable elements may include one or more conveyors or transport vehicles that operate outside the sorting system 15.

[0184] Figures 15 to 21 show a discharge conveyor 450 that guides or transfers items from a sorting container 20 to an empty container (e.g., an empty box 500). The discharge conveyor 450 includes a nearly horizontal conveyor 460 configured to receive items discharged from the sorting containers 20 acquired by the acquisition vehicle 300. For example, the sorting container 20 is supported on a horizontal conveyor 460, and the items discharged from the sorting container 20 are placed on the horizontal plane of the horizontal conveyor 460.

[0185] The horizontal conveyor 460 has a first end adjacent to the passage 100 and a second end located above the loading position 475. Alternatively, empty containers 500, such as boxes, may be placed at the loading position 475, and items may be discharged from the horizontal conveyor 460 into the containers 500.

[0186] Alternatively, one or more guide elements may be placed around the loading position 475 to guide items from the second end of the horizontal conveyor 460 into the container 500 at the loading position 475. The guide element preferably forms an opening smaller than the opening of the container 500 into which the items are loaded. In this way, the guide element functions like a funnel, directing the item into container 500 at loading position 475.

[0187] For example, an angled guide mechanism 430 or inclined surface adjacent to the second end of the horizontal conveyor 460 may guide items into the box and prevent items from falling below the horizontal conveyor 460. A stopper or end wall 470 may be placed opposite the second end of the horizontal conveyor 460. The end wall 470 is configured to prevent items discharged from the horizontal conveyor 460 from moving outward beyond the sides of the empty boxes at the loading position 475.

[0188] The discharge conveyor 450 may include side walls or guide mechanisms 430 to prevent items from falling from the sides of the horizontal conveyor 460. For example, the side wall may extend along the side of the horizontal conveyor 460 and vertically upward from the first end to the second end of the horizontal conveyor 460. The side walls may be substantially vertical. Alternatively, the side walls may form a valley-like shape due to their angle. In this configuration, the side walls direct the items downwards toward the horizontal conveyor belt 460.

[0189] As shown in Figures 15 to 18, the discharge conveyor 450 optionally includes side walls to prevent items from falling off the sides of the horizontal conveyor 460. Furthermore, the side wall may include side wall conveyors 462, 464 that move items along the length of the discharge conveyor 450. The side wall conveyors 462 and 464 sandwich the horizontal conveyor 460 and extend along at least a portion of the horizontal conveyor 460. As shown in Figure 16, the side wall conveyors 462 and 464 optionally extend beyond the second end of the horizontal conveyor 460 to the loading position 475.

[0190] The side wall conveyors 462 and 464 may be a series of rollers forming a roller bed. However, in this embodiment, the side wall conveyors 462 and 464 are made up of endless belts wrapped around rollers. The rollers of the side wall conveyors 462 and 464 may rotate around a vertical axis such that the contact surface with the conveyor belt is substantially perpendicular. However, as shown in Figures 16 to 18, the side wall conveyors 462 and 464 are formed such that the surface of the conveyor belt forms an obtuse angle with the surface of the horizontal belt.

[0191] The side wall conveyors 462 and 464 may operate in a first direction, i.e., forward, to move items toward the loading position 475. Furthermore, the side wall conveyors 462 and 464 may operate in a second direction, i.e., the reverse direction, to move the items away from the loading position 475. During normal operation, the side wall conveyors 462 and 464 move in the forward direction. However, the side wall conveyors 462 and 464 may selectively reverse rotation to loosen or release items that may be stuck or jammed in the discharge conveyor 450.

[0192] Furthermore, these side wall conveyors 462 and 464 may operate independently, with one side wall conveyor 462 operating in a first direction and the second side wall conveyor 464 operating in a second direction. The opposing movement of the side wall conveyors 462 and 464 generates a twisting motion or torque in the items within the discharge conveyor 450, which can release or loosen any items that may be stuck or jammed within the discharge conveyor 450.

[0193] The side walls and / or side wall conveyors 462, 464 may be fixedly positioned. In a fixed configuration, the distance between multiple side walls and / or side wall conveyors 462, 464 is fixed. Alternatively, the side walls and / or side wall conveyors 462 and 464 may be flexibly connected to each other so that the distance between them can be varied.

[0194] Various mechanisms may be used to move the side walls and / or side wall conveyors 462, 464 relative to each other. For example, the rollers supporting the side wall conveyors 462 and 464 may be movable outward from the horizontal conveyor 460. Furthermore, the biasing element may bias the side wall conveyors 462 and 464 inward toward the horizontal conveyor 460. However, if one or more items become jammed between multiple side walls or side wall conveyors 462, 464, the lateral force from the jammed items may exceed the biasing force, causing one or both of the side walls and / or side wall conveyors 462, 464 to move outward, thereby releasing or loosening the jam.

[0195] The discharge conveyor assembly 450 may include one or more sensors to detect whether one or more items are being obstructed from the discharge conveyor assembly 450 to one of the containers 500 due to a blockage or any other reason. For example, the discharge conveyor assembly 450 may include a number of beam-blocking sensors arranged along the length of the discharge conveyor assembly 450 to monitor the movement of items along the discharge conveyor assembly 450. Alternatively, the discharge conveyor assembly 450 may include one or more light curtains that detect the presence of items at multiple locations along the longitudinal direction of the discharge conveyor assembly 450. Thus, the discharge conveyor assembly 450 includes one or more elements that detect the presence of items at one or more points along the longitudinal direction of the discharge conveyor assembly 450.

[0196] Optionally, the discharge conveyor assembly 450 may include one or more sensors that detect the presence of items along the longitudinal direction of the horizontal conveyor 460. Optionally, the discharge conveyor assembly 450 may include one or more sensors that detect the presence of items along the longitudinal direction of the first sidewall conveyor 462. Optionally, the discharge conveyor assembly 450 may include one or more sensors that detect the presence of items along the longitudinal direction of the second sidewall conveyor 464. Furthermore, the discharge conveyor assembly 450 may include one or more sensors along each of the three conveyors 460, 462, and 464 so that the material handling system 10 can detect the presence of items on each of the three conveyors 460, 462, and 464.

[0197] Sensors on the discharge conveyor assembly 450 may provide signals indicating whether items are jammed at several points within the discharge conveyor assembly 450. The material handling system 10 may control the operation of conveyors 460, 462, and 464 based on signals received from sensors. For example, if a sensor provides a signal indicating that there is no blockage, the central control unit 800 may control the conveyors so that the horizontal conveyor 460, the first side wall conveyor 462, and the second side wall conveyor 464 all operate in the forward direction, driving the items toward the discharge point 475. Alternatively, if one or more sensors provide a signal indicating a blockage, the central control unit 800 may control the conveyors 460, 462, and 464 to change their movement. For example, as described above, the material handling system 10 may generate a twisting motion by rotating one side wall conveyor 462 in the reverse direction while driving the other side wall conveyor 464 in the forward direction, thereby rotating the items and clearing jammed items.

[0198] The central control unit 800 may not only control the operation of conveyors 460, 462, and 464 in response to signals from sensors, but may also resolve blockages by controlling conveyors 460, 462, and 464 based on procedures that have already been performed. For example, as described above, the material handling system 10 may declare a jam in response to a signal received by one or more sensors, and as a result, the central control unit 800 may reverse the rotation of one of the side wall conveyors 462, 464. If, after one of the side wall conveyors 462 or 464 is reversed, the sensor continuously detects a blockage, the central control unit 800 may change the operation of the conveyors 460, 462, and 464. For example, if the first sidewall conveyor 462 is rotated in the reverse direction and the second sidewall conveyor 464 is driven in the forward direction, but a blockage is still detected, the central control device 800 may reverse the direction of the two sidewall conveyors 462 and 464, driving the first sidewall conveyor 462 in the forward direction and rotating the second sidewall conveyor 464 in the reverse direction. Alternatively, both side wall conveyors 462 and 464 may be rotated in opposite directions. Alternatively, if the sensor continuously detects a blockage, one of the side wall conveyors 462, 464 and the horizontal conveyor 460 can be reversed.

[0199] Therefore, the central control unit 800 may change the direction of one or more conveyors 460, 462, 464 multiple times in response to signals received from sensors positioned along the longitudinal direction of the discharge conveyor assembly 450.

[0200] Referring to Figures 15 and 19 through 21, it may be desirable for the discharge point 400 to include a holding mechanism to hold the container when the items are being transported into the container. An assembly for holding empty containers, such as boxes, is shown in combination with the aforementioned discharge conveyor 450. However, it should be understood that the container holding mechanism may be incorporated into the structure of the discharge station 400, which does not include the discharge conveyor such as the aforementioned sloped section 430. Furthermore, it should be noted that the material handling system 10 can function perfectly well in various applications even without a container holding mechanism.

[0201] The container holding mechanism 520 may be configured to hold the container being loaded at the loading position 475. The container holding mechanism 520 may include a movable holding mechanism 530 that is displaceable between an engaged position and a retracted position. In the first position, the movable holding mechanism 530 holds the container in a fixed position at the loading position 475. In the second position, the movable holding mechanism 530 releases the container, allowing the container 500 to be freely transported from the loading position 475.

[0202] The movable holding mechanism 530 may have a substantially flat, plate-like shape that operates to be pressed against the side of the container. Furthermore, a fixed wall or fixed plate 550 may be positioned opposite the movable holding mechanism 530 (see Figures 19 and 21). In this manner, at the first position, the movable holding mechanism 530 presses the container against the fixed wall 550, gripping or holding the container in a predetermined position.

[0203] The movable holding mechanism 530 may also include an end wall 532 that protrudes in a direction transverse to the plane of the movable holding mechanism 530. Furthermore, this end wall 532 may function as a stopper to stop the discharge container at the loading position 475 as the discharge container moves along the conveyor 650. In particular, the end wall 532 may protrude into the container's path when the container moves to the loading position 475.

[0204] The movable holding mechanism 530 may be moved between a first position (see Figure 19) and a second position (see Figure 20) using various mechanisms. In this embodiment, the container holding mechanism 520 includes an actuator 540 such as a solenoid, and a link mechanism 545 connects the movable holding mechanism 530 to the solenoid.

[0205] The material handling system 10 may include a conveyor that transports the containers from the sorting device after the sorting containers 20 have been emptied at one of the discharge points 400. Furthermore, the material handling system 10 may include a conveyor that transports empty containers to the discharge area 400 to receive items from the sorting containers 20.

[0206] Figure 2 shows an example of a conveyor that transports containers from the sorting device after items have been transferred from the sorting container 20 to the containers. This conveyor may include a transfer conveyor 660 that moves containers along a path parallel to the passage 100 of the sorting device 15. The transfer conveyor 660 may include one or more conveyor belts, one or more rollers, or similar mechanisms that move the containers generally horizontally along a horizontal path. Alternatively, the transfer conveyor 660 may include a shuttle or other mobile vehicle for loading containers after the items have been transferred from the sorting container 20 into the containers.

