Modular Package Sorting System

Abstract

The present invention relates to a system and method for sorting a wide variety of packages, including, but not limited to, parcels, mail pieces, bundles, and other similar items. Embodiments of the present invention relate, inter alia, to interchangeable sorting modules having sorting stations that can be used to quickly and accurately sort packages of various shapes and sizes. A further aspect of the present invention relates to a control architecture for operating such interchangeable sorting modules. Such a control architecture may include a programmable logic controller for controlling each of the interchangeable sorting modules.

Description

[Technical Field]

[0001] This application claims priority to U.S. Patent Application No. 16 / 537,503, filed August 9, 2019.

[0002] The present invention relates to a system and method for sorting a wide range of packages, mail pieces, bundles and other items commonly handled in e-commerce shipping facilities and distribution centers by utilizing modular product handling components. More particularly, the present invention relates to a control architecture for such modular sorters. [Background technology]

[0003] The volume of products sorted and transported by material handling systems is increasing rapidly in the United States and around the world. Much of the volume increase can be attributed to the growth of e-commerce, whereby products are purchased over the Internet by consumers and businesses without the intermediation of a physical retail store and delivered from fulfillment centers where individual orders are selected from inventoried inventory, packed, and shipped directly to the purchaser. The majority of e-commerce shipments are smaller in size and weight than a case or pallet.

[0004] Automated sorting systems are a key technology that enables fulfillment centers and shipping organizations to prepare large volumes of orders for shipment and move them through sometimes complex logistics systems to buyers. High speed, low cost, and automated operation are key attributes for efficiency and competitiveness. Two of the most common sorter types are loop sorters and linear sorters.

[0005] Loop sorters are typically housed in a large building and resemble small trains with multiple package-holding segments (hereafter referred to as "cars" or "sorter trays") moving rapidly around a closed loop. Along one portion of the loop, packages are transferred onto individual cars at so-called "guidance stations." The packages at a given guidance station can be of various shapes and / or sizes. As the sorter car moves around the loop, there are numerous locations, called "sort points," where the train's contents can be transferred, or "sorted," to containers or attached conveyors. Various methods are used to remove product from the sorter car. Methods include tipping the car on its side, driving a lateral conveyor belt over the car, and dropping product through the car via a "bomb bay" door. Linear sorters perform the same transport and sorting functions as loop-style sorters.

[0006] A linear sorter directs items onto a single linear conveyor, where all packages enter the sorter's head and are then released into bins located on the right or left side of the sorter spine. The conveyor functions to move packages to the right or left at the correct time to eject them into a waiting bin or into a further conveyor designated by the sorter system. Typical ejection methods include "shoes," in which a mechanism embedded within the conveyor moves left and right to push packages off the conveyor, and "pusher" methods, in which a fixed actuator external to the conveyor pushes packages left and right at the exact moment they are ejected from the conveyor.

[0007] More recently, different types of sorters have been developed that utilize conveyor belts composed of many plastic or metal links with multiple rotating or other moving elements embedded in the conveyor belt structure. The tops of the moving elements contact the products being conveyed, and the bottoms of the elements contact fixed or moving mechanisms below the conveyor belt. When these elements contact the mechanisms below the conveyor belt, their movement can be controlled, thus altering the movement of items on top and deflecting them away from the conveyor. The conveyor belt can be long, for example, a single belt for the entire sorter, or the belt can be broken down into shorter sections whose action needs to be adjusted to achieve any number of discharge points for the sorter.

[0008] New designs, such as U.S. Patent Application No. 15 / 916,248, filed March 3, 2018, show how short sections of such connected belts can be used to construct individual sorting modules, and multiple independent modules (each capable of moving packages from the conveyor) can be connected together to form sorters of different lengths. Sorters constructed from modular units may be configured to accommodate various initial sort point and package size requirements, and modules can be easily added or removed to accommodate changing needs. Summary of the Invention

[0009] It is to be understood that both the following summary and detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. Neither the following summary nor description of the invention is intended to define or limit the scope of the invention to the specific features set forth in the summary or description. Rather, the scope of the invention is defined by the appended claims. In certain embodiments, the disclosed embodiments may include one or more of the features described herein.

[0010] The new modular package sorter system allows for the configuration of different sized sorters by combining a standard guidance subsystem with standardized sort modules that are economical to manufacture in volume. The distributed control architecture and control software are the same for any size sorter. Supervisory control software runs on a computer within the guidance subsystem, while a programmable logic controller (PLC) is embedded in each sort module to locally control its operation. Individual PLCs are programmed with identical control and communication capabilities. Each sort module runs independently and also coordinates package transitions between each other. Each sort module has local adaptive control capabilities that can dynamically change speed, detect jams, or respond independently to operator inputs without affecting adjacent modules or burdening the supervisory control system. Overall, this provides a robust sorting solution that is scalable, cost-effective, reliable, and fault-tolerant.

[0011] The novel low-cost package sorter system design has a modular structure and a distributed control architecture. It should be understood that a wide variety of items can be sorted by systems according to various embodiments of the present invention, and the term "package" is not meant to be limiting. Wherever the term "package" is used, it can be substituted with the term "object." The term "package" refers to a mailing package, which can be of a wide variety of different shapes and sizes. Mailing packages typically have information, particularly addressing information, encoded in some machine-readable format, typically a barcode. However, embodiments of the present invention are also useful for objects that do not have machine-readable addressing information, where the addressing can be ascertained according to programmed logic depending on the object's characteristics, which can be determined by a computer or manually entered. For example, a meat processing plant could use such a system, where the addressing is determined based on the size, shape, and / or source animal of the meat cut, and that information can be manually entered and / or automatically detected. The sorter system in embodiments has two main subsystems: a guidance subsystem and a sorting subsystem.

[0012] The guidance subsystem is where packages are introduced into the sorter. This subsystem is standardized for all sorters, regardless of the length or number of sort points. All guidance systems use the same electronic components, interconnecting cables, wiring, and supporting documentation. The standardized mechanical configuration makes this subsystem low cost to manufacture. Also, the control software does not change with the requirements of different size sorters with different numbers of sort points.

[0013] The sorter control computer and system software is located within the guidance subsystem and provides overall control of the sorter system to start, stop, and manage the sorting scheme, control the I / O bus, and interface with the data collection system for package guidance. A sorting scheme is a rule that associates package sort points with package data; for example, it may be a correspondence table that associates package data, particularly destination addresses, with sort point destinations so that packages are sorted (via their sort point destinations) to trucks that service routes within the destination address's area. These sorting schemes can change even within a day; for example, mail trucks can be split into morning and afternoon routes, and the sorting schemes can change accordingly.

[0014] The display screen and keyboard in the sorter control computer provide a human-machine interface (HMI) for operating the sorter, updating the sorting scheme, and managing sorter operations. For example, an operator can turn the system on or off (e.g., between standby and operating modes) and read log files and other records to see, for example, how many packages have been sorted to different points, the average package weight, how many jams or other errors have been reported and where they are in the system, fault codes, etc. Typically, when an error or other warning condition occurs, this is reflected on the display and the operator can address the problem from the HMI, although the operator can also use local controls, such as buttons / switches and indicator lights located elsewhere in the system, to determine and address the problem.

[0015] The conveyor components in the guidance subsystem are controlled by a sorter control computer to move the packages through a series of stations that read package address information, determine dimensions, and measure the package weight. The sorter control computer collects package information and determines which sort point destination on the sorter the package should be delivered to.

[0016] Once the package sort point destination is determined, the sorter control computer prepares a package-specific data set and sends this data to the first of a series of programmable logic controllers (PLCs) installed in the series of sort modules that make up the sort subsystem. The PLCs control the operation of the sort modules, either alone or in conjunction with the sorter control computer. The sorter control computer uses this data set to pass transport control to the series of PLCs formed by the series of sort modules. In the preferred embodiment, each sort module has its own local PLC, but in some embodiments, a PLC may control a smaller group of sort modules, or a single sort module may have multiple PLCs to control the module's expanded functionality.

[0017] While PLCs are well known and are used throughout as a preferred example, other controllers known in the art can be used for the same purpose. It should be understood that various computing devices can operate as controllers, and that controllers and control computers can include hardware, firmware, and / or software. In general, the configuration of a controller, control computer, or other computing device can refer to specific logic embodied in hardware, firmware, and / or software. In other words, a controller or computing device may be configured to provide specific functionality by programmatically providing appropriate logic in software or by implementing it in hardware / firmware. Thus, the configuration of a controller described herein may refer to a logical module of the controller that can be combined with other modules or divided into submodules regardless of physical organization or storage. When a specific function is attributed to a controller or control computer, it may be achieved by hardware, firmware, software, or a combination thereof. Such software may be a collection of software units, which may have entrances and exits, written in a programming language such as, but not limited to, SWIFT, Objective C, Java, Lua, C, C++, or C#. A software unit may be compiled and linked into an executable program, installed in a dynamic link library, or written in an interpreted programming language such as, but not limited to, BASIC, Perl, or Python. It will be appreciated that a software unit may be called from other units or from itself, and / or may be called in response to a detected event or interrupt.Software units configured to execute on computing devices by their hardware processors may be provided on a computer-readable medium such as a compact disc, digital video disc, flash drive, magnetic disk, or any other tangible medium, or as a digital download (and may originally be stored in a compressed or installable format that requires installation, decompression, or decryption before execution). Such software code may be partially or completely stored in a memory device of the computing device during execution for execution by the computing device. Software instructions may also be embedded in firmware, such as an EPROM. It will be further understood that hardware modules may consist of connected logic units, such as gates and flip-flops, and / or may consist of programmable units, such as programmable gate arrays or processors.