[0207] The transfer conveyor 660 moves the full container 510 from the discharge point 400 to the output conveyor 675. The output conveyor 675 moves the full container 510 away from the sorting device 15. The output conveyor 675 may include one or more conveyor belts, one or more rollers, or similar mechanisms for moving the container 510 substantially horizontally along a horizontal path. Alternatively, the output conveyor 675 may include a shuttle or other mobile vehicle for loading the containers 510.

[0208] As shown in Figure 2, the output conveyor 675 may be positioned at an angle to the transfer conveyor 660. In this way, the transfer conveyor 660 moves the full container 510 along the path from the discharge point 400 to the output conveyor 675. When container 510 arrives at the end of the transfer conveyor 660, container 510 is transported onto the output conveyor 675.

[0209] The material handling system 10 may include one or more container input conveyors 650 that supply empty containers 500 to a discharge point 400 that receives items from the sorting containers 20 as described above. For example, as shown in Figures 1 and 2, the material handling system 10 may include container input conveyors 650-1, 650-2, 650-3, and 650-4. Each of the four conveyor lines supplies 500 empty containers to the discharge point 400. In the embodiments shown in Figures 1 and 2, each container input conveyor 650-1, 650-2, 650-3, and 650-4 leads to a different discharge point 400. In this way, each container input conveyor 650 independently supplies an empty container 500 to one of the discharge points 400. Therefore, each container input conveyor 650 may be controlled individually.

[0210] Optionally, the container input conveyor 650 may be configured to transport containers 500 having different physical characteristics. Physical characteristics may refer to the dimensions of the container 500, such as length, width, and height, or to the type of container 500, such as a tote bag, container, or cardboard box. For example, container input conveyor 650-1 may transport extra-large cardboard boxes to discharge area 400-1, container input conveyor 650-2 may transport large cardboard boxes to discharge area 400-2, container input conveyor 650-3 may transport medium-sized cardboard boxes to discharge area 400-3, and container input conveyor 650-4 may transport small cardboard boxes to discharge area 400-4.

[0211] Depending on the application, it may not be desirable to automatically transport and supply container 500 to discharge point 400. Alternatively, the material handling system 10 may have a single container input conveyor 650 that supplies empty containers 500 to each discharge point 400. Therefore, please understand that the number of container input conveyors 650 may vary depending on the application. Similarly, the direction and orientation of the container input conveyor 650 may vary depending on the application.

[0212] For example, Figures 15 and 19 through 21 show an alternative container input conveyor 650'. This alternative container input conveyor 650' has an input path that moves empty containers 500 parallel to the aisle 100 of the sorting device. The empty container 500 moves along this route towards the loading position 475 at the discharge point 450. At loading position 475, an item is loaded into a container from one of the sorting containers 20. In Figure 15, the container being loaded at loading position 475 is indicated by 505.

[0213] The container moves from the discharge point 400 toward the orthogonal transfer path 655, which moves the full container 510 toward the transfer conveyor 660 in a direction perpendicular to the container input conveyor 650'. The transfer conveyor 660' is configured to transport the full container 510 along a path parallel to the aisle and in the opposite direction to the direction of movement of the input conveyor 650'. As mentioned above, the number and arrangement of container input conveyors, container transfer conveyors, and container output conveyors may vary depending on a variety of factors, including the size and shape of the available floor space, the number of sorting systems 15 used, and the types of items to be sorted.

[0214] In the above description, the material handling system 10 is described as having a single sorting device 15 that sorts items and transfers the sorted items to containers that are transported by an output conveyor 675. However, the material handling system 10 may include a plurality of sorting devices connected to each other by one or more common input conveyors for supplying empty containers to the sorting devices, and / or one or more common output conveyors for transporting full containers from the sorting devices.

[0215] In the above description, after the item group is sorted into the sorting container 20, the sorting container 20 is transported to the discharge area 400, where the items are discharged from the sorting container 20 into other containers. However, instead of transferring items from one sorting container 20 to another at the discharge point 400, the entire sorting container 20 may be discharged at the discharge point 400. For example, the discharge area 400 may include a conveyor or other movable elements on which the sorting containers 20 can be placed. The acquisition vehicle 300 may transfer the full sorting containers 20 onto the conveyor belt at the discharge point, similar to how the acquisition vehicle 300 moves the full sorting containers 20 from the acquisition vehicle 300 by operating the transfer mechanism 350.

[0216] When the full sorting container 20 is transferred onto the conveyor at the discharge point 400, the full sorting container 20 may be transported onto the transfer conveyor and / or an output conveyor similar to the conveyor described above, moving the full sorting container away from the sorting device 15.

[0217] In a configuration in which a full sorting container 20 is discharged from the sorting device, instead of emptying the full sorting container 20, the material handling system 10 may also include a mechanism to replenish the sorting device with an empty sorting container 20 after the full sorting container 20 has been discharged. For example, a conveyor belt may transport empty sorting containers 20 toward a discharge point 400, and after a retrieval vehicle 300 has discharged full sorting containers 20, the retrieval vehicle 300 may retrieve empty sorting containers 20 and transport them to a sorting location where there are no empty sorting containers 20.

[0218] Therefore, as described above, the material handling system 10 may, after sorting the items into the sorting container 20, either transfer the sorted items from the sorting container 20 to another container 500, or discharge the entire sorting container 20 from the sorting device to discharge the items. Furthermore, the material handling system 10 can combine these two functions by discharging the full sorting container 20 from the sorting device and then transferring the items into another container.

[0219] Referring to Figures 22A to 22C, another embodiment is shown in which sorting containers 20 containing sorted items are transferred onto a container output conveyor 700. For example, the sorting container 20 is acquired by the acquisition vehicle 300 as described above and transported to the discharge site 400'. At the discharge point 400', the acquisition vehicle 300 may transfer the full sorting container 20 onto the container output conveyor 700.

[0220] The container output conveyor 700 transports the full sorting containers 20 along a path on the container input conveyor 650 that transports empty containers 505. As shown in Figure 22B, the container output conveyor 700 has a gap above the container input conveyor 650, allowing items to be discharged from the sorting container 20 into the empty container 505 at the loading position. The sorting container 20 is supported by the discharge station 400' across its gap by support and / or guides similar to those of the guide track 420 described above. When this is done, the bottom trapdoor 25 of the sorting container 20 opens, and the items inside the sorting container 20 fall into the container 505 below the sorting container 20.

[0221] After items are discharged from the sorting container 20, the empty sorting container 20 is transported along the container output conveyor 700. When the sorting container 20 is being transported through the gap in the container output conveyor 700, the trap door 25 of the sorting container 20 is closed. Subsequently, the empty sorting containers 20 are transported toward the sorting device and become available for transfer into the sorting device by one of the acquisition vehicles 300.

[0222] In yet another embodiment shown in Figures 23A to 23C, the material handling system 10 transports a full sorting container 20 from a sorting device along an output conveyor 700, and then transports items from the full sorting container 20 into an empty container 505 such as a box. In this second embodiment, the output conveyor 700 for the full sorting container 20 selectively discharges items into empty boxes 505A and 505B on separate container conveyors 650A and 650B.

[0223] The output conveyor 700 may include one or more movable compartments that selectively open to discharge items from the sorting container 20. For example, the output conveyor 700 may include a first movable section 725A located above the first container input conveyor 650A and a second movable section 725B located above the second container input conveyor 650B.

[0224] In the first position, each movable compartment 725A, 725B is configured to provide a surface that supports the sorting container 20 and to maintain the trapdoor 25 of the sorting container 20 in a closed state. In the second position, each movable section 725A, 725B moves away from the path of the output conveyor 700, providing a gap or opening for the trap door 25 of the sorting container 20 to open. For example, as shown in Figure 23C, the movable compartment 725 may rotate in the same way as the trapdoor 25. Similar to the embodiments described above, a container support portion 730 may be provided on the movable compartment so that the sorting container 20 is supported through the gap in the output conveyor 700 when one of the movable compartments 725 is opened.

[0225] When one of the movable compartments 725 moves to the open position, the container support section 730 supports the sorting container 20, preventing the sorting container 20 from falling out of the opening of the output conveyor 700. The sorting container 20 is supported, and while the rotating section 725B is open, the trapdoor 25 of the sorting container 20 opens, allowing items to fall into container 505B on the container input conveyor 650B. Similarly, when the sorting container 20 is positioned on the first container input conveyor, the first rotating compartment 725A may rotate and open so that items are discharged from the sorting container 20 into an empty container 505A.

[0226] Referring to Figures 1 to 4, the material handling system 10 may include one or more box assembly devices 600. The box assembly machine 600 automatically manufactures cardboard boxes from supplied cardboard. The box assembly device 600 can cut out a certain length of cardboard from the supplied cardboard, then cut and fold the cardboard pieces to create an empty box 500. As shown in Figure 1, the material handling system 10 may include a plurality of box assembly devices 600-1, 600-2, 600-3, and 600-4. All of these box assembly devices 600-1, 600-2, 600-3, and 600-4 may produce boxes of the same size, or they may produce boxes of different sizes and configurations. For example, the first box assembly device 600-1 may produce a box of a first size, the second box assembly device 600-2 may produce a box of a second size, the third box assembly device 600-3 may produce a box of a third size, and the fourth box assembly device 600-4 may produce a box of a fourth size.

[0227] The material handling system 10 may include multiple container input conveyors 650 that transport empty boxes 500 from box assembly devices 600-1, 600-2, 600-3, and 600-4 to the discharge area 400. These container input conveyors 650 may be configured to transport boxes 500 from any box assembly devices 600-1, 600-2, 600-3, 600-4 to any discharge point 400. Alternatively, as shown in Figure 1, the container input conveyors 650 from the box assembly devices 600-1, 600-2, 600-3, and 600-4 to the discharge point 400 may be separate, and each box assembly device 600-1, 600-2, 600-3, and 600-4 may supply empty boxes 500 to only one discharge point 400. <About operation>

[0228] The material handling system 10 sorts multiple items into sorting containers 20, and after the items have been sorted into sorting containers 20, it automatically retrieves the sorting containers 20. The material handling system 10 may empty the acquired sorting container 20. Alternatively, the material handling system 10 may discharge the sorting container 20 from the material handling system 10 and process the sorting container 20 at a location away from the material handling system 10.

[0229] The process of sorting items into multiple sorting containers 20 may optionally include a step of loading the items onto multiple independently operating transport vehicles 200 that operate within a passage 100. To transport items, one of the transport vehicles 200 may travel along a vertical circular path within the passage 100 from the loading position to one of the sorting containers 20. Upon arriving at the sorting container 20, the transport vehicle 200 may operate its transfer mechanism to transport the items into the sorting container 20. After transporting an item, the transport vehicle 200 may travel along a vertical circular path within the passage 100, return to the loading position, and receive another item to transport. This process may be repeated using a transport vehicle 200 to sort multiple items into multiple sorting containers 20.

[0230] As described above, the sorting process may optionally include an item scanning step, in which the characteristics of each item are identified by scanning the items before loading them into one of the transport vehicles 200. For example, this characteristic may be a unique identifier, such as a product identification code. Alternatively, this process may include a step of manually entering information about the characteristics, such as entering a product identification code by key. Subsequently, the central control unit 800 may use this characteristic to determine which sorting container 20 will transport the items.

[0231] The item sorting process may also include steps of transporting the items along a conveyor belt and scanning the items while they are being transported. Scanners positioned along the conveyor belt, such as barcode scanners or line scan cameras, may scan items as they are being transported along the conveyor belt. The conveyor transports the items to one of the transport vehicles 200 at the loading location, making the items ready to be loaded onto the transport vehicle 200. Alternatively, the sorting process may also include the step of scanning the items and placing them directly into one of the transport vehicles 200. For example, an operator may manually place items onto the transport vehicle 200, or an automated element such as a robotic arm may directly place items onto the transport vehicle 200.

[0232] The sorting process may also include moving transport vehicles 200 within a passage 100 along a vertical annular path that includes one or more vertical sections and one or more horizontal sections. The sorting containers 20 may be located on both sides of the passage 100, so that the transport vehicle 200 may move items forward into the sorting container 20 on one side of the passage 100, or backward into the sorting container 20 on a second side of the passage 100.

[0233] The step of moving the transport vehicle 200 may include the step of moving the transport vehicle 200 along the track 105 within the passage 100. The step of moving the transport vehicle 200 may include driving the transport vehicle 200 vertically or lifting the transport vehicle 200. The step of driving the transport vehicles 200 may include the step of operating gates 135, which control the direction of movement of each transport vehicle 200 by operating gates 135 along the track 105 at intersections.

[0234] The central control unit 800 may control the transport of items and stack them in the sorting container 20. Specifically, the central control unit 800 may store identification information for item groups that are stacked together in one of the sorting containers 20. For example, the central control unit 800 may receive information about the item group required for a specific order. The central control unit 800 provides control signals to the transport vehicles 200 to transport the ordered items into one of the sorting containers 20. When all the items for the order have been stacked in the sorting container 20, the central control unit 800 determines that the sorting container 20 is ready for pickup.

[0235] The central control unit 800 may individually control each transport vehicle 200 and move each transport vehicle 200 along a vertical annular path within the passage 100, but each transport vehicle 200 may follow various paths depending on the sorting container 20 to which the items are being transported. For example, the first transport vehicle 200 travels along the first route to the first sorting container 20, and the second transport vehicle 200 travels along the second route to the second sorting container 20.

[0236] The sorting process may include a step of determining the route of the transport vehicle 200 based on the sorting container 20 to which the items are to be sorted. Specifically, the central control unit 800 determines the route of the transport vehicle 200 and transmits information about the sorting container 20 to which the items are to be transported to the transport vehicle 200.

[0237] After determining the route of the transport vehicles 200, the central control unit 800 may direct the transport vehicles 200 to the appropriate lane by providing signals to control the gates 135 located along the track 105. The gate 135 may be directly actuated by an actuator such as a solenoid, and the central control unit 800 may provide a signal to the gate solenoid. Alternatively, the transport vehicle 200 may include an actuator that drives a gate 135 located along the track 105. The central control unit 800 may provide signals to the transport vehicle 200, selectively operate the actuators to selectively operate the gate 135, and direct the transport vehicle 200 along an appropriate path.

[0238] The sorting process may include a step of stopping the transport vehicle 200 so that it is positioned in the gap above the sorting container 20 to which the items are to be transported. For example, the top of the transport vehicle 200 may be aligned with the gap between a suitable sorting container 20 and the lower end of a sorting container 20 directly above it.

[0239] While the transport vehicle 200 is stopped, a control device mounted on the transport vehicle 200 may send an appropriate signal to the conveyor motor to drive the conveyor belt, driving the items forward and discharging them into the sorting container 20.

[0240] The step of obtaining a container may include identifying a sorting container 20 from among a plurality of sorting containers 20. Specifically, the central control unit 800 may determine that all items within an item group have been transported to a single sorting container 20. When items within an item group are transported to a sorting container 20, the central control unit 800 may identify that sorting container 20 as the sorting container 20 to be acquired.

[0241] The process of acquiring the sorting container 20 may also include the process of driving the acquisition vehicle 300 through the passage 100 to the sorting container 20 to be acquired. This acquisition vehicle 300 may be the same vehicle as the transport vehicle 200, or it may have a different configuration from the transport vehicle 200. The acquisition vehicle 300 may move within the passage 100 in a vertical and / or horizontal direction.

[0242] Optionally, when acquiring a sorting container 20, the acquisition vehicle 300 may move from the waiting area to the storage area where the sorting container 20 is acquired. For example, the material handling system 10 may include one or more acquisition vehicles 300 that are not used for transporting items. Therefore, when the acquisition vehicle 300 is not in operation, the acquisition vehicle 300 may be waiting in a location outside the transport route of the transport vehicle 200.

[0243] The waiting area for the acquired vehicle 300 is preferably within the passageway 100. For example, as shown in Figures 1 and 5, the material handling system 10 may include a waiting line 150 within the passage 100. The waiting line 150 may be positioned at any location along the length of the aisle 100. In this embodiment, the waiting line 150 is located adjacent to the loading line 140, where items are loaded onto the transport vehicle 200. The storage area or storage container may be arranged along the waiting line 150. However, in this embodiment, since the storage containers are not arranged along the waiting line 150, the need for the transport vehicles 200 to pass through the waiting line 150 is minimized.

[0244] The acquired vehicle 300 may move within the passage 100 instead of remaining in a standby state when not in use. For example, the central control unit 800 may track the distance between multiple transport vehicles 200 moving within the passage 100. The central control unit 800 may control the movement of the acquisition vehicle 300 so that it moves within the space between the transport vehicles 200. Specifically, the central control unit 800 may control the movement path of the acquisition vehicle 300 to minimize the influence that the acquisition vehicle 300 has on the movement of the transport vehicle 200 when the acquisition vehicle 300 is not in use.

[0245] As described above, the step of acquiring the sorting container 20 may include the step of moving the acquisition vehicle 300 to the sorting container 20 within the passage 100. When the acquisition vehicle 300 moves to a location adjacent to the sorting container 20, the sorting container 20 may be transferred onto the acquisition vehicle 300 while it is in the passageway 100. In other words, the sorting container 20 is moved from the storage area into the passageway 100.

[0246] The sorting container 20 may be transferred onto the acquisition vehicle 300 by a mechanism provided at the storage location, or the acquisition vehicle 300 may include a transfer mechanism for transferring the sorting container 20 onto the acquisition vehicle 300. In this embodiment, the acquisition vehicle 300 includes a transfer mechanism that engages with the sorting container 20 and transfers the sorting container 20 onto the acquisition vehicle 300. Optionally, the process of transporting the sorting container 20 may include the steps of extending the transport mechanism 350 from the acquisition vehicle 300 to a position where it engages with the sorting container 20, and then retracting the transport mechanism to pull the sorting container 20 onto the acquisition vehicle 300.

[0247] The step of extending the transfer mechanism 350 may include the step of extending one or more telescopic arms 352 toward the sorting container 20. Optionally, the transfer mechanism 350 may include retractable engagement elements such as rotatable latch fingers 355, 357. The step of extending the telescopic arm 352 may include the step of maintaining the latch elements 355, 357 in the retracted position while the telescopic arm 352 is extended. After the telescopic arm 352 is extended, the engaging element may engage with the sorting container 20. For example, after the telescopic arm 352 extends to the storage location where the sorting container 20 is placed, the latch fingers 355 and 357 may rotate to a protruding position to engage with the sorting container 20.

[0248] The step of retracting the transfer mechanism may include retracting the telescopic arm 352 to the retracted position and pulling the telescopic arm 352 in, thereby drawing the sorting container 20 onto the acquisition vehicle 300. Furthermore, the step of retracting the telescopic arm 352 may include the step of maintaining the latch elements 355 and 357 in a protruding position so that the latch elements 355 and 357 maintain engagement with the sorting container 20 when the telescopic arm 352 is retracted.

[0249] Referring to Figures 8 to 10, the operation of the acquisition vehicle 300 when acquiring the sorting container 20 is shown. Figure 8 shows the acquisition vehicle 300 with the transfer mechanism 350 in a retracted position. When the acquisition vehicle 300 is aligned with the sorting container 20 to be acquired, the motor on the acquisition vehicle 300 operates, causing the drive mechanism (for example, one or more gears) to rotate, thereby extending the transfer mechanism 350 to the extended position as shown in Figure 9. At this position, the transfer mechanism 350 extends to the storage location, and the telescopic arm 352 clamps the sorting container 20, as shown in Figure 11B. When the retractable arm 352 extends, the latch 355 is activated and protrudes by continuing to drive the motor, engaging with the sorting container 20. In this embodiment, the latches 355 and 357 operate by rotating them to the protruding position, as shown in Figure 10. The sorting container 20 is held between a front latch 355 that contacts the front end of the sorting container 20 and a rear latch 357 that contacts the rear end of the sorting container 20 (see Figure 11C). In this manner, the sorting container 20 is securely held, and moves forward or backward in response to the extension or contraction of the telescopic arm 352.

[0250] The step of acquiring the sorting container 20 may optionally include the step of releasing the sorting container 20 from the sorting container holding mechanism 42. For example, the storage location may include a holding mechanism 42 that engages with the sorting container 20 to prevent the sorting container 20 from moving away from the storage location. In the example described above, the holding mechanism 42 may engage with the surface of the sorting container 20 to hold the sorting container 20 in place. The holding mechanism 42 may also be a stopper 42 that contacts the surface of the sorting container 20 to prevent the sorting container 20 from moving.

[0251] The step of releasing the sorting container holding mechanism 42 may include the step of operating the actuator 44 to move the sorting container holding mechanism 42. The step of operating the actuator 44 may include keeping the actuator 44 engaged so that the holding mechanism 42 is maintained in the released position for substantially the entire duration that the sorting container 20 is moved from the storage location. The step of releasing the sorting container holding mechanism 42 by operating the actuator 44 may include the step of extending the transfer mechanism 350 to the storage location. Optionally, the step of operating the actuator 44 may include the step of aligning the transfer mechanism 350 with the actuator 44.