[0018] The controllers referred to herein, in various embodiments, can be fully local, fully remote, or a combination thereof, and can employ one or more processors and hardware located in one or more local and / or remote locations. The logic used to manage the configuration and operation of the controller and control computer can be contained on various signal-bearing media. Exemplary signal-bearing media include, but are not limited to: (i) information permanently stored on a non-writable storage medium (e.g., a read-only memory device within a computer, such as a CD-ROM disk readable by a CD-ROM drive); (ii) alterable information stored on a writable storage medium (e.g., a hard disk drive or solid-state storage device); and (iii) information communicated to a computer by a communications medium, such as over a computer or telephone network, including wireless communications.

[0019] The latter embodiment specifically includes information downloaded from the Internet and / or other networks. Such signal-bearing media, when carrying computer-readable instructions that direct the functions of the present invention, represent part of embodiments of the present invention. Generally, the routines executed to implement embodiments of the present invention may be part of an operating system, or a specific application, component, program, module, object, or sequence of instructions. The disclosed software may include variables and data structures that reside local to the program or are found in memory or on storage devices.

[0020] Each of the processes, methods, and algorithms described herein may be embodied in code instructions executed by one or more computing devices comprising computer hardware or computer processors, and may be fully or partially automated. The processes and algorithms may be implemented partially or wholly in application-specific circuitry.

[0021] Some actions described herein may be more or less automated according to algorithms and / or preset operator preferences. Thus, where an operation is shown or described as being performed by an operator, it should be understood that in various embodiments and / or situations, the operation may be performed by a sorter control computer or sort module controller, or by an operator, on a larger or smaller scale, using the sorter control computer or another computing device (e.g., a user may type out instructions or select from preselected options generated by the control computer). Similarly, where an operation is shown or described as being performed by a sorter control computer and / or controller, the operation may, in various circumstances and embodiments, be performed autonomously by that computing device or with more or less user input.

[0022] It should be understood that the sorter control computer can be implemented in a variety of known ways in different embodiments of the present invention. For example, the sorter control computer may be implemented as any type of computing device, either in a single device or distributed across multiple devices (including the cloud). The sorter control computer may be primarily remote or primarily local, and may interface primarily locally via inputs such as a keyboard and display, or primarily remotely via an app or other software. The sorter control computer, or any portion thereof, may be located in any location, near or far from the guidance subsystem and sorting module. The sorter control computer may have multiple local interfaces (e.g., keyboard, mouse, display) in different physical locations, may have both local and remote access points, etc.

[0023] The sorting subsystem is formed by a series of sorting modules physically connected end-to-end. Each sorting module has a transport surface with a way to transport product to the next sorting module and another way to transport product to the right or left from the sorting module for package sorting into a waiting container or package transport device. The package transport device may be a conveyor, skate wheels, or any other known material handling and transport device, or even another sorting module. In some embodiments, sorting modules may be arranged side-by-side, although this is generally not the most typical implementation. In many applications, packages sorted to the left or right through a sorting module exit the sorting module system by exiting the side of the sorting module. Each sorting module has its own PLC that provides local control for the sorting module's mechanical operation and communicates with adjacent sorting module PLCs both upstream and downstream. The same PLC also communicates, under a separate protocol, with a sorter control computer located in the guidance subsystem to provide status information about each module and relay operator input from touch buttons and indicator lights.

[0024] In some embodiments, the touch button and indicator light are combined into a touch lamp button, which may essentially be a push button with an integrated LED or other light. The light can be used to indicate a problem with that section of the sorter, such as a slow flash for a full container or a fast flash if a jam is detected and the sorter stops as a result. Any known indicator light can be used; for example, information can be conveyed based on the color of the light, whether the light is flashing or steady, and, if flashing, its frequency. The button is an input device for the operator; typically, a simple push button can be pressed to take the associated sort point offline, change the container used to receive packages at that sort point, and press again to activate the sort point and turn off the slow flash (for example) that indicated a container was nearing full. In the case of a jam that has stalled the sort module, button usage can be similar. The jammed material is pushed out of the way by the operator, who can then touch the button to indicate the jam is cleared and resume operation of the sort module. In a typical embodiment, an operator can control individual local sort modules directly with their associated buttons or remotely from the sorter control computer, resulting in a mixed local-global control architecture: the PLC of each sort module controls the buttons / lights of the same sort module, but the operator can send messages from the sorter control computer to the local PLC to turn off lights, restart modules, etc., and the PLC can in turn relay that message back to the sorter control computer when a button is operated locally.

[0025] The data set prepared by the sorter control computer is communicated to the first PLC of the sort module as the package enters the sorter subsystem. Typically, package entry into the sorter subsystem is determined using through-beam array sensors located in front of each sort module, as described in more detail below. These sensors detect each package as it progresses along the sort module and can determine the leading and trailing edges of each package and when the edge crosses the through-beam array. Thus, while conveyor and package speeds are known from motor encoders, the through-beam array can also be used to determine package speed. Package speed can aid, for example, in ejection from the sort module to a sort point. For example, as described in more detail below, package length and module length can be used to determine whether package speed should be adjusted to improve ejection reliability and / or reduce the risk of jamming. The PLC in each sort module receives the incoming package data set from its upstream neighbor. Based on the data, the PLC executes a program to either pass the package to the next sort module or eject the package to a sort point on the right or left side. If the package sort point destination is further downstream from the sorter, the data set is sent to the next downstream module PLC, and the process repeats itself until the package reaches its intended sort point destination. In many embodiments, all types of modules are identical, each with its own PLC, set of sensors, indicators, push buttons, and motors (e.g., as described in detail herein). Identical sort modules allow for very efficient manufacturing and low cost while retaining flexibility. For example, depending on space constraints, it may be desirable for the sorting subsystem to perform pivoting, which can be achieved, for example, by inserting "pie-slice" rollers or conveyor sections between sorting modules.In some embodiments, the sort modules may be identical except for size; for example, smaller sort modules may be used in certain locations, such as at the ends of the sort subsystem, to better handle smaller packages. In general, sort module size may be selected based on the objects being sorted. A local power source may be connected to the overall power distribution system and provide local DC power to one or more modules.

[0026] The common design and construction of the sorter modules reduces manufacturing costs because all modules are the same, regardless of sorter size. The distributed control architecture allows each sort module to self-control and includes standard protocols for communication to adjacent modules, transporting packages between modules, and communicating status with the sorter control computer. The addition or subtraction of additional modules does not affect other modules or the sorter control software and requires only changes to configuration settings.

[0027] A common PLC program installed on each of the sort modules contains many adaptive subroutines that can be activated by the data sets associated with each package. These adaptive features increase the overall performance and reliability of the sorter system. Non-limiting examples include how to change the timing or speed of sort module functions based on package length, and how the sort module transport speed can be changed based on the sort point destination and prediction of the desired operation at the next downstream sort module.

[0028] The speed of each sort module can be controlled by its respective PLC. To reduce jams, if a large package is identified that may be difficult to eject to one side or stop within a single module due to its momentum and sliding, the transport speed of the module containing the package can be slowed without slowing down other modules, allowing for reliable transport. In embodiments, if a package slides far enough between modules to cross a through-beam array (or other) sensor when it is supposed to have been ejected to either side or stopped, the system will notice the unexpected package and signal a jam. By slowing the sort module before the module that sorts large packages from the system, the system can reduce the chance that a package will slide past its intended sort point into the next module, causing a jam and, in most embodiments, requiring manual handling of the package to return it to its sort point on the track. This is a very important feature of modular systems, making them much more reliable than traditional single-conveyor systems that always drive the entire system at the same speed.

[0029] Note that package length can be calculated from the time between leading and trailing edge detection by the through beam array, or by image or other data collection in the guidance subsystem. In some embodiments, package weight collected in the guidance subsystem, for example, can also be used to trigger a slowdown in the sort module conveying speed. In either case, package length relative to the length of the sort module is a very important factor, as it determines the amount of travel distance the package has before extending from the end of the sort module.

[0030] Parameters for when the sorting module slows down and at what speed may be preset based on the characteristics of a given system and / or the objects being sorted, but may also be adapted over time using known AI techniques. Jams and their locations are recorded, and if jam frequency is relatively high, the sorting module's speed is reduced to determine whether it reduces jam frequency. If slowing the speed is found to reduce the number of jams, the speed can be slowly reduced, for example, until the jam frequency is within 10% of the system average or until overall throughput is maximized (i.e., if below a certain speed, the number of objects being successfully sorted per unit time decreases, the speed is increased again to find an optimum). As an example, if furniture varnish is spilled on one sorting module and reduces the coefficient of friction of the conveyor surface, that sorting module will be identified as jamming more frequently by the system, and the sorting module's speed will be reduced so that the jam rate returns to match that of the other sorting modules. This is a significant improvement over traditional sorting systems with a single speed.

[0031] In some embodiments, each sort module starts when a sensor located in the gap detects the leading edge of a package just before the module detects it. The package is not sorted outward from that sort module to the sort point destination, but passes through the sort module without stopping when the next sort module is cleared and ready to accept the next package. The sort module continues to run and transport the package to the downstream sort module, stopping when the sensor at the beginning of the downstream sort module detects the trailing edge of the package.