[0252] Optionally, the acquired vehicle 300 may include multiple side walls 330, with a substantially horizontal plane 320 between the multiple side walls 330. The front opening extends between a plurality of side walls 330 along the front end of the acquired vehicle 300, and the rear opening may extend between a plurality of side walls 330 along the rear end. The step of obtaining the sorting container 20 may include the step of moving the sorting container 20 onto a substantially horizontal plane 320 through a front opening or a rear opening.

[0253] As described above, this process may include the step of emptying the acquired sorting container 20. The method for emptying the acquired sorting container 20 may include the step of driving the acquisition vehicle 300 within the passage 100 to a location where the sorting container 20 can be emptied. Specifically, this process may include the step of moving the acquisition vehicle 300 vertically and / or horizontally along a route from a storage location from which the sorting containers 20 are acquired to a discharge point 400 where the sorting containers 20 can be emptied.

[0254] The central control unit 800 may determine the route of the acquired vehicle 300 within the passage 100 based on one or more of several variables. For example, the material handling system 10 may include multiple discharge points 400. Each discharge station 400 may be configured to accept items or orders having specific characteristics. For example, one discharge station 400 may be configured to accept a group of items whose total weight is below a first threshold, and another discharge station 400 may be configured to accept a group of items whose total weight exceeds a first threshold. Similarly, different discharge points 400 may be configured to accept orders based on characteristics such as the number of items in the sorting container 20, the estimated volume of items in the sorting container 20, and the maximum length of items in the sorting container 20.

[0255] Alternatively, each discharge point 400 may be configured to accept the sorting container 20 regardless of the physical characteristics of the items in the sorting container 20. In other words, each discharge point 400 is configured to accept any sorting container 20, regardless of the item group within the sorting container 20. In this way, the central control unit 800 can determine which discharge station 400 to direct the acquired sorting container 20 to, based on a variety of factors including, but not limited to, the proximity of the acquired sorting container 20 to the discharge station 400, traffic conditions between the location of the acquired sorting container 20 and the discharge station 400 (i.e., the movement of the transport vehicle 200 and the acquisition vehicle 300), and the availability of the discharge station 400 (i.e., whether the acquisition vehicle 300 is currently at the discharge station 400 or is heading toward the discharge station 400).

[0256] The step of moving the acquisition vehicle 300 to the discharge station 400 may include the step of driving the acquisition vehicle 300 along the track 105 within the passage 100. The steps for driving the acquired vehicle 300 may include driving a first drive wheel 310 on one side of the passage 100 and driving a second drive wheel 310 on the other side of the passage 100.

[0257] The process of emptying the sorting container 20 may include the step of transferring the sorting container 20 from the acquisition vehicle 300. The sorting container 20 may be transported from the acquisition vehicle 300 at the discharge point 400. Optionally, the sorting container 20 may be transported by operating the transfer mechanism 350 to push it out of the acquisition vehicle 300.

[0258] The step of moving the sorting container 20 from the acquisition vehicle 300 at the discharge location 400 may be the same as, but in the reverse order, the step of transferring the sorting container 20 from one of the storage locations onto the acquisition vehicle 300. For example, Figures 11A to 11D show the step of transferring the sorting container 20 from one of the storage locations when the central control unit 800 determines that all items within a predetermined group have been stacked in the sorting container 20. In Figure 11A, the acquired vehicle 300 is positioned in the storage area, and the support surface 320 of the acquired vehicle 300 is at the same height as, or slightly lower than, the bottom surface of the sorting container 20. In Figure 11B, the transfer mechanism 350 extends to the storage location. In Figure 11C, the engaging elements 355 and 357 are moved to engage with the sorting container 20. In Figure 11D, the transfer mechanism 350 is retracted with the engaging elements 355 and 357 engaged with the sorting container 20, and the sorting container 20 is transferred onto the acquisition vehicle 300. In contrast, the process of transferring the sorting containers 20 from the acquisition vehicle 300 may begin with aligning the acquisition vehicle 300 with the conveyor or guide mechanism 430 of the discharge point 400. Next, with the engaging element engaged with the sorting container 20, the transfer mechanism 350 extends, causing the sorting container 20 to be moved from the acquisition vehicle 300.

[0259] The sorting container 20 may include a movable wall, and the process of discharging items from the sorting container 20 may include a step of displacing the movable wall. For example, the acquisition vehicle 300 may include an actuator that can operate to displace a movable wall to discharge items from the sorting container 20. Alternatively, the sorting container 20 may displace its movable wall in cooperation with the mechanism of the discharge station 400. In this embodiment, the bottom wall of the sorting container 20 is displaceable, and the process includes supporting the sorting container 20, thereby displacing the bottom wall to the open position and allowing items to fall from the bottom of the sorting container 20.

[0260] The process of discharging items from the sorting container 20 may include the step of aligning the sorting container 20 with a guide mechanism 430 or 435 that directs the items toward the container 500. After the step of aligning the sorting container 20 with the guidance mechanism 430, the sorting container 20 is opened and the guidance mechanism 430 directs the items into the container 500.

[0261] The item discharge process optionally includes aligning an empty container 500 with a guide mechanism 430 that guides items discharged from the sorting container 20. The process of aligning the empty container 500 may include the step of transporting the empty container 500 along the container input conveyor 650 to the discharge location 475. The method may further include the step of engaging the empty container 500, which holds the empty container 500 at the discharge point 475 by engaging the empty container 500 at the discharge point 475 while the items are being transferred from the sorting container 20 into the container 500. The step of engaging the empty container 500 may include the step of clamping the empty container 500 in place, or the step of restricting the movement of the container 500 by engaging the container 500 between one or more stoppers.

[0262] The full container after the items have been transferred into container 500 is shown as 510 in Figures 1 and 2. When the full container 510 is transported from the discharge point 475, the empty container 500 is moved to the discharge point 475, making it possible to receive items from the next sorting container 20. The full container 510 may be transported by a horizontal conveyor such as a transfer conveyor 660, which may then transport the container 510 along with the sorted items to an output conveyor 700 that transports the container 510 from the sorting device 15.

[0263] Referring to Figures 15 to 21, the process of discharging items from the sorting container 20 may include the step of dropping the items onto a nearly horizontal conveyor 460. The horizontal conveyor 460 may transport items toward a discharge point 475 which is aligned with a container 500 located below the horizontal conveyor 460.

[0264] The process of transporting items toward the discharge area 475 may include the process of driving side wall conveyors 462 and 464 that sandwich the horizontal conveyor 460 and are inclined relative to the horizontal conveyor 460. The side wall conveyors 462 and 464 are driven in the forward direction to transport items downward toward the horizontal conveyor 460 and toward the discharge area 475.

[0265] This method may optionally include a step of moving the side wall conveyors 462 and 464 relative to each other, thereby increasing the distance between them.

[0266] The method for discharging items may optionally include a step of detecting whether items are jammed somewhere along the path between the sorting container 20 and the empty container 500. Furthermore, the material handling system 10 may include an item-moving step in which it attempts to free stuck items by moving them along a path. For example, the method may include the step of twisting items that may be jammed along the path of the horizontal conveyor 460 by driving one side wall conveyor 462 in the forward direction while driving a second side wall conveyor 464 in the reverse direction.

[0267] Optionally, the item discharge process may include a step of gradually releasing items from the sorting container 20. This prevents items from being released or transferred all at once. Releasing items in stages can limit or minimize the possibility of items getting stuck when being transported into Container 500. The step of gradually releasing items from the sorting container 20 may include the step of gradually opening the movable walls of the sorting container 20. For example, the movable wall may include multiple sections such as door sections 25A, B, and C, and the method may include the step of sequentially opening these door sections 25A, B, and C. Alternatively, the method may include a step of gradually opening the movable wall of the sorting container 20, thereby gradually widening the opening of the sorting container 20 from which items are discharged by gradually opening or moving the movable wall of the sorting container 20.

[0268] After the items have been discharged from the sorting container 20, this process may include the step of transferring the sorting container 20 back onto the acquisition vehicle 300. The step of transferring the sorting container 20 back onto the acquisition vehicle 300 may include the step of closing the movable wall while the sorting container 20 is being transferred onto the acquisition vehicle 300.

[0269] After transferring the empty sorting container 20 back onto the acquisition vehicle 300, the acquisition vehicle 300 may move vertically or horizontally within the passage 100 to follow a route to an empty storage location (i.e., a storage location without the sorting container 20). This empty storage location may be the same as the storage location where the acquiring vehicle 300 acquired the sorting container 20, or it may be a different storage location. When the acquisition vehicle 300 arrives at the empty storage location, the acquisition vehicle 300 transports the empty sorting containers 20 to the storage location by performing the steps shown in Figures 11A to 11D in reverse order.

[0270] The step of transporting the empty sorting container 20 to an empty storage location may include the step of operating the holding mechanism to the released position while the sorting container 20 is being transported to the storage location, and then operating the holding mechanism to the held position so that the holding mechanism engages with the sorting container 20 and holds the sorting container 20.

[0271] As described above, this method may include a step of discharging the full sorting container 20 from the sorting system 15, rather than emptying the full sorting container 20. In this method, items may be sorted into sorting containers 20 as described above, and sorting containers 20 may be retrieved when they are full. The acquired sorting containers 20 may then be transported to one of the discharge points 400 as described above. At the discharge point 400, instead of transporting the sorting container 20 from the acquisition vehicle 300 to empty it, the sorting container 20 is transported onto a conveyor belt at the discharge point 400. For example, the full sorting container 20 may be transferred from the sorting system 15 by moving it onto the transfer conveyor 660.

[0272] The method may further include the step of transporting the full sorting containers 20 onto a conveyor belt at the discharge point 400 by the acquisition vehicle 300, and then transferring the empty sorting containers 20 onto the acquisition vehicle 300. For example, the material handling system 10 may include a conveyor that supplies empty sorting containers 20 to the discharge point 400. This conveyor may be controlled to move empty containers 505 to the discharge area 400 after the acquisition vehicle 300 has discharged the full sorting containers 20. Subsequently, the acquisition vehicle 300 may transfer empty sorting containers 20 onto the acquisition vehicle 300 in the same manner as when the acquisition vehicle 300 acquires full sorting containers 20 from the storage location, as described above.

[0273] Once the empty sorting containers 20 are loaded onto the acquisition vehicle 300, the acquisition vehicle 300 may move to one of the empty storage locations and transfer the empty sorting containers 20 to the empty storage location as described above.

[0274] Furthermore, the process of discharging the full sorting container 20 from the acquisition vehicle 300 may include a step of automatically emptying the sorting container 20 after it has been transported from the discharge point 400.