[0032] However, if the next module is unclear, the package must be stopped before entering the next module. In this case, the first sort module starts as described above when the inlet sensor detects the leading edge of the package. However, the sort module must stop the package before blocking the inlet sensor of the downstream sort module. To stop the package in time, the same sensor that detects the leading edge of the package is also used to detect the trailing edge of the package and signal the sort module to stop.

[0033] The available stopping distance is a function of the package length and the length of the sort module. For example, if the sort module is 40 inches long and transports 10-inch packages at 40 inches per second, the package will have 30 inches, or 3 / 4 second, before it reaches the end of the sort module and is detected by the entrance sensor to the next sort module. Based on the type of package, the time sufficient to stop a 10-inch long package is 3 / 4 of a second, or 30 inches.

[0034] Larger packages, unless compensation is provided, reduce the available stopping distance and stopping time. As an example, if the same sorting module is 40 inches long and transports a 20-inch package at 40 inches per second, the package will only have 20 inches, or 1 / 2 second, to stop after its trailing edge passes the inlet sensor. This may not be enough time or distance to stop the package if it needs to be stopped before moving on to the next sorting module. Insufficient stopping distance and stopping time will result in excessive jams and reduce the sorter's overall throughput.

[0035] Rather than slowing down the entire sorter, the adaptive functionality of the program running on the sort module's PLC can be used to slow the sort module's conveying speed only when necessary for larger packages. In this example, the sort module's PLC knows that the package is 20 inches long (determined when the package is guided and / or by sensors). Based on pre-programmed values ​​or machine learning, the PLC knows that 40 inches per second is too fast and will not provide the desired operational reliability. Therefore, the PLC slows the module's conveying speed to 20 inches per second when a 20-inch package needs to stop before moving on to the next sort module, allowing 20 inches, or exactly one second, for the 20-inch package to stop. Additionally, the slower conveying speed for large packages increases the reliability of their separation from the sorter at the sort point destination module.

[0036] The ability to dynamically adjust the speed of the sort module based on package size is an adaptive control feature that allows the sorter to operate at maximum speed and capacity for most packages, but slow down when needed for larger packages to avoid jams and improve reliability.

[0037] Other features of the PLC program common to all sort modules may include the ability to detect stuck or missing packages and communicate status information between the individual sort modules and the supervisory sort computer.

[0038] In normal operation, the PLC will not advance to the previous sort module until its conveyor surface is clear, so that less than half of the sort modules have packages at any given time (although in the event of a jam that stops a sort module and creates a backup behind the jammed sort module, packages can "line up" with packages on all sort modules behind the stopped sort module), and less than half of the sort module conveyor surface is running (at least in the non-discharge direction) at any given time. As a direct result, a sorter in such an embodiment generates at most half the noise of a non-module sorter, and wear on the sorter conveyor surface and mechanical system is significantly reduced. As much as half of the sort module conveyor surface is running only in very high-volume situations (and that is often not the case), which is relatively rare in most sorter implementations (or in the rare "purge" scenario described below, where more than half of the sort module conveyor surface may be running at any one time). At other times, significantly less than half of the sort module conveyor surface will be running at any one time. For example, an operator may load a few packages onto the sorting system, then return to grab and load a few more, etc. In such a scenario, only a few sort module conveyor surfaces may be running at any given time. In particular, sort modules toward the ends of a linear sorting system exhibit very low capacity and operate very infrequently. As such, noise and wear are reduced by more than half in most operating conditions compared to a sorting system with a single long (non-modular) conveyor surface.

[0039] It should be noted that this control rule, which stops the sort module conveyor surface when the next downstream sort module is not clear, is a very simple rule that provides high reliability in a modular sorting system. However, in other embodiments, higher throughput can be achieved for volume sorting by relaxing the rule that stops packages until the next sort module is clear. For example, if a package on the next downstream sort module has its leading edge detected to pass the sensor immediately after the next downstream sort module (i.e., before the subsequent downstream sort module after the next downstream sort module), the package may be expected to immediately clear the next downstream sort module and pass completely onto the subsequent downstream sort module. In this way, the package is not stopped; rather, the sort module may continue running and allow the package to proceed to the next downstream sort module based on the prediction that the package there will soon exit that next downstream sort module. Such logic may, in some embodiments, be implemented only when a large number of packages are detected and / or reliability is not expected to be adversely affected beyond at least a certain threshold level.

[0040] According to at least some embodiments, a modular package sorting system is disclosed herein, the system comprising: a plurality of sort modules configured to transport packages to one of a plurality of sort points corresponding to the sort point destinations of the packages; and a distributed control architecture comprising a plurality of controllers, each of the plurality of controllers associated with one sort module in the plurality of sort modules, and each of the plurality of controllers configured to communicate with one or other controllers in the plurality of controllers, including sending and receiving electronic data packets, and using information contained in the electronic data packets to determine whether to transport the package from the associated one sort module to a subsequent sort module or to a sort point associated with the one sort module based on the sort point destination of the package, the electronic data packets including the sort point destination of the package, and each of the plurality of controllers capable of controlling its respective sort module.

[0041] In at least some embodiments described above, the modular package sorting system further includes a guidance subsystem configured to initially receive the package and transport it to the plurality of sorting modules, and the guidance subsystem configured to not transport the package to the plurality of sorting modules until information is successfully read from the label on the package.

[0042] The guidance subsystem may be further configured to obtain details regarding the received package, thereby determining a sort point destination for the received package based on the obtained details, and transmitting the sort point destination to the plurality of sort modules.

[0043] Such information about the received package may include address information, dimensions, and weight.

[0044] The guidance subsystem may also be configured to send the sort point destination to a first controller of a plurality of controllers associated with a first sort module of the plurality of sort modules to which the package is transported from the guidance subsystem.

[0045] In at least some of the above-described embodiments of the modular package sorting system, each of the plurality of controllers is configured to communicate with a subsequent controller of the plurality of controllers, each subsequent controller being associated with an immediately subsequent sort module of the plurality of sort modules, and the controller is configured to convey packages toward the sort module through the sort module associated with the controller and to transmit a sort point destination to the subsequent controller.

[0046] The multiple sort modules in at least some of the embodiments described above can be rearranged in any order, while each controller maintains the ability to communicate with subsequent controllers associated with the sort modules to which its associated sort module is configured to transport packages, even if the identity of the subsequent controller changes due to the rearrangement.

[0047] Additionally, the guidance subsystem may include a conveyor component controlled by a sorter control computer configured to move packages through a series of stations and collect details about received packages.

[0048] In at least some of the embodiments described above, each of the multiple controllers can control its respective sort module independently of the sorter control computer.

[0049] In at least some of the previously described embodiments of the modular package sorting system, the guidance subsystem may be configured to determine the sort point destination based at least in part on address information, package dimensions, and / or weight.

[0050] The guidance subsystem may further comprise an imaging device, a dimensioner, and a weighing system, and the guidance subsystem is configured to read the barcode of the package with the imaging device, and if the barcode cannot be read, the guidance subsystem is configured to stop guiding the package in response to an input command and clear the obtained information about the received package, so as to stop guiding the package until the barcode is successfully read or the required information is manually input.

[0051] Additionally, at least some of the above-described embodiments of the modular package sorting system include a sorter control computer configured to determine sort point destinations based on information about received packages. Such a sorter control computer may be configured to communicate with multiple controllers.

[0052] In at least some embodiments described above, the sorter control computer is configured to track the volume of packages sorted to each of the plurality of sort points based on dimensional information of packages determined to have each sort point as its sort point destination, compare the volume of the package to the capacity of each of the plurality of sort points, and provide a notification when a particular sort point is determined to be within a threshold percentage of its volume.

[0053] The sorter control computer may further be configured to log errors, report error rates and error locations, and bypass and / or reduce the speed of sort modules experiencing errors.

[0054] In at least some of the embodiments described above, the plurality of sorting modules comprises a series of sorting modules physically connected end-to-end and configured to transport articles from a first sorting module to a last sorting module across the series, and a controller associated with each sorting module is configured to communicate with controllers associated with the immediately preceding and succeeding sorting modules in the series, if present.

[0055] Further, each controller of the plurality of controllers is programmed to perform identical operations, including receiving a sort point destination from the guidance subsystem or from the controller of a immediately preceding sort module, using the sort point destination to determine whether to move the package toward the sort point by shifting it to the side of the associated sort module or to transport the package to the immediately succeeding sort module, and when transporting the package to the immediately succeeding sort module, sending the sort point destination to the controller associated with the immediately succeeding sort module.

[0056] In at least some embodiments described above, each of the plurality of sort modules includes a conveyor surface configured to move articles on the conveyor surface forward and to either side.

[0057] The conveyor surface may further comprise a transport actuator configured to move articles on the conveyor surface back and forth, and a second transport actuator configured to move articles on the conveyor surface to either side.

[0058] In at least some of the above-described embodiments of the modular package sorting system, each controller is configured to control the mechanical operation of the conveyor surface of a corresponding sort module, the multiple sort point destinations are located on one or more sides of the multiple sort modules, and the multiple sort modules are configured to deliver packages to the sort point destinations by conveying the sort point destinations to the one or more sides of the sort modules.

[0059] Each controller may be further programmed to reduce the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module exceeds a size and / or weight threshold.

[0060] Each controller may be further programmed to slow down the speed of the conveyor surface of the corresponding sort module when an item on the conveyor surface of the corresponding sort module exceeds a size and / or weight threshold and has a sort point destination located adjacent to the immediately succeeding sort module. In some embodiments, a decision as to whether to slow down the conveyor surface to maximize system throughput can be made based on a trade-off between increased reliability and reduced speed. A reduced speed tends to reduce overall throughput when volumes within the system are large, as other packages are delayed waiting for packages on subsequent sort modules to be ejected or moved to the subsequent sort module. However, this loss may be offset by increased reliability if the reduced speed reduces the probability of jams or other errors that could result in reduced throughput. The slowdown decision may be made based on, for example, package characteristics (e.g., size, weight, and / or material), conveyor characteristics (e.g., material), system speed, and / or system package capacity. The decision of when and / or how to slow down a package may be made by, for example, a sorter control computer during steering, and this decision may be included in electronic data associated with the package transported with the package from one PLC to the next as the package is transported across the sort module. Alternatively, this decision may be made or adjusted by an individual PLC as the package's electronic data is received. For example, if a package is steered, e.g., if the overall system speed or system package volume changes, the decision may be updated to incorporate any changed conditions. In some embodiments, the sorter control computer may use actual reliability information in combination with historical information regarding decisions made regarding whether to slow each package and when / how to update its estimate of the impact of such decisions on system reliability, thereby improving the accuracy of its decisions in achieving optimal throughput.

[0061] Further, each controller of the plurality of controllers may be programmed to increase the speed of the conveyor surface of the corresponding sort module when an item on the conveyor surface of the corresponding sort module has a sort point destination located beyond the immediately succeeding sort module and a predetermined number of subsequent sort modules do not have items on their respective conveyor surfaces.

[0062] Each controller may be further configured to provide status information regarding the associated sort module.

[0063] In at least some of the aforementioned embodiments of the modular package sorting system, the system includes sensors configured to track the movement of packages across the sorting module, the sensors including proximity sensors, through-beam sensors, ultrasonic sensors, and / or reflective sensors.

[0064] The sensor may include a plurality of angled through beam array sensors, each of the plurality of angled through beam array sensors including a light beam array including a plurality of individual light beams, at least one of the plurality of individual light beams being diagonal to the conveyor plane, an emitter, and a receiver.

[0065] The sensors may further comprise sensors between the sort modules to determine when an item passes from one sort module to another, each such sensor being associated with a controller associated with the sort module before or after the sensor, the controller associated with the sensor being configured to report a jam and / or stop the associated sort module when the associated sensor does not sense an item when expected or when the associated sensor senses an item for more than a predetermined amount of time due to communications received by the controller associated with the sensor.

[0066] In at least some embodiments of the modular package sorting system described above, the multiple controllers are configured to, before moving each package from one sort module to the next, determine whether another package has been placed in the next sort module, and if so, wait before moving the package to the next sort module until no other packages have been placed in the next sort module. Each of the multiple controllers has its own set of rules.

[0067] Furthermore, in at least some of the embodiments described above, the distributed control architecture is configured to distribute control of multiple sort modules among multiple controllers.

[0068] Further, in at least some embodiments described above, the electronic packet of data includes details regarding the physical dimensions of the package. Also, each of the plurality of controllers may be configured to receive an electronic packet of data from a previous controller in sequence and then communicate the electronic packet of data to the next controller in the sequence. In at least some embodiments described above, the transmission of the electronic packet of data occurs simultaneously with the transport of the package from an associated sort module to a subsequent sort module or to a sort point associated with a sort module.

[0069] The electronic packet of data may further include information identifying the package and / or the dimensions of the package and / or the weight of the package.

[0070] In at least some embodiments of the modular package sorting system, each of the plurality of controllers is further configured to determine a rate from among a plurality of rates at which to feed the packages to a subsequent sort module, the plurality of rates being pre-installed in each of the plurality of controllers.

[0071] Such speed determination may depend at least on whether the package should be discharged to a sort point associated with a subsequent sort module.

[0072] The speed determination may further depend at least on whether the package should be discharged to a sort point associated with a sort module downstream of the subsequent sort module. The speed determination may further depend at least on the physical dimensions of the package. In at least some of the embodiments described above, the determined rate is different from the rate at which the associated one sort module received the packages.

[0073] Further, in at least some embodiments described above, a first controller of the plurality of controllers is associated with a first sort module of the plurality of sort modules, a second controller of the plurality of controllers is associated with a second sort module of the plurality of sort modules, and a third controller of the plurality of controllers is associated with a third sort module of the plurality of sort modules, the first, second, and third sort modules being connected in series and configured to receive a query from the first controller regarding whether the second sort module is empty and to transmit a response to the query from the first controller when the second sort module is empty, select a speed from among a plurality of speeds pre-installed in the second controller for sending the package to the third sort module when a package received on the second sort module is to be transported to the third sort module, and transmit a query regarding whether the third sort module is empty to the third controller, and then send the package to the third controller only after receiving a response to the query from the third controller.

[0074] Each of the multiple controllers may be further configured to communicate only with the controllers associated with the sort modules immediately preceding and immediately following the associated sort module, the communication including responding to a request from the controller associated with the immediately preceding sort module, receiving a packet including a sort point destination for the package from the immediately preceding sort module to the associated sort module when a package is transported from the immediately preceding sort module to the associated sort module, sending a request to the controller associated with the immediately succeeding sort module when the sort point destination of the package is not the sort point associated with the sort module, and sending a packet of data to the immediately succeeding sort module when a package is transported to the immediately succeeding sort module.

[0075] In at least some of the embodiments described above, the modular package sorting system further includes a second plurality of sorting modules, each of which has only an immediately preceding sorting module or an immediately succeeding sorting module, but not both, and such immediately preceding sorting module or immediately succeeding sorting module is one of the plurality of sorting modules.

[0076] In one or more further embodiments, a modular package sorting system includes a plurality of sort modules configured to transport a package to one of a plurality of sort points corresponding to the package's sort point destination, and a distributed control architecture including a plurality of controllers, each of the plurality of controllers associated with a sort module within the plurality of controllers, each of the plurality of controllers configured to communicate with one or more other controllers within the plurality of controllers and determine whether to transport a package from an associated sort module to a next sort module or to a sort point associated with a sort module based on the package's sort point destination, each of the plurality of controllers capable of controlling its respective sort module. The package sorting system further includes a guidance subsystem configured to initially receive a package and transport it to the plurality of sort modules, the guidance subsystem configured to prevent the package from being transported to the plurality of sort modules until information is successfully read from a label on the package, the guidance subsystem configured to obtain information about the received package, determine a sort point destination for the received package based on the obtained information, and send the sort point destination to the plurality of sort modules. The package sorting system further comprises a sort control computer configured to determine a sort point destination based on details about the received package, the sort control computer configured to remove control of the two or more sort modules from the controller, operate the two or more sort modules together, and purge the two or more sort modules of packages in response to detection of a jam and / or user input.

[0077] In one or more such embodiments of the modular package sorting system described above, the sorter control computer may be configured to, when controlling two or more sort modules, leave one or more other sort modules under the control of their controller.

[0078] A modular package sorting system according to various embodiments is configured to transport a package to one of a plurality of sort points corresponding to a sort point destination of the package, and includes a plurality of controllers, each of the plurality of controllers associated with a sort module in the plurality of sort modules, each of the plurality of controllers configured to communicate with one or more other controllers in the plurality of controllers to determine whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module, and each of the plurality of controllers is configured to receive a request for a first ready message based on the sort point destination for the package, and when the corresponding sort module is empty, When it is determined that the package received on the corresponding sort module is to be ejected in a right or left sorting direction or transported to another sort module, the controller transmits a first ready message, determines whether the package received on the corresponding sort module is to be ejected in a right or left sorting direction or transported to another sort module, transmits the first ready message when the package received on the corresponding sort module is to be transported to the next sort module, transmits a request for a second ready message to a controller corresponding to the other sort module, receives a second ready message from the controller corresponding to the other sort module, transmits the package received on the corresponding sort module to the other sort module, and responds to receiving the second ready message from the controller corresponding to the other sort module.

[0079] In at least a further embodiment of the modular package sorting system, the system comprises a plurality of self-controlling sort modules configured to transport a package to one of a plurality of sort points, each of the plurality of controllers being associated with one sort module among the plurality of sort modules, each of the plurality of controllers being configured to determine, upon receiving a package on its corresponding sort module, whether to transport the package to a subsequent sort module or to a sort point associated with the corresponding sort module, configured to communicate, upon the package being transported to the subsequent sort module, with the controller associated with the subsequent sort module by sending a request for a ready message to the controller corresponding to the subsequent sort module and by receiving a ready message from the controller corresponding to the subsequent sort module, and configured to send the package to the subsequent sort module after receiving a ready message from the controller corresponding to the subsequent sort module.

[0080] In at least some of the above-described further embodiments, the message received from a controller associated with the subsequent sort module indicates that the subsequent sort module is ready to receive the package.

[0081] Each of the plurality of controllers may be further configured to enable self-control of its respective sorting module.

[0082] In at least some further embodiments, each of the plurality of controllers includes an identical standard protocol for communicating with a sort module adjacent to the associated sort module, the standard protocol configured to enable transmission of the package to the subsequent sort module.

[0083] Additionally, each of the multiple controllers may be autonomous from a central operator supervisory control.

[0084] In at least some further embodiments of the modular package sorting system, the plurality of sort modules comprises a series of sort modules physically connected end-to-end and configured to transport items from a first sort module to a last sort module across the series, and a controller associated with each sort module is configured to communicate with controllers associated with sort modules immediately before and after the sort modules in the series, if present.