[0275] Referring to Figures 22A to 22C, the step of emptying a full sorting container 20 may include the step of operating the output conveyor 700 to transport the full sorting container 20 from the sorting device. The output conveyor 700 may transport the full sorting container 20 toward an opening on the conveyor 650 that transports the empty container 505 located at the discharge point 400, so that the empty container 505 can receive items from the sorting container 20. The sorting container 20 may, while positioned on top of the empty container 505, discharge items into the empty container 505.

[0276] A method for discharging items from the sorting container 20 may include a step of supporting the sorting container 20 while positioning it over a gap in the output conveyor 700 so that the bottom of the sorting container 20 can open freely. When the bottom door 25 of the sorting container 20 is opened, the items inside the sorting container 20 can fall into the box 505 below. After items are discharged from the sorting container 20, the sorting container 20 moves along the output conveyor 700, and the full container 505 moves along the container input conveyor 650.

[0277] Referring to Figures 23A to 23C, the process of emptying the sorting container 20 may include the step of operating the movable sections 725A and 725B of the output conveyor 700 to selectively form an opening. Such a process may include the step of identifying a location from which items should be discharged from the sorting container 20 and transporting the full sorting container 20 toward that location. Furthermore, this process may include the step of operating the container input conveyors 650A and 650B to position empty containers 505 in specific locations for emptying the sorting containers 20. Furthermore, this method may include the step of operating a movable conveyor section to create a gap within the output conveyor 700 by operating the movable conveyor section at a specific location. Furthermore, the method may include a step of supporting the sorting container 20 so that the bottom door 25 of the sorting container 20 can be opened to allow items to be discharged from the sorting container 20 into the container 505.

[0278] Optionally, this process may include the step of creating an empty container and transporting the empty container toward the discharge point 400. Optionally, this process may include the step of creating several empty containers having different physical characteristics and selecting a discharge point 400 to which the containers will be transported based on the physical characteristics of the empty containers.

[0279] It should be understood that the method described above may include the step of sorting items into the sorting container 20 while the acquiring vehicle 300 acquires the sorting container 20 from the storage location, moves the acquired sorting container 20 to the discharge point 400, empties the acquired sorting container 20, and / or returns the empty sorting container 20 to the empty storage location.

[0280] In the above explanation, items are sorted into sorting containers 20 before being discharged from one of the 400 discharge points. However, please understand that this process may also include a step of transporting items, where the items are transported directly to the discharge point 400 and then discharged into containers. In this way, certain items are transported directly to the container without passing through the sorting container 20, and become transferable from the sorting device.

[0281] In some cases, items within a group (such as items in an order) may be too large or too numerous to fit into a single sorting container 20. In such cases, the central control unit 800 controls the transport vehicle 200 to transport the items into two or more separate sorting containers 20. Since these sorting containers 20 are identified collectively for a single order, no sorting container 20 is retrieved until all items for the order have been sorted into the sorting container 20 identified for that order. Subsequently, the material handling system 10 retrieves multiple sorting containers 20, transports each sorting container 20 to one of the discharge points 400, and all items in each sorting container 20 are discharged into a single container. Thus, this method may include the step of holding the container at the discharge location 400 after the initial sorting container 20 has discharged items into the container and become empty.

[0282] Alternatively, the multiple sorting containers 20 may be sequentially transported to the discharge location 400, and then sequentially discharged into multiple empty containers to be emptied. The central control unit 800 may identify each individual container and identify them as belonging to the same order.

[0283] The material handling system 10 may process item groups and control the order in which items are sorted into multiple sorting containers 20. Furthermore, the material handling system 10 can also control the order in which containers are acquired by the acquisition bot 300.

[0284] According to one embodiment, the material handling system 10 may sort multiple items for a single order into multiple sorting containers 20. The sorting of items may be performed by multiple sorting containers 20 operating within the passage 100, as described above. The material handling system 10 may determine, based on the first characteristic, which sorting container 20 to sort the ordered items into. For example, the first characteristic may be the weight of the item, and the material handling system 10 may sort items whose weight exceeds a threshold into the first sorting container 20 and items whose weight falls below the threshold into the second sorting container 20. Thus, the material handling system 10 may sort items for a single order into multiple sorting containers 20 based on the characteristics of each item, thereby sorting items with common characteristics together into one sorting container 20.

[0285] The first characteristic may be any of the various characteristics of the item, including but not limited to length, width, height, weight, fragility, density, volume, and shape.

[0286] The material handling system 10 may also control the acquisition order of the sorting containers 20 by the acquisition bot 300. One way to control the order in which the sorting containers 20 are acquired is to acquire them in the order in which they become full. Specifically, when the last item for an order is sorted into sorting container 20, the sorting container 20 may be identified as full or as ready for pickup. The material handling system 10 may determine the priority for acquiring the sorting containers 20 based on the order in which each sorting container 20 is identified as full, or the order in which it is identified as ready for acquisition.

[0287] The material handling system 10 may control the order in which the sorting containers 20 are retrieved in order to maintain order consistency, rather than controlling the order in which the sorting containers 20 are identified as full or ready for retrieval. Specifically, if items for a given order are sorted into multiple sorting containers 20, the material handling system 10 may delay retrieving any of the sorting containers 20 for the order until all items for the order have been sorted. For example, suppose an order includes items A through F, and items A, B, and C are sorted into the first sorting container 20, and items D, E, and F are sorted into the second sorting container 20. When items A, B, and C are sorted into the first sorting container 20, all items have been sorted into the first sorting container 20, and therefore the sorting container 20 can be considered full. However, if any of items D, E, or F has not yet been sorted into the second sorting container 20, the material handling system 10 may delay acquiring the first sorting container 20. Specifically, the first sorting container 20 does not need to be designated as ready for pickup until all items have been sorted into all sorting containers 20 for the order. Once the last item for the order has been sorted, all sorting containers 20 containing items for the order may be designated as ready for pickup.

[0288] When all sorting containers 20 for an order are designated as ready for pickup, the material handling system 10 may control the pickup of the sorting containers 20 and process the items for the order in batches. For example, in one application, all items from multiple sorting containers 20 for a single order may be discharged into a single container at one of the discharge points 400. In such cases, the sorting containers 20 for orders are acquired sequentially and transported to a common discharge point 400. A single container is held at the discharge point 400 until all items from the 20 sorting containers for the order have been discharged into the container. Afterward, the container, now full of all the items for the order, is moved from Discharge Point 400.

[0289] In another application, instead of discharging items from multiple sorting containers 20 for a single order, an electronic tag associated with a single order may be attached to those sorting containers 20, and those sorting containers 20 may be processed together by sequentially discharging them from the sorting system 15. For example, the material handling system 10 may control the discharge of other sorting containers 20 for other orders so that all sorting containers 20 for a single order are discharged sequentially without any other sorting containers 20 for other orders being inserted between multiple sorting containers 20 for a single order on the conveyor. In this way, multiple sorting containers 20 for a single order are transported continuously along the output conveyor (such as the conveyor 700).

[0290] As described above, items for ordering are sorted into multiple sorting containers 20 based on the characteristics of the items, and items with similar characteristics may be sorted into the same sorting container 20. Based on the characteristics of the items in the sorting container 20, it may be desirable to retrieve the sorting container 20 in a specific order. For example, an order containing multiple items may be sorted into multiple sorting containers 20, such as two sorting containers 20. The first sorting container 20 may sort items whose weight exceeds a certain threshold. The second sorting container 20 may be used to sort items with a weight below its threshold. After the ordered items have been sorted into two sorting containers 20, the material handling system 10 may first retrieve the first item, transport the first sorting container 20 to the discharge point 400, and discharge the heavier items into a container. Subsequently, the material handling system 10 may acquire the second sorting container 20, transport the second sorting container 20 to the discharge point 400, and discharge the lighter items into the container. In this way, the material handling system 10 avoids discharging heavier items in an order onto lighter items, thus preventing damage to the lighter items. Therefore, the material handling system 10 can operate to sequentially acquire multiple sorting containers 20 so that items are discharged into a common container based on the physical characteristics of the items in the order.

[0291] As described above, the material handling system 10 is capable of sorting items into sorting containers 20 and then discharging items from one or more sorting containers 20 into containers. Optionally, the material handling system 10 may also include one or more elements that push the items back into the container after they have been discharged into it. For example, after items are placed in a container, one or more items may protrude above the top edge of the open container. The material handling system 10 may include a structure configured to push the protruding item downward into the box. This structure is preferable when protruding items are pushed below the top edge of the box.

[0292] Optionally, the structure for pushing items into the container may include a height limit bar that extends across the entire width of the container. This bar extends to a predetermined height, for example, the height of the edge of the box. The bar may be positioned adjacent to the discharge area 400 so that the box passes underneath it as it is transported from the discharge area 400. In this way, items that protrude above the edge of the container will hit the height limit bar as the container passes under the bar, and will be pushed downwards into the container.

[0293] Optionally, the structure that pushes items into the container may include a soft element such as a curtain that extends across the entire width of the conveyor adjacent to the discharge point 400, so that the container passes under the curtain as it is transported away from the discharge point 400. The curtain hangs down above the container and extends below the top edge of the container. Optionally, the curtain may be made up of multiple panels, forming a segmented curtain with separate panels. In this way, if an item inside the container protrudes above the edge of the container, the curtain will push the item downwards into the container as the container passes underneath it.

[0294] Therefore, the material handling system 10 may optionally include a step of discharging items into a container and a step of making contact with items that are protruding beyond a threshold, thereby pushing the items downward into the container. Optionally, the step of making contact with items that protrude beyond a threshold may be performed during the step of moving the container from the discharge point 400.

[0295] Another embodiment of the material handling system 10 may include the steps of obtaining an item sorting container 20 and discharging the items from the sorting container 20 into a container. The step of discharging items into a container may include the step of dropping items into the container. The material handling system 10 may also include a step of organizing the items inside the container by shaking or rattling the container. For example, this method may include a step of shaking the container back and forth. Similarly, this method may include a step of vibrating a container to arrange items by vibrating the container. Optionally, the step of arranging the items inside the container may be performed while the container is located at discharge point 400.

[0296] The above description described a material handling system 10 having a sorting system with a single aisle. However, the material handling system 10 may include multiple passages, and each passage system may be configured as described above. Optionally, a multi-aisle system may be provided with a feed system that delivers items to be sorted to each aisle. The transport system may include, but is not limited to, transport vehicles 200 or conveyors, any of the various systems available.

[0297] The central control unit 800 may be configured to control the feeding system such that the feeding system sends a first item group to a first sorting passage and a second item group to a second passage. Thus, the first passage may be used to process items having the first characteristic, and the second passage may be used to process items having the second characteristic. The characteristics used by the feeding system to determine the path through which an item is sent may be any of a variety of characteristics, including physical characteristics such as size, weight, and shape. However, the characteristics do not have to be the physical attributes of the item.