[0085] Further, each controller of the plurality of controllers is programmed to perform identical operations, including receiving a sort point destination from the guidance subsystem or from the controller of a previous sort module, using the sort point destination to determine whether to move the package to the side of the sort module corresponding to the sort point associated with the corresponding sort module or to transport the package to the immediately succeeding sort module, and when transporting the package to the immediately succeeding sort module, sending the sort point destination to the controller associated with the immediately succeeding sort module.

[0086] Each of the plurality of types of modules may further comprise a conveyor surface configured to move articles on the conveyor surface forward and to either side.

[0087] The conveyor surface includes a transport actuator configured to move articles back and forth on the conveyor surface, and a second transport actuator configured to move articles on the conveyor surface to either side.

[0088] In at least some further embodiments, each controller is configured to control the mechanical operation of the conveyor surface of a corresponding sort module, the multiple sort point destinations are located on one or more sides of the multiple sort modules, and the multiple sort modules are configured to deliver packages to the sort point destinations by transporting the sort point destinations to the one or more sides of the sort module.

[0089] Each controller of the plurality of controllers may be programmed to reduce the speed of the conveyor surface of the corresponding sort module when items on the conveyor surface of the corresponding sort module exceed a size threshold and / or a weight threshold.

[0090] Each controller of the plurality of controllers may be further programmed to reduce the speed of the conveyor surface of the corresponding sort module when an item on the conveyor surface of the corresponding sort module has a sort point destination located adjacent to the immediately succeeding sort module.

[0091] Each controller of the plurality of controllers may be further programmed to increase the speed of the conveyor surface of the corresponding sort module when an item on the conveyor surface of the corresponding sort module has a sort point destination located beyond the immediately succeeding sort module and a predetermined number of subsequent sort modules do not have items on their respective conveyor surfaces.

[0092] Each controller may further be configured to provide status information regarding the corresponding sort module.

[0093] In at least some of the other embodiments of the modular package sorting system, the system includes sensors configured to track the movement of packages across the sorting module, the sensors including proximity sensors, through-beam sensors, ultrasonic sensors, and / or reflective sensors.

[0094] The sensor includes a plurality of angled through beam array sensors, each of the plurality of angled through beam array sensors including a light beam array including a plurality of individual light beams, at least one of the plurality of individual light beams being diagonal to the conveyor plane, an emitter, and a receiver.

[0095] The sensors may further comprise sensors between the sort modules to determine when an item passes from one sort module to another, each such sensor being associated with a controller associated with the sort module before or after the sensor, the controller associated with the sensor being configured to report a jam and / or stop the associated sort module when the associated sensor does not sense an item when expected or when the associated sensor senses an item for more than a predetermined amount of time due to communications received by the controller associated with the sensor.

[0096] In at least some further embodiments of the modular package sorting system, the plurality of controllers are configured to determine whether another package has been placed on the next sort module before moving each package from one sort module to the next sort module, and if so, wait to move the package onto the next sort module until no other packages have been placed on the next sort module.

[0097] In some embodiments of the present invention, a controller associated with a given sort module sends messages only to the controller associated with the preceding sort module. Thus, for example, a first ready message is sent only from the controller of the corresponding sort module to the controller of the associated sort module. Furthermore, a second ready message is sent only from the controller of another sort module to the controller of the corresponding sort module.

[0098] In a further aspect, a controller associated with a given sort module only receives messages from controllers associated with subsequent sort modules. Thus, for example, a first ready message is received by the controller of one associated sort module only from the controller of the corresponding sort module. Further, a second ready message is received by the controller of the corresponding sort module only from the controller of another sort module.

[0099] In various embodiments of the modular package sorting system, the system includes other sort modules configured to transport the package to one of the other sort points corresponding to the sort point destination of the package and including other controllers, each of the other controllers associated with one sort module in the other controllers, each of the other controllers in communication with one or the other of the other controllers, and configured to determine, based on the sort point destination of the package, whether to transport the package from the associated one sort module to the next sort module or to the sort point associated with the one sort module.

[0100] In some of the various embodiments described above, the modular package sorting system further includes a guidance subsystem configured to initially receive the package and transport it to the plurality of sorting modules, and the guidance subsystem configured to not transport the package to the plurality of sorting modules until information is successfully read from the label on the package.

[0101] The guidance subsystem may be further configured to obtain details about the received package, determine a sort point destination for the received package based on the obtained details, and send the sort point destination to the plurality of sort modules.

[0102] The guidance subsystem may be further configured to send the sort point destination to a first controller of a plurality of controllers associated with a first sort module of the plurality of sort modules to which the package is transported from the guidance subsystem.

[0103] In some of the various embodiments described above, each of the plurality of controllers is configured to communicate with a subsequent controller of the plurality of controllers, each subsequent controller being associated with an immediately subsequent sort module of the plurality of sort modules, and the controller is configured to transport the package through the sort module associated with the controller and send the sort point destination to the subsequent controller.

[0104] Furthermore, multiple sort modules may be rearranged in any order while maintaining the ability of the associated sort module to communicate with a subsequent controller associated with the sort module to which it is configured to communicate packages, even if the rearrangement changes the identity of the subsequent controller.

[0105] The guidance subsystem may further comprise a conveyor component controlled by a sorter control computer configured to move the packages through a series of stations and to collect details about the received packages. Further, the information about the received packages may include address information, dimensions, and weight.

[0106] The guidance subsystem may be further configured to determine a sort point destination based at least in part on address information, package dimensions, and / or weight.

[0107] In some of the various embodiments of the modular package sorting system described above, the guidance subsystem includes an imaging device, a dimensioner, and a weighing system, and the guidance subsystem is configured to read the barcode of the package with the imaging device and, if the barcode cannot be read, to stop guiding the package until the barcode is successfully read or the required information is manually entered, and the guidance subsystem is configured to stop guiding the package and clear the acquired information about the received package in response to an input command.

[0108] Additionally, some of the various embodiments of the modular package sorting system described above further comprise a sorter control computer configured to determine a sort point destination based on information about the received packages.

[0109] The sorter control computer may also be configured to communicate with multiple controllers.

[0110] Additionally, the sorter control computer may be configured to track the volume of packages sorted to each of the plurality of sort points based on dimensional information of packages determined to have each sort point as its sort point destination, compare the package volume to the capacity of each of the plurality of sort points, and provide a notification when a particular sort point is determined to be within a threshold percentage of its capacity.

[0111] The sorter control computer may further be configured to log errors, report error rates and error locations, and bypass and / or reduce the speed of sort modules experiencing errors.

[0112] The sorter control computer may be further configured to remove control of two or more sort modules from the controller, operate two or more sort modules together, and purge two or more sort modules of packages in response to jam detection and / or user input.

[0113] The sorter control computer may also be configured, when controlling two or more sort modules, to leave one or more other sort modules under the control of their controllers.

[0114] In some of the various embodiments of the modular package sorting system described above, each of the plurality of controllers is configured to receive a request for a first ready message, send the first ready message when the corresponding sort module is determined to be empty, determine whether the package received on the corresponding sort module should be discharged in a right or left sorting direction or transported to another sort module, send a request for a second ready message to the controller corresponding to the other sort module when the package received on the corresponding sort module should be transported to the other sort module, receive a second ready message from the controller corresponding to the other sort module, and send the package received on the corresponding sort module to the other sort module in response to receiving the second ready message from the controller corresponding to the other sort module.

[0115] The plurality of sorting modules further includes a series of sorting modules physically connected end-to-end and configured to transport items from a first sorting module to a last sorting module across the series of sorting modules, and a controller associated with each sorting module is configured to communicate with controllers associated with the immediately preceding and succeeding sorting modules, when present.

[0116] Additionally, each controller of the multiple controllers may be programmed to perform the same operations, including receiving a sort point destination from the guidance subsystem or from the controller of a immediately preceding sort module, using the sort point destination to determine whether to move the package toward the sort point to the side of the associated sort module or to transport the package to the immediately succeeding sort module, and when transporting the package to the immediately succeeding sort module, sending the sort point destination to the controller associated with the immediately succeeding sort module.

[0117] In some of the various embodiments of the modular package sorting system described above, each of the plurality of sorting modules includes a conveyor surface configured to move articles on the conveyor surface forward and to either side.

[0118] The conveyor surface may comprise a transport actuator configured to move articles on the conveyor surface forward and backward, and a second transport actuator configured to move articles on the conveyor surface to either side.

[0119] Further, each controller may be configured to control the mechanical operation of the conveyor surface of the corresponding sort module, and multiple sort point destinations may be located on one or more sides of the multiple sort modules, and the multiple sort modules may be configured to deliver packages to the sort point destinations by transporting the sort point destinations to the one or more sides of the sort modules.

[0120] Each controller of the plurality of controllers may be programmed to reduce the speed of the conveyor surface of the corresponding sort module when items on the conveyor surface of the corresponding sort module exceed a size threshold and / or a weight threshold.

[0121] Each controller of the plurality of controllers may be further programmed to reduce the speed of the conveyor surface of the corresponding sort module when an item on the conveyor surface of the corresponding sort module has a sort point destination located adjacent to the immediately succeeding sort module.

[0122] Each controller of the plurality of controllers may be further programmed to increase the speed of the conveyor surface of the corresponding sort module when an item on the conveyor surface of the corresponding sort module has a sort point destination located beyond the immediately succeeding sort module and a predetermined number of subsequent sort modules do not have items on their respective conveyor surfaces.

[0123] Each controller may be further configured to provide status information regarding the associated sort module.

[0124] In some of the various embodiments of the modular package sorting system described above, the system further includes sensors configured to track the movement of packages across the sorting module, and the sensors may include proximity sensors, thru-beam sensors, ultrasonic sensors, and / or reflective sensors.

[0125] The sensor may include a plurality of angled through beam array sensors, each of the plurality of angled through beam array sensors may include a light beam array including a plurality of individual light beams, at least one of the plurality of individual light beams being diagonal to the conveyor plane, an emitter, and a receiver.

[0126] The sensors may further comprise sensors between the sort modules to determine when an item passes from one sort module to another, each such sensor being associated with a controller associated with the sort module before or after the sensor, the controller associated with the sensor being configured to report a jam and / or stop the associated sort module when the associated sensor does not sense an item when expected or when the associated sensor senses an item for more than a predetermined amount of time due to communications received by the controller associated with the sensor.

[0127] In some of the various aforementioned embodiments of the modular package sorting system, the multiple controllers are configured to determine whether another package is located on the next sort module before moving each package from one sort module to the next sort module, and if so, wait to move the package onto the next sort module until no other packages are located on the next sort module.

[0128] Thus, based on the above and continuing description, the invention, in its various embodiments, can comprise one or more of the following features in any non-mutually exclusive combination.

[0129] A modular package sorting system including: a plurality of sort modules configured to transport packages to one of a plurality of sort points corresponding to a sort point destination of the package; and a distributed control architecture including a plurality of controllers, each of the plurality of controllers being associated with one sort module within the plurality of sort modules.

[0130] Each of the plurality of controllers of the modular package sorting system configured to communicate with one or more other controllers in the plurality of controllers is configured to receive and transmit electronic packets of data and to use information contained in the electronic packets of data to determine whether to transport a package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module based on the package's sort point destination.

[0131] Each of the plurality of controllers of the modular package sorting system is capable of controlling its respective sorting module.

[0132] Each of the plurality of controllers of the modular package sorting system is configured to communicate with a subsequent controller of the plurality of controllers, and each subsequent controller is associated with an immediately subsequent sort module of the plurality of sort modules that the controller is configured to transport packages through the sort module associated with the controller and send a sort point destination to the subsequent controller.

[0133] The electronic packets of data sent and received by the plurality of controllers include a sort point destination for the package.

[0134] The electronic data packet further includes information regarding the physical dimensions of the package. A distributed control architecture is configured to distribute control of multiple sort modules among multiple controllers.

[0135] A modular package sorting system including a guidance subsystem configured to initially receive a package and transport it to a plurality of sort modules, the guidance subsystem configured to not transport the package to the plurality of sort modules until information is successfully read from a label on the package.

[0136] The directing subsystem is configured to obtain details about the received package, determine a sort point destination for the received package based on the obtained details, and send the sort point destination to the plurality of sort modules.

[0137] The guiding subsystem is configured to send the sort point destination to a first controller of a plurality of controllers associated with a first sort module of the plurality of sort modules to which the package is conveyed from the guiding subsystem.

[0138] The guidance subsystem is configured to determine the sort point destination based at least in part on address information, package dimensions, and / or weight.

[0139] The guidance subsystem comprises a conveyor component controlled by a sorter control computer configured to move packages through a series of stations and to collect information about received packages.

[0140] Information about the package received should include address information, dimensions, and weight.

[0141] The guidance subsystem further comprises an imaging device, a dimensioner, and a weighing system, and the guidance subsystem is configured to read the barcode of the package with the imaging device, and if the barcode cannot be read, to stop guiding the package until the barcode is successfully read or the required information is manually input, and the guidance subsystem is configured to stop guiding the package and clear the acquired information about the received package in response to an input command.

[0142] The multiple sort modules in the modular package sorting system can be rearranged in any order while each controller maintains the ability to communicate with subsequent controllers associated with the sort modules to which its associated sort module is configured to transport packages, even if the identity of the subsequent controller changes due to the rearrangement.

[0143] A modular package sorting system including a sorter control computer configured to determine a sort point destination based on details about a received package.

[0144] The sorter control computer can be configured to communicate with multiple controllers.

[0145] The sorter control computer may be further configured to track the volume of packages sorted to each of the plurality of sort points based on dimensional information of packages determined to have each sort point as its sort point destination, compare the package volume to the capacity of each of the plurality of sort points, and provide a notification when a particular sort point is determined to be within a threshold percentage of its capacity.

[0146] The sorter control computer may further be configured to log errors, report error rates and error locations, and bypass and / or reduce the speed of sort modules experiencing errors.

[0147] 1. A modular package sorting system comprising: a plurality of sort modules configured to transport a package to one of a plurality of sort points corresponding to a sort point destination of the package; and a distributed control architecture comprising a plurality of controllers, each of the plurality of controllers associated with one sort module in the plurality of sort modules, each of the plurality of controllers configured to communicate with one or more other controllers in the plurality of controllers and to determine, based on the sort point destination of the package, whether to transport the package from one associated sort module to a next sort module or to a sort point associated with a sort module, and each of the plurality of controllers capable of controlling its respective sort module.

[0148] The modular package sorting system further includes a guidance subsystem configured to initially receive a package and transport it to the plurality of sort modules, the guidance subsystem configured to not transport the package to the plurality of sort modules until information is successfully read from a label on the package, and the guidance subsystem configured to obtain information about the received package, determine a sort point destination for the received package based on the obtained information, and send the sort point destination to the plurality of sort modules.

[0149] The modular package sorting system further includes a sorter control computer configured to determine a sort point destination based on information about the received packages, and the sorter control computer is configured to remove control of two or more sort modules from the controller, operate the two or more sort modules together, purge the two or more sort modules of packages, and respond to jam detection and / or user input.

[0150] The sorter control computer of the modular package sorting system may be configured such that when controlling two or more sort modules, one or more other sort modules remain under the control of their controller.

[0151] a plurality of controllers configured to transport a package to one of a plurality of sort points corresponding to a sort point destination of the package, each of the plurality of controllers being associated with one sort module among the plurality of sort modules, each of the plurality of controllers being configured to communicate with one or more other controllers among the plurality of controllers based on the sort point destination for the package, and to determine based on the sort point destination of the package whether to transport the package from the associated one sort module to a subsequent sort module or to a sort point associated with the one sort module, each of the plurality of controllers being configured to receive a request for a first ready message, a controller corresponding to the other sort module; a controller corresponding to the other sort module; and a controller corresponding to the other sort module. The modular package sorting system of claim 1, further comprising: a controller corresponding to the other sort module; a controller corresponding to the other sort module; a controller corresponding to the other sort module; a controller corresponding to the other sort module; and a controller corresponding to the other sort module;

[0152] The plurality of sorting modules comprises a series of sorting modules physically connected end-to-end and configured to transfer items from a first sorting module to a last sorting module across the series of sorting modules, and a controller associated with each sorting module is configured to communicate with a controller associated with the immediately preceding and succeeding sorting modules.

[0153] Each controller in the plurality of controllers is programmed to perform identical operations, including receiving a sort point destination from the guidance subsystem or from the controller of a immediately preceding sort module, using the sort point destination to determine whether to move the package toward the sort point by shifting it to the side of the associated sort module or to transport the package to a immediately succeeding sort module, and when transporting the package to a immediately succeeding sort module, sending the sort point destination to a controller associated with the immediately succeeding sort module.

[0154] Each of the plurality of types of modules may include a conveyor surface configured to move articles on the conveyor surface forward and to either side.

[0155] The conveyor surface may comprise a transport actuator configured to move articles on the conveyor surface forward and backward, and a second transport actuator configured to move articles on the conveyor surface to either side.

[0156] Each controller of the plurality of controllers is configured to control the mechanical operation of the conveyor surface of a corresponding sort module, the plurality of sort point destinations are disposed on one or more sides of the plurality of sort modules, and the plurality of sort modules are configured to deliver packages to the sort point destinations by conveying the sort point destinations to the one or more sides of the sort module.

[0157] Each controller of the plurality of controllers is programmed to reduce the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module exceeds a size threshold and / or a weight threshold.

[0158] Each controller of the plurality of controllers is further programmed to reduce the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module has a sort point destination located adjacent to the immediately succeeding sort module.

[0159] Each controller of the plurality of controllers is further programmed to increase the speed of the conveyor surface of the corresponding sort module when an item on the conveyor surface of the corresponding sort module has a sort point destination located beyond the immediately succeeding sort module and a predetermined number of subsequent sort modules do not have items on their respective conveyor surfaces.

[0160] Each controller of the plurality of controllers configured to provide status information regarding an associated sort module.

[0161] The modular package sorting system further includes a sensor configured to track movement of the package across the sorting module, the sensor including a proximity sensor, a through beam sensor, an ultrasonic sensor, and / or a reflective sensor.

[0162] The sensor comprises a plurality of angled through beam array sensors, each of the plurality of angled through beam array sensors comprising a light beam array comprising a plurality of individual light beams, at least one of the plurality of individual light beams being oblique to the conveyor surface, an emitter, and a receiver.

[0163] The sensors may include sensors between sort modules for determining when an item passes from one sort module to another, each such sensor being associated with a controller associated with a sort module before or after the sensor, the controller associated with the sensor being configured to report a jam and / or stop the associated sort module when the associated sensor does not sense an item when expected due to a communication received by the controller associated with the sensor, or when the associated sensor senses an item for more than a predetermined amount of time.

[0164] The plurality of controllers of the modular package sorting system are configured to, before moving each package from one sort module to the next sort module, determine whether another package is positioned on the next sort module, and if so, wait to move the package to the next sort module until no other package is positioned on the next sort module.