[0298] Therefore, the material handling system 10 may include the step of sending items through multiple passages of a sorting device. Each passageway may be configured to sort items into multiple sorting locations and to stack the items in those locations. Once the sorting of items for an order is complete, the sorting device may use an acquisition device to acquire the sorted containers 20 for the completed order and transport the sorted containers 20 to the discharge area 400. At the discharge point 400, the sorting containers 20 are either emptied or unloaded and transported from the sorting equipment. Optionally, the material handling system 10 may include a step of detecting the characteristics of each item and determining the path through which the item is sent. Furthermore, the material handling system 10 may include a step of controlling the feeding system to selectively feed items based on a step of determining the path through which the items are fed.

[0299] As described above, the material handling system 10 may also operate by stacking items in the sorting container 20, and when the sorting container 20 is full, retrieving the sorting container 20 and discharging the items onto a conveyor belt rather than discharging them from the sorting container 20 into another container (see, for example, Figures 22A to 22C, Figures 23A to 23C, and the above description). In the above description, the material handling system 10 is described as sending empty sorting containers 20 to the acquisition vehicle 300 after the acquisition vehicle 300 has unloaded full sorting containers 20 onto the output conveyor 700. However, for certain purposes, it may be preferable to load a sorting container 20 that already contains items onto the acquisition vehicle 300, rather than loading an empty sorting container 20 onto it. Therefore, after the acquisition vehicle 300 has discharged the sorting container 20 from the passageway, the material handling system 10 may send a replacement container toward the acquisition vehicle 300. The replacement container may be an empty container or a container that contains one or more items. The replacement container may then be loaded onto the acquisition vehicle 300. Subsequently, the acquired vehicle 300 transports the replacement containers to one of the sorting locations, where the items are sorted into the replacement containers.

[0300] In yet another embodiment, a system is provided for sorting items using multiple passages. This system may use multiple lanes to sort items for a single order. For example, as described above, the material handling system 10 may include a step of sorting items into first and second sorting passages based on the characteristics of the items. Furthermore, as described above, the material handling system 10 may be configured to send a replacement container to the sorting passage after the sorting container 20 has been discharged from the passage, and the discharged sorting container 20 may be replaced with a replacement container containing items. Therefore, multiple items may be sorted into a first sorting container 20 in a first storage area adjacent to the first aisle. Optionally, items may be sorted into the first sorting container 20 using multiple sorting vehicles 200, as described above. The first acquisition vehicle 300 in the first passage may acquire the first sorting container 20 and discharge the sorting container 20 from the first passage. The discharged sorting containers 20 may be transported to a second passage. A second acquisition vehicle 300 located in the second passage may acquire the first sorting container 20 at an input / output location or an output location 400. Subsequently, the second acquisition vehicle 300 may transport the first sorting container 20 along the second passage to the second sorting location. Subsequently, while the first sorting container 20 is in the second storage location, one or more items may be sorted into the first sorting container 20. For example, one or more transport vehicles 200 may move along a second aisle and sort one or more items into a first sorting container 20 located in a second storage area.

[0301] Optionally, the material handling system 10 may also include the step of acquiring the first sorting container 20 using an acquisition vehicle 300 in the second sorting passage after the first sorting container 20 has received all the necessary items from the second sorting passage. In this way, the first sorting container 20 contains items from both the first and second aisles. Subsequently, the acquisition vehicle 300 transports the first sorting container 20 to the discharge station 400, where the first sorting container 20 is discharged from the second passage.

[0302] As shown in Figures 1 and 2, the material handling system 10 may include one or more discharge points 400 located along the passage 100 of the sorting system 15. Although the material handling system 10 is shown to include a discharge area 400 located on one side of the passage 100, it should be understood that the discharge area 400 may be located on either side of the passage 100. Furthermore, the discharge area 400 may be located on both sides of the passage 100.

[0303] The material handling system 10 may operate in such a way as to shorten the cycle time when one of the acquisition vehicles 300 discharges a sorting container 20 from the sorting system 15. For example, if the sorting system 15 includes discharge points 400 on both sides of the passage 100, and the two discharge points 400 are arranged in the same row, the material handling system 10 may control the flow of replacement totes to the discharge points so that the acquisition vehicle 300 loads replacement sorting containers 20 onto the acquisition vehicle 300 at one discharge point 400 while simultaneously discharging the full sorting containers 20 to the second discharge point 400.

[0304] The process of loading and unloading the full sorting container 20 while simultaneously loading replacement containers will be explained with reference to Figures 8 to 10. Specifically, when the acquisition vehicle 300 is at a predetermined position within a passage 100 having a first discharge area 400 on one side and a second discharge area 400 on the second side, the acquisition mechanism 350 on the acquisition vehicle 300 may extend toward a replacement container at the first discharge area 400 while the full sorting container 20 is placed on the support surface 320. Specifically, the material handling system 10 may control the feeding of the replacement containers to transport them so that they are positioned at the first discharge location 400. The acquisition mechanism 350 can engage with the replacement container and pull the replacement container toward the acquisition vehicle 300. When the acquisition mechanism 350 pulls the replacement container toward the support surface 320, the acquisition mechanism 350 pushes the full sorting container 20 away from the support surface 320 toward the second discharge area 400, which is opposite the first discharge area 400. For example, as shown in Figure 10, the acquisition mechanism 350 may include a front latch 355 and a rear latch 357. The front latch 355 pulls the replacement container onto the retrieval vehicle 300, and the rear latch 357 pushes the full sorting container 20 out of the retrieval vehicle 300. By loading replacement containers while simultaneously pushing out the full sorting container 20, the material handling system 10 may reduce the time the acquisition bot waits at the discharge point 400.

[0305] Figure 24A is a block diagram showing a warehouse operation or distribution center configuration that utilizes a warehouse management system and incorporates a material handling device configured according to the embodiments described above and other embodiments described later.

[0306] Figure 24A is a block diagram showing one or more sorting and container acquisition / exchange (SBRE) systems generally represented in 2410-1 through 2410-n. These systems can operate to sort the items assigned to each item group into designated sorting containers temporarily associated with the item group. Item groups correspond to the items necessary to fulfill an order. In the embodiment shown in Figure 24A, the item group corresponds to the items necessary to fulfill the order. In Figure 24A, the roles of sorting and sorting retrieval, discharge (emptying), and / or transport are managed under the direction of a centralized warehouse management system 2420, which forms part of the order fulfillment arrangement 2400. As shown in Figure 24A, the order fulfillment arrangement 2400 also includes the order entry and scheduling system, which is generally shown in 2435, and in this system, for example, an administrator can set a minimum inventory threshold for replenishment warnings and track inventory levels when new orders are received and processed. The order fulfillment configuration 2400 optionally includes a return authorization (RMA) processing system 2450, in which return items approved for return to stock are processed and may be sent as input items to one or more SBRE2410s, such as SBRE2410-1 through SBRE2410-n (depending on the order flow), or returned to one or more storage locations of automated storage and retrieval systems (ASRS), as generally indicated in 2460-1 through 60-m.

[0307] Figure 24B is a block diagram showing in more detail one or more sorting and sorting container retrieval / exchange systems (SBREs) whose operation is coordinated by the warehouse management system (WMS) 2420, which can be performed in the operation of an order fulfillment center such as the order fulfillment center 2400 shown in Figure 24A, as SBRE systems 2410-1 to 2410-n. SBRE2410-1 includes a control device 2413, an item input station 2414, a transport mechanism 2415 which in one embodiment includes an independent mobile vehicle configured to receive a plurality of items arriving at the input station 2414 and transport them to an array of a plurality of sorting containers, and a sorting container acquisition mechanism 2416 which in one embodiment includes an independent mobile vehicle configured to take out a plurality of sorting containers when a group of items for an order to be processed by an order fulfillment center or distribution center has been stacked into a plurality of sorting containers, and is configured to transport the taken-out sorting containers to a transport station, as will be described in detail later, thereby transporting the sorting containers out of SBRE2410-1 in a batch. In the latter, SBRE2410-1 further includes one or more feed conveyors, outgoing conveyors, and lateral feed conveyors, similar to the embodiments described above. The contents of the sorting container may be discharged and transferred to another container (for example, cartons or other packaging for shipment to customers, or, in the case of a distribution center, larger containers such as pallet boxes for transport to sales locations). The term "exchange" used here refers to both the transfer of the contents of a sorting container from the system without emptying them, and the transfer of the contents of a sorting container to another container. <Regarding shipping>

[0308] In the latter case, the empty sorting container may be returned to an available location where a new group of items (for example, items that can be sorted to different customers or delivery destinations) may be stacked on top. A container that has received items discharged from the first sorting container in the first discharge area may remain in that discharge area to receive other items necessary to fulfill the order requirements. Alternatively, a partially full container may be transferred to another SBRE2410 (SBRE2410-n) by the control device 2413 of SBRE2410-1 using one of the feed / discharge conveyors, and receive additional items in the discharge area of ​​that other SBRE2410. Furthermore, a partially full sorting container may receive additional items at another location outside of SBRE2410, where, for example, items exceeding the handling limits of delivery system 2415 may be incorporated into the remaining items applicable to the order.

[0309] In the former case, a separate feed / discharge conveyor may be used in a different type of discharge area to receive the sorting container without discharging its contents, and then transport the sorting container from SBRE2410-1 to a destination away from SBRE2410 in SBRE2410-n.

[0310] The transport mechanism or transport system 2415 shown in Figure 24B is generally implemented in a first group of self-propelled transport vehicles indicated by reference numerals 2415-1 to 2415-j, and the acquisition mechanism or acquisition system 2416 is generally implemented in a second group of self-propelled sorting container acquisition vehicles indicated by reference numerals 2416-1 to 2416-m. The first group of transport vehicles 2415-1 to 2415-j and the second group of acquisition vehicles 2416-1 to 2416-m are tracked along horizontal and / or vertical sections of an item acquisition path that connects an input station of an SBRE 2410, such as item input station 2414, to an output station or output area of ​​that SBRE 2410. In one embodiment, transport vehicles 2415-1 to 2415-j and acquisition vehicles 2416-1 to 2416-m receive instructions from the control device 2413 when it is necessary to define an appropriate item acquisition route for each transport vehicle 2415 as it travels along a path from the point where it receives items from the guidance module to the point where it discharges items into a sorting container. A gate mechanism is provided at the intersection of the horizontal and vertical tracks, which is mechanically operated by a transport vehicle such as transport vehicle 140-1, and the transport vehicle is guided along both the horizontal and vertical sections that define the vertical ring path.