[0165] 1. A modular package sorting system including a plurality of self-controlling sort modules, the plurality of self-controlling sort modules being configured to transport a package to one of a plurality of sort points, the plurality of self-controlling sort modules being configured to transport the package to one of a plurality of sort points, the plurality of self-controlling sort modules being configured to transport the package to a subsequent sort module or to a sort point associated with the subsequent sort module when the package is received on the corresponding sort module, the plurality of self-controlling sort modules being configured to communicate with the controller associated with the subsequent sort module when the package is to be transported to the subsequent sort module by sending a request for a ready message to the controller corresponding to the subsequent sort module and by receiving a ready message from the controller corresponding to the subsequent sort module, and the plurality of self-controlling sort modules being configured to send the package to the subsequent sort module after receiving a ready message from the controller corresponding to the subsequent sort module.

[0166] A message received from the controller associated with the subsequent sort module indicates that the subsequent sort module is ready to receive the package.

[0167] Each of the plurality of controllers of the modular package sorting system is capable of controlling its respective sorting module independently from the sorting machine control computer.

[0168] Each of the plurality of controllers is configured to enable self-control of a respective sorting module.

[0169] Each of the multiple controllers has its own set of rules.

[0170] Each of the plurality of controllers may be provided with the same standard protocol for communicating with a sort module adjacent to the associated sort module.

[0171] The standard protocol is configured to enable sending the package to the subsequent sorting module.

[0172] Each of the plurality of controllers is autonomous from a central operator supervisory control.

[0173] Each of the plurality of controllers is configured to receive electronic packets of data in sequence from a previous controller and then communicate the electronic packets of data in sequence to a subsequent controller.

[0174] The transmission of the electronic packets of data occurs simultaneously with the transport of the package from one associated sorting module to a subsequent sorting module or to a sorting point associated with one sorting module.

[0175] The electronic packet of data further includes details identifying the package and / or package dimensions and / or package weight.

[0176] Each of the plurality of controllers is further configured to determine a rate from among a plurality of rates at which to send the packages to a subsequent sort module.

[0177] The speed decision depends at least on whether the package should be discharged to a sort point associated with a subsequent sort module.

[0178] The speed determination may depend at least on whether the package should be discharged to a sort point associated with a sort module downstream of the subsequent sort module.

[0179] The determined rate may be different from the rate at which the packages are received by the relevant sorting module.

[0180] The multiple speeds may be pre-installed in each of the multiple controllers.

[0181] The speed determination may depend at least on the physical dimensions of the package.

[0182] The multiple sort modules of the modular package sorting system comprise a series of sort modules physically connected end-to-end and configured to transfer items from a first sort module to a last sort module across the series of sort modules, and a controller associated with each sort module is configured to communicate with a controller associated with the immediately preceding and succeeding sort modules.

[0183] Each controller of the plurality of controllers is programmed to perform identical operations, including receiving a sort point destination from the guidance subsystem or from the controller of a previous sort module, using the sort point destination to determine whether to move the package to the side of the sort module corresponding to the sort point associated with the corresponding sort module or to transport the package to the immediately succeeding sort module, and when transporting the package to the immediately succeeding sort module, sending the sort point destination to the controller associated with the immediately succeeding sort module.

[0184] Each of the plurality of sorting modules includes a conveyor surface configured to move articles on the conveyor surface forward and to either side.

[0185] The conveyor surface may comprise a transport actuator configured to move articles on the conveyor surface forward and backward, and a second transport actuator configured to move articles on the conveyor surface to either side.

[0186] Each controller of the plurality of controllers is configured to control the mechanical operation of the conveyor surface of a corresponding sort module, the plurality of sort point destinations are disposed on one or more sides of the plurality of sort modules, and the plurality of sort modules are configured to deliver packages to the sort point destinations by conveying the sort point destinations to the one or more sides of the sort module.

[0187] Each controller of the plurality of controllers is programmed to reduce the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module exceeds a size threshold and / or a weight threshold.

[0188] Each controller of the plurality of controllers is programmed to reduce the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module has a sort point destination located adjacent to the immediately succeeding sort module.

[0189] Each controller of the plurality of controllers is programmed to increase the speed of the conveyor surface of the corresponding sort module when an item on the conveyor surface of the corresponding sort module has a sort point destination located beyond the immediately succeeding sort module and a predetermined number of subsequent sort modules do not have items on their respective conveyor surfaces.

[0190] Each controller is configured to provide status information regarding a corresponding sort module.

[0191] A modular package sorting system including sensors configured to track movement of packages across a sorting module, the sensors including proximity sensors, thru-beam sensors, ultrasonic sensors, and / or reflective sensors.

[0192] The sensor comprises a plurality of angled through beam array sensors, each of the plurality of angled through beam array sensors comprising a light beam array comprising a plurality of individual light beams, at least one of the plurality of individual light beams being oblique to the conveyor surface, an emitter, and a receiver.

[0193] The sensors may include sensors between sort modules for determining when an item passes from one sort module to another, each such sensor being associated with a controller associated with a sort module before or after the sensor, the controller associated with the sensor being configured to report a jam and / or stop the associated sort module when the associated sensor does not sense an item when expected due to a communication received by the controller associated with the sensor, or when the associated sensor senses an item for more than a predetermined amount of time.

[0194] The controllers are also configured to determine whether another package has been placed on the next sort module before moving each package from one sort module to the next sort module, and if so, to wait before moving the package to the next sort module until no other package has been placed on the next sort module.

[0195] A first controller in the plurality of controllers is associated with a first sort module in the plurality of sort modules, a second controller in the plurality of controllers is associated with a second sort module in the plurality of sort modules, and a third controller in the plurality of controllers is associated with a third sort module in the plurality of sort modules, and the first sort module, the second sort module, and the third sort module are connected in series.

[0196] The second controller receives a query from the first controller as to whether the second sort module is empty, transmits a response to the query from the first controller when the second sort module is empty, and when transporting a package received by the second sort module to the third sort module, selects a speed from among a plurality of speeds pre-installed in the second controller for sending the package to the third sort module, transmits a query to the third controller as to whether the third sort module is empty, and sends the package to the third sort module only after receiving a response to the query to the third controller from the third controller.

[0197] Each of the plurality of controllers is further configured to communicate only with controllers associated with the sort modules immediately preceding and immediately following the associated sort module, and to respond to requests from the controller associated with the immediately preceding sort module, the communication including receiving a packet including a sort point destination for a package from the immediately preceding sort module when the package is transported from the immediately preceding sort module to the associated sort module, sending a request to the controller associated with the immediately succeeding sort module when the sort point destination of the package is not the sort point associated with the sort module, and sending a packet of data to the immediately succeeding sort module when the package is transported to the immediately succeeding sort module.

[0198] The modular package sorting system includes a second plurality of sort modules, each of which has only a immediately preceding sort module or a immediately succeeding sort module, but not both, where such immediately preceding sort module or immediately succeeding sort module is one of the plurality of sort modules. A modular package sorting system including a plurality of sort modules configured to transport a package to one of a plurality of sort points corresponding to a sort point destination of the package, the modular package sorting system including a plurality of controllers, each of the plurality of controllers associated with one sort module in the plurality of sort modules, each of the plurality of controllers in communication with one or more other controllers in the plurality of controllers, and configured to determine, based on the sort point destination of the package, whether to transport the package from the associated one sort module to the next sort module or to the sort point associated with the one sort module. [Brief explanation of the drawings]

[0199] The accompanying drawings, which are submitted herewith and constitute a part of this specification, illustrate exemplary embodiments and, together with the detailed description, further enable those skilled in the art to make and use these and other embodiments that will be apparent to those skilled in the art. The present invention is described in more detail with the aid of the following drawings: [Figure 1] FIG. 2 illustrates a top-level control architecture in one embodiment of the present invention. [Figure 2] FIG. 1 illustrates a guidance system in accordance with an embodiment of the present invention. [Figure 3] FIG. 10 illustrates a guidance system handoff to a sorter subsystem in one embodiment of the present invention. [Figure 4] FIG. 10 illustrates inter-module handoff in a sorter subsystem in one embodiment of the present invention. [Figure 5] FIG. 1 illustrates a sort module component in one embodiment of the present invention. [Figure 6]FIG. 1 illustrates a sample module design in one embodiment of the present invention. [Figure 7] FIG. 1 illustrates an angled through-beam sensor array in one embodiment of the present invention. [Figure 8] FIG. 10 illustrates adaptive speed control for large packages in one embodiment of the present invention. [Figure 9] FIG. 10 illustrates adaptive speed control for proactive sorting in one embodiment of the present invention. [Figure 10] FIG. 4 illustrates jam detection logic in one embodiment of the present invention. [Figure 11] FIG. 10 illustrates continuous sorting in one embodiment of the present invention. [Figure 12] FIG. 10 illustrates a zone purge in one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0200] This specification discloses one or more embodiments incorporating features of the present invention. References to described embodiments, and throughout this specification to "one embodiment," "an embodiment," "an example embodiment," etc., indicate that the described embodiment may include a particular feature, structure, or characteristic. Such phrases are not necessarily limited to referring to the same embodiment. When a particular feature, structure, or characteristic is described in connection with an embodiment, one skilled in the art may apply such feature, structure, or characteristic to other embodiments, whether or not explicitly stated.

[0201] In some figures, similar reference numerals may be used for similar elements having similar functions in different figures. The described embodiments and their detailed structures and elements are provided merely to aid in a comprehensive understanding of the present invention. Thus, it is apparent that the present invention may be implemented in various ways and does not require any of the specific features described herein. Also, well-known functions or configurations will not be described in detail, as unnecessary detailed descriptions would obscure the present invention. Any signal arrows in the figures should be considered merely illustrative and not limiting, unless otherwise noted.