[0311] Both vehicle groups 2415 and 2416 have multiple types of transfer mechanisms and are capable of simultaneously performing both the functions of transporting items and retrieving sorting containers. In other embodiments, a small number of vehicles configured to have only sorting and retrieval functions may be used, and these vehicles may move between multiple lanes depending on the level of sorting work performed by the item transport vehicles within each lane of each SBRE2410. The number of vehicles responsible for sorting and retrieval functions can be far fewer than the number of vehicles performing sorting work, for example, around 15% to 35%.

[0312] At the discharge site of the SBRE2410, optional discharge assist devices such as a downward-sloping ramp or a discharge conveyor may be provided, as shown in Figures 15 to 21. In the embodiment shown in Figure 24B, the discharge auxiliary conveyor systems 2419-1 to 2419-p incorporate, in addition to the aforementioned horizontal conveyor, first side wall conveyor, and second side wall conveyor, a sensor 2418 as an input means for reversible control of conveyor drive motors (not shown) that operate the horizontal conveyor, first side wall conveyor, and second side wall conveyor of the discharge conveyor.

[0313] The WMS2420 shown in Figure 24B functions as a control device that directs the operation of one or more SBRE systems 2410, such as system 2410-1. Therefore, the WMS2420 includes a central processing unit (CPU) 2402, an input / output interface 2406, support circuitry 2408, memory 2404, and one or more network interfaces 2401. The CPU 2402 is configured to execute the sorting and container acquisition / discharge and exchange (SBRE) control module, which includes the item transport control module 2430 and the sorting container acquisition control module 2440, by retrieving and executing commands stored in memory 2404. The SBRE control module includes an item transport control module 2430 which includes a sorting container item group scheduler 2432, an item guidance event monitor 2434, an item group completion warning generation unit 2438, and a sorting container availability monitor. These modules perform functions that allow the item transport control module 2430 to specify the destination sorting container for each item subject to at least one order and / or a valid RMA replenishment process. Memory 2404 also includes other WMS modules 2455 and operating system 2457.

[0314] The sorting container acquisition control module 2440 includes a sorting container acquisition sequencer, a sorting container destination selection unit 2444, a container feed conveyor control unit 2446 (for receiving items from sorting containers and exchanging containers that have left the system via a feed conveyor), a conveyor feed conveyor control unit 2448 (for moving containers and / or sorting containers from discharge points and passages), and a sorting container / container lateral feed control unit 2449 (for directing containers or sorting containers toward other discharge points and allowing them to receive items from other sorting containers before being moved from passages by a feed conveyor).

[0315] The system in Figure 25A performs sorting and the acquisition, discharge, and exchange of sorting containers in the same way as the system in Figure 24B, but uses an intermediate device (equipment control system or ECS2550) that performs some of the control functions performed by the WMS in Figure 24B. The ECS2550 includes an item stacking, discharge, and group transfer control module 2540, which includes a sorting container item group association module 2542, a sorting container position state module, a sorting container acquisition sequencer, and a sorting container destination selection unit. The item transport vehicle status monitor 2550 includes an item transport vehicle status monitor, an item transport vehicle position monitor, an acquired vehicle status monitor, a vehicle traffic control unit that manages the relative position between the transport vehicle and the acquired vehicle to avoid collisions, and an optional gate / path section control unit.

[0316] The vehicle traffic control unit provides the vehicle with a message that allows the vehicle to proceed along a section of the route to its assigned destination. Once the journey to that section is complete, the vehicle will stop unless it receives the next instruction message to proceed. Other modules include the input control unit.

[0317] The ECS2550 further includes an input control module 2530, which includes modules 2534, 2536, 2538, 2539, and 2532, and an item group integration and I / O control unit 2560, which includes submodules 2562, 2564, 2566, 2568, 2563, and 2567. Module 2532, shown as an option, is used to authenticate operators (when item input is performed by a human) to ensure product integrity and traceability in highly regulated industries, such as the medical field.

[0318] Other components common to both the apparatus in Figure 24B and Figure 25A are given the same or similar reference numerals, and these components are not described herein.

[0319] Figure 25B is a block diagram showing the functional components of the input area 2514 of the items that can form part of the system in Figure 25A. At item input location 2514, items are sequentially loaded onto an item transport system (e.g., a vehicle), thereby guiding the items into the system. Since the characteristics of items can be used to control vehicle operation, the system may need to be aware of these characteristics. In one example, these characteristics are stored in a central database and are known, and the system tracks the progress of items and obtains the item's identification information when the item arrives at item input 2514. Thus, since the item's identification information is known, system 2514 can retrieve data about the item's characteristics stored in the database. Alternatively, the items are scanned and / or weighed at item input 2514, and one or more characteristics of each item are identified.

[0320] In one embodiment, each item is manually scanned at a locator station, and one or more features of the item are detected. These features are used to verify the identification information of the item. Once an item is identified, various properties of the item may be retrieved from a central database, and the item may then be processed based on these known properties. For example, the guidance station 602 may include a scanning station for scanning product codes such as barcodes. Once the product code is determined, the system retrieves information about the product from the central database. This information will be used to control further processing of the item, as will be explained later.

[0321] In the second embodiment, the item is scanned at the induction station 602, and various physical characteristics of the item are detected. For example, the guide station 602 may measure characteristics of the item such as length, height, and / or width. Similarly, the weight or shape of the item may be detected. These characteristics may be detected manually or automatically at the induction station 602. For example, a series of sensors may be used to detect the length of an item, or a scale may be used to automatically weigh the item. Alternatively, an operator may analyze each item and input information about each item via an input mechanism such as a mouse, keyboard, or touchscreen. For example, the system may include a touchscreen that displays one or more questions or choices. One example is packaging. Are the items packaged in plastic bags, blister packs, or are they loose? Is the item flat, cylindrical, or circular? The system has default properties, and the operator may only identify an element's properties if those properties differ from the default values. For example, an item's default properties could be flat or rectangular. If an item is rounded (for example, spherical or cylindrical), the operator enters information indicating that the item is rounded, and then the item is processed accordingly. Based on the detected information, the items will be processed appropriately.

[0322] As mentioned above, the item input area 2514 may have various configurations, including manual configuration, automatic configuration, or a combination of manual and automatic functions. In a manual system, the operator inputs information for each item, and the system dispenses the items according to that information. In automated systems, the input system includes elements that scan each item and detect information about each item. The system then transports the items according to the scanned information.

[0323] The input system includes a workspace equipped with input devices such as a conveyor belt and a keyboard, as well as a monitor. The operator reads information from items such as ID tags, inputs the information from the tags into an input system using a keyboard or other input device, and places the items onto the conveyor belt. The conveyor then transports the item to input area 2514. For example, an operator may visually read the information attached to an item, or they may use an electronic scanner, such as a barcode reader, to read a barcode or other mark on the item. Sensors positioned along the conveyor belt may track items as the conveyor belt transports them towards the loading area.

[0324] Alternatively, as shown in Figure 25C, a plan view showing the components of the item input station 2514 in Figure 25B, the item input station 2514 may include a scan station 2570 that automatically detects the characteristics of the item. Specifically, the item input station 2514 may include one or more feed conveyors, such as a conveyor 2536A, which transports the items to a scanning station 2570 that is capable of receiving items and detecting one or more physical properties of the items. From the scanning station 2570, the transfer conveyor 2536B shown in Figure 25B transports the items to the loading station 2539A, where the items are either loaded onto the receiving surface of the item transport mechanism 2415 or sent to a waste container.

[0325] The input feed conveyor may be any of the various conveying devices designed to transport items. In particular, the input feed conveyor may be designed to receive items that have fallen onto it. For example, the input feed conveyor may be a horizontal conveyor belt or a horizontal roller bed formed of several substantially horizontal rollers, and these rollers may be driven so that items move along the conveyor away from the rollers.

[0326] Figures 25D and 25E illustrate an exemplary method for controlling a discharge conveyor 2650, which consists of conveyors 2662, 2664, and 2660 of the discharge auxiliary conveyor system 2600. Sensors such as the path blockage sensor 2640 detect whether an item is unable to pass through the transport path of the discharge conveyor 2650. If the process fails, steps 2621, 2622, 2624, 2625, 2626, 2628, and 2629 in Figure 25E are executed in order.

[0327] Figure 26 is a graph illustrating the exchange of messages and / or commands between multiple logical control elements of a sorting and container acquisition / discharge / exchange (SBRE) system.

[0328] Figure 27 is a flowchart illustrating an automated process in which stacked item groups are sorted into sorting containers, a vehicle is operated to retrieve the sorting containers containing the stacked item groups, the vehicle is operated in a passageway to transfer the contents of the sorting containers to another container, and / or the sorting containers containing the stacked item groups are replaced with empty containers, or the containers containing parts of the item groups to be combined with other items are replaced with containers containing those parts. Figure 28 is a flowchart illustrating an exemplary process of assigning item groups or item subgroups to the locations of sorting containers. Figure 29 is a flowchart showing the item transport vehicle traffic control process, which adjusts the movement of transport vehicles during item sorting. Figure 30 is a flowchart showing the sorting and acquisition vehicle traffic control process, which adjusts the movement of the vehicle acquiring the sorting containers while sorting and acquiring the sorting containers are being performed simultaneously in the passageway. Figure 31A is a flowchart showing the sorting container ordering process, in which the contents of multiple sorting containers are combined within the same container. Figure 31B is a flowchart showing the process of discharging and / or replacing sorting containers. Figure 32 is a flowchart illustrating a modified sorting container ordering process that uses determined information about the characteristics of one or more items or groups of items to determine the order in which the contents of multiple sorting containers are combined within the same container.

[0329] Various embodiments of methods and apparatus for organizing, enriching, and presenting message content incorporating one or more media files, as described herein, may be implemented on one or more computer systems that may interact with various other devices. One such computer system is the computer system 3300 shown in Figure 33, which may implement the illustrated elements or functions in various embodiments. Furthermore, this computer system 3300 may be configured to carry out the method described above. The computer system 3300 may be used to implement any other system, apparatus, element, function, or method of the embodiments described above. The illustrated computer system 3300 may be configured to implement in various embodiments any of the methods described and / or illustrated herein, such as method 2700 (Figure 27), method 2800 (Figure 28), method 2900 (Figure 29), method 3000 (Figure 30), and / or any other method described and / or illustrated herein, as program directives 3322 that can be executed by the processor (for example, program directives that can be executed by the processor 3310).

[0330] The illustrated computer system 1200 includes one or more processors 3310a to 3310n connected to system memory 3320 via an input / output (I / O) interface 3330. The computer system 3300 further includes a network interface 3340 connected to the I / O interface 3330, and one or more input / output devices 3350, such as a cursor control device 3360, a keyboard 3370, and a display 3380. The computer system 3300 may then use any of these components to receive the user input described above. A user interface may be generated and displayed on display 3380. In some cases, the embodiment may be implemented using a single instance of the computer system 3300, but in other embodiments, multiple such systems, or multiple nodes constituting the computer system 3300, may be configured to host different parts or instances. For example, some elements may be implemented via one or more nodes of the computer system 3300 that are different from the nodes that implement other elements. In another embodiment, multiple nodes may implement the computer system 3300 in a distributed manner.

[0331] In different embodiments, the computer system 3300 may include, but is not limited to, any of the various types of devices, including, a personal computer system, a desktop computer, a laptop, a notebook, or a netbook computer, a mainframe computer system, a handheld computer, a workshop, a network computer, an application server, a storage device, peripherals such as switches, a modem, a router, or any general type of computing or electronic device.

[0332] The computer system 3300 may be a uniprocessor system including one processor 3310, or a multiprocessor system including multiple processors 3310 (for example, 2, 4, 8, or any other appropriate number). Furthermore, this processor 3310 may be any suitable processor capable of executing instructions. For example, in various embodiments, the processor 3310 may be a general-purpose processor or an embedded processor that executes any of the various instruction configurations (ISAs). Each processor 3310 in a multiprocessor system does not necessarily need to run the same ISA, but it may be implemented in common.

[0333] The system memory 3320 may be configured to store program instructions 3322 and / or data 3324 that are accessible to the processor 3310. The system memory 3320 may be implemented using any suitable memory technology, such as static random access memory (SRAM), synchronous dynamic RAM (SDRAM), non-volatile / flash memory, or any other type of memory. In the illustrated embodiment, a program command 3322 and data 3324 that implement any element of the above-described embodiment may be stored in the system memory 3320. In other embodiments, the program instructions 3322 and / or data 3324 may be received, transmitted, or stored on various types of computer-accessible media, or similar media, separate from the system memory 3320 or the computer system 1200.

[0334] In one embodiment, the I / O interface 3330 may be configured to coordinate I / O communication between the processor 3310, the system memory 3320, and any peripheral devices in the device, including other peripheral interfaces such as the network interface 3340 or the input / output device 3350. The I / O interface 3330 may convert the necessary protocols, timings, or other data to convert data signals from one component (e.g., system memory 3320) into a format suitable for use by another component (e.g., processor 3310). The I / O interface 3330 may include elements that support devices connected via various types of peripheral buses, such as a PCI bus standard or a Universal Serial Bus (USB) standard. The functionality of the I / O interface 3330 may be divided into two or more separate components, such as a northbridge and a southbridge. Furthermore, some or all of the functions of the I / O interface 3330, such as the interface to the system memory 3320, may be directly incorporated into the processor 3310.

[0335] The network interface 3340 may be configured to enable data exchange between the computer system 3300 and other devices such as one or more display devices (not shown) connected to a network (e.g., network 3390), or one or more external systems, or between the computer system 3300 and multiple nodes. In various embodiments, the network 3390 may include, but is not limited to, one or more networks, including, a local area network (LAN) (e.g., Ethernet or an enterprise network), a wide area network (WAN) (e.g., the Internet), a wireless data network, other electronic data networks, or a combination thereof. The network interface 3340 may support communication over any suitable general-purpose data network, such as a wired or wireless Ethernet network; over a telecommunications / telephone network, such as an analog voice network or a digital optical fiber communication network; over a storage area network, such as a Fibre Channel SAN; or over any other suitable type of network and / or protocol.

[0336] The input / output device 3350 may include one or more communication terminals, keyboards, keypads, touchpads, scanning devices, voice recognition devices or optical recognition devices, or other devices suitable for inputting or accessing data by one or more computer systems 3300. Multiple input / output devices 3350 may be located within the computer system 900, or they may be distributed across various nodes of the computer system 1200. Similar input / output devices may exist separately from the computer system 1200 and interact with one or more nodes of the computer system 1200 via wired or wireless connections such as a network interface 3340.

[0337] Those skilled in the art will understand that modifications or changes can be made to the above embodiments without departing from the broad inventive concept of the present invention. For example, in the above description, the material handling system 10 is described as a series of vehicles guided by a track. However, the material handling system 10 does not necessarily need to include a track. For example, a vehicle may travel along the ground, not just along a track.

[0338] In addition to a system in which the vehicle moves along the ground without a track, the material handling system 10 may incorporate a guide assembly that includes one or more rails or other physical guide mechanisms that come into contact with the mechanism on the vehicle to move the vehicle along the path. For example, a vehicle may include one or more contact elements, such as wheels, rollers, guide tabs, pins, or other elements, each of which can engage with a guide assembly. The guide assembly may consist of linear elements, such as straight rails, or curved elements. The guide assembly may be curved in a horizontal plane so that the rail fits within that plane, or the guide mechanism may be curved vertically so that the rail lies within a single plane. To enable the vehicle to move horizontally in multiple vertical positions, the guide assembly may include multiple guide mechanisms or rails that are spaced apart from each other in a vertical direction. The guidance mechanism may also include an elevator that moves the vehicle between multiple rails that are spaced apart vertically.

[0339] As can be understood from the above description, the material handling system 10 may be incorporated into various systems that guide a vehicle along an open area by using a physical guidance mechanism or by guiding the vehicle along a route to a storage or transfer location.

[0340] The material handling systems and methods described herein may be implemented in various embodiments using software, hardware, or a combination thereof. Furthermore, the order of the methods may be changed, and various elements may be added, rearranged, combined, omitted, or otherwise modified. All embodiments described herein are presented in a non-limiting manner. Various modifications and changes may be made, as will be obvious to those skilled in the art who would benefit from this disclosure. Within the description of specific embodiments, a method for carrying out the invention according to the embodiment is described. These embodiments are illustrative and not intended to limit the invention. Many variations, modifications, additions, and improvements are possible. Therefore, multiple examples may be applied to a component described herein as a single example. The boundaries between various components, operations, and data stores are somewhat arbitrary, and specific operations are illustrated using specific exemplary configurations. Other functional assignments are conceivable and may be included in the claims described below. Finally, structures and functions shown as separate components in the exemplary configurations may be implemented as a combination of structures or components. The above-mentioned and other variations, modifications, additions, and improvements may also fall within the scope of the embodiments defined in the claims below.

[0341] Therefore, it should be understood that the present invention is not limited to the specific embodiments described herein, but is intended to include all changes and modifications that fall within the scope and spirit of the invention as described in the claims.

Claims

1. An item sorting device comprising: an input station for acquiring information used to identify multiple destinations applicable to multiple items to be sorted; multiple sorting containers; and racks configured to define a passage and support the multiple sorting containers at multiple positions spatially spaced apart along at least a first or second side of the passage, Multiple discharge points located adjacent to the aforementioned passage, A transport mechanism that can operate within the passage to transport multiple items to the multiple sorting containers, thereby stacking item groups applicable to an order, An acquisition mechanism is configured to operate within the passage, move with the passage, acquire each of a plurality of sorting containers containing a plurality of sorted items, transport each of the plurality of sorting containers within the passage to one or more locations adjacent to the discharge area, and discharge the plurality of items from at least one of the transported plurality of sorting containers into a container moved from the passage. A conveyor that moves the container from the aforementioned passage, An item sorting device characterized by having the following features.

2. The first group of sorting containers is supported by the rack along the first side of the passage, The second group of sorting containers is arranged along the second side of the passage, The item sorting device according to claim 1, wherein the acquisition mechanism is operable to move the plurality of sorting containers into the passage.

3. The item sorting device according to claim 1 or claim 2, wherein the acquisition mechanism is movable vertically and / or horizontally within the passage.

4. The item sorting device according to any one of claims 1 to 3, wherein the transport mechanism includes a plurality of transport vehicles that can operate independently.

5. The aforementioned plurality of transport vehicles include a transport mechanism, The item sorting device according to claim 4, wherein the transfer mechanism is operable in a first direction to transfer items from the plurality of transport vehicles to one of the plurality of sorting containers along the first side of the passage, and is operable in a second direction to transfer items from the transport vehicles to one of the plurality of sorting containers along the second side of the passage.

6. The item sorting apparatus according to claim 4 or 5, wherein the plurality of transport vehicles are operable to move along a vertical annular path within the passage.

7. Each transport vehicle includes an energy storage device that provides power for the operation of the transport vehicle, An item sorting device according to any one of claims 4 to 6, wherein a charging element is provided in the passage for charging the plurality of transport vehicles as they move within the passage.

8. The item sorting device according to any one of claims 4 to 7, further comprising a track for guiding the plurality of transport vehicles to the plurality of sorting containers.

9. The item sorting device according to any one of claims 1 to 8, wherein the acquisition mechanism includes a plurality of acquisition vehicles.

10. The item sorting apparatus according to claim 9, further comprising a transfer mechanism configured such that the plurality of acquisition vehicles engage with the plurality of sorting containers.

11. The item sorting apparatus according to claim 9 or 10, wherein each of the acquisition vehicles includes an energy storage device that provides power for the operation of the acquisition vehicle.

12. The item sorting apparatus according to any one of claims 9 to 11, comprising one or more discharge ports configured to receive items after they have been sorted into the sorting containers.

13. The item sorting device according to any one of claims 1 to 12, wherein the plurality of sorting containers include a movable wall.

14. The item sorting apparatus according to claim 13, wherein the discharge station is configured to facilitate the movement of the movable wall so that an item can be discharged from the sorting container when one of the plurality of sorting containers is transported to the discharge station.

15. A method for sorting multiple items into multiple groups, At the loading area, the process involves loading multiple items one by one onto a transport mechanism that can move within the passageway, A step of operating the transport mechanism in the passage, thereby transporting items to each of a plurality of sorting containers arranged along the passage, A step of transporting each loaded item along a vertical annular path within the passage, wherein the vertical annular path includes the loading location and each destination adjacent to one of the plurality of sorting containers, The steps include operating the transfer mechanism of the transport mechanism to place items into each of the plurality of sorting containers and stacking item groups in the plurality of sorting containers, The steps include operating the transport mechanism within the passage, A step of determining that the item group assigned to the sorting container has been stacked in the first sorting container, The step of obtaining the first sorting container, The steps include moving the acquisition mechanism within the passage to a position adjacent to the first sorting container, The steps include: moving the first sorting container and the stacked items into the passage while holding the first sorting container; The steps include transporting the first sorting container to the first discharge point within the aforementioned passage, The first discharge point involves discharging the stacked items from the first sorting container to a first container located away from the passageway, The steps include moving the first container in a direction parallel to the passage, The second discharge point includes the step of receiving the stacked items from the second sorting container acquired by the sorting mechanism into the first container, The steps include transporting the first container from the second discharge point, A step of obtaining the first sorting container, which includes, A method for sorting multiple items, including [specific item], into multiple groups.

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