[0202] This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.

[0203] Terms such as "first," "second," and the like may be used herein to describe various elements, but it will be understood that these elements should not be limited by these terms. These terms are used merely to distinguish one element from another. For example, a first element could be referred to as a second element, and similarly, a second element could be referred to as a first element, without departing from the spirit of the exemplary embodiments. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly dictates otherwise.

[0204] It should also be noted that in some alternative implementations, the functions / acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed substantially concurrently or may sometimes be executed in the reverse order, depending on the functions / acts involved.

[0205] Figure 1 provides an overview of the top-level control architecture of the sorter design showing the distributed control architecture between the guidance subsystem and the sorter subsystem.

[0206] The guidance subsystem (1) is where packages (2) enter the sorter. The sorter control computer (3) controls the conveyor section (4) of the guidance subsystem to move the packages in the flow direction (5). The sorter control computer collects information about the packages, determines their sort point destination, and creates a data set specific to each package. The data set is sent via the sort module I / O network (6) to a first PLC (7) residing in the first sort module (8) of the sorter subsystem (9). Each subsequent sort module in the sorter subsystem is identical to the first sort module and has its own PLC for either moving the package in the flow direction (10) or moving the package in the sorting direction (11) to await a sort container (12) or conveyor. The data set and package are transferred sequentially through each sort module PLC in the direction of the sorter (13) until the package is sorted and sorting is complete for that package. The sorter subsystem (9) can be expanded with additional sorting modules without affecting the guidance subsystem (1) or the sorter control computer (3).

[0207] Figure 2 shows details of the guidance subsystem (1), in which a sorter control computer (3) provides supervisory control of the sorter system and interfaces with various hardware systems for scanning, weighing, and sizing packages. The sorter control computer (3) controls individual conveyor sections (4) to transport packages (2) through the guidance subsystem. The sorter control computer (3) collects information about packages as they pass through cameras (14), dimensioners (15), and weighing systems (16). The sorter control computer uses this data to create a unique record for each package and to determine how the packages should be sorted in the sorter subsystem (9). The sort point destination can be determined locally by the sorter control computer (3) or by a remote server (17) accessed via a data connection (18). The sort point destination is typically determined based on the destination address, particularly the destination zip code, but may also be determined based on package size and / or weight and / or other data, for example. The logic used to convert package-related data into a sort point destination is visible and modifiable from the sorter control computer. There can be multiple levels of such sorting logic, e.g., primary, secondary, and tertiary. For example, one level can narrow the sort point possibilities based on one factor, such as address, while another level can further narrow based on additional criteria, such as size. For example, a mail handler may have size and weight restrictions on mailbags, so a hand-carry route may exclude packages over a certain size and / or weight that must be routed by vehicle or truck, and separate sort points may be assigned for hand-carry and vehicle / truck deliveries. Once the sort point destination is determined, data including the sort point destination is prepared for the package and sent to the first sort module PLC (7) using the sort module I / O network (6) via wired, such as an Ethernet cable, or wireless, such as Wi-Fi, communication.

[0208] The guidance subsystem provides overall control of the sorter operation and controls the package guidance function. The continuous process for package guidance provides an automatic check for "unreadable" or defective barcodes. If the barcode (or other machine-readable code, depending on the implementation) is successfully read but indicates that the package (or other object) should not be in the system, it may be sorted to a reject bin. If a package (2) is not read by the camera (14), the sorter control computer (3) does not move the package to the next conveyor section and the guidance sequence stops. This significantly reduces the number of "no reads" and the need to re-run packages. The process may resume once the package's destination address is manually entered or successfully rescanned, or it may be started with another package once the package is removed from the guidance subsystem. An operator may manually enter relevant information (e.g., destination address) or rescan (e.g., by waving the barcode in front of a barcode scanner) to ensure the required information is received, at which point the sorter control computer moves the package to the next conveyor section. In some embodiments, if an operator is not available, the package may be diverted to a reject area for later rescanning while other packages continue to be steered. A system that stops steerage until the required information is received offers advantages over existing systems that perform barcode reading far downstream, have no way to reposition or manually manipulate the package, and typically result in about 10% of packages being unreadable and sent to a reject bin for rerun.

[0209] Damaged barcodes are common in the shipping industry, so the sorter control computer also supports manual entry of routes or sort point destination bins to facilitate operation. In mail processing applications, typically, each sort point corresponds to a different mail route, and each route is assigned to a separate delivery vehicle. For such manual entry, the sorter computer allows an operator to manually enter the route or sort point destination bin using a keyboard (19) or touchscreen monitor (20), and the guidance subsystem processes the package according to the operator's input.

[0210] The sorter control computer offers another very useful feature: it allows the operator to reverse a package in the guidance subsystem for removal and erase any previously collected data. This feature is used if a package becomes stuck somewhere in the guidance conveyor section during the data collection process. If an error is detected along the guidance subsystem (1), the sorter control computer provides the operator with a "reverse" push button (21) for quick resolution. Pressing the push button notifies the sorter control computer (3) and stops the conveyor section (4) from moving. Holding the button down slowly reverses the package until it is within the operator's reach, allowing it to be repositioned or removed. After manually retrieving the stuck package, the operator can rescan its barcode to re-direct the same package or scan another package into the system to resume operation. The sorter control computer automatically replaces the data associated with the stuck package with the new package data.

[0211] The sorter control computer (3) can also track the volume of parcels sorted to each sort point based on the sum of the volumes determined by the dimensions of parcels with the same sort point destination. This data can be used to provide notification to an operator when a particular bin is becoming full and needs to be replaced. The threshold for providing such notification may be user-configurable, for example, via the sorter control computer, such as when the estimated volume of packages delivered to a sort point is within 20% of the capacity at that sort point. The estimated volume of a package varies depending on the size and angle of the package (or other object), which can result in a loose or tightly packed package. In some embodiments, the user can select the approximate size and shape range of the items to be scanned, and a density factor can be estimated, allowing appropriate volume and fill safety thresholds to be assigned. The operator can also adjust the thresholds on the fly after determining whether a container is full or empty when a replacement is indicated.

[0212] The capacities of sort point bins can be set in the sorter control computer when the system is initially set up and can be manually updated by manual entry (or remotely) as needed when bins are replaced. Alternatively, bins may have barcodes, RFID chips, or similar stored capacity information, and corresponding sensors may read the capacity information and provide it to the sorter control computer. In some embodiments, a set of containers with known capacities are provided for use with the system as sort points, and these capacities may be preloaded into the sorter control computer. Packages with known capacities, such as flat-rate shipping boxes, may have their capacities preloaded into the sorter control computer. In other embodiments, users can supply containers, and the sorter control computer may communicate with the containers to automatically identify their relevant characteristics. Keeping bins from overfilling with packages is an important operational function because overfilled bins can cause package backflows and cause jams in the sorter subsystem that are more difficult and time-consuming to resolve.

[0213] If a jam is detected by any sort module 22, it is reported to the sorter control computer. The sorter control computer can log these errors for analysis and notify maintenance personnel of the error rate and the location of the error within the sorter. For example, if the frequency of jams on a given sort module exceeds a preset threshold over a period of time, the sorter control computer can initiate corrective action, such as slowing the transport speed of the faulty sort module or skipping the module entirely, until the cause of the error is determined and a more permanent repair is possible. When a sort module is "skipped," all packages are simply transported by that sort module to the next sort module and ejected from the side. Packages that would have been ejected by that sort module ultimately end up in a reject bin, from which they can be collected and re-injected into the sort stream when the sort module returns to full operation.

[0214] Figure 3 illustrates the guidance subsystem handoff to the sorter subsystem (9). Details of the guidance subsystem are as described above in this specification, particularly as shown in Figure 2. Specifically, a sorter control computer (3) controls individual conveyor sections (4) to transport packages (2) through the guidance subsystem. The sorter control computer (3) collects information about packages as they pass through cameras (14), dimensioners (15), and weighing systems (16). The sorter control computer uses this data to create a unique record for each package and to determine how the packages should be sorted in the sorter subsystem (9). Sort point destinations can be determined locally by the sorter control computer (3) or by a remote server (17) accessed by a data connection (18). Additionally, the sorter control computer supports manual entry of routes or sort point destination bins to facilitate operation. In mail processing applications, typically, each sort point corresponds to a different mail route, and each route is assigned to a separate delivery vehicle. For such manual input, the sorter computer allows an operator to manually enter a route or sort point destination bin using a keyboard (19) or touchscreen monitor (20), and the guidance subsystem processes the package according to the operator's input. The sorter control computer also allows an operator to reverse and remove a package in the guidance subsystem, erasing any previously collected data. This function is used if a package becomes stuck somewhere in the guidance conveyor section during the data collection process. The sorter control computer provides a "reverse" push button (21) for the operator to quickly resolve any errors detected along the guidance subsystem (1). If a jam is detected by any of the sort modules (22), the jam is reported to the sorter control computer. The sorter control computer records these errors for analysis and can notify maintenance personnel of the error rate and the location of the error within the sorter.The sorter control computer can initiate corrective action to slow the transport rate of the faulty sort module or to skip the module entirely until the cause of the error is determined and a more permanent repair is made.

[0215] During handoff from the guidance subsystem to the sorter subsystem (9), the first sort module PLC (7) first communicates with the sort computer (3) in the guidance subsystem (1) to move the package (23) onto the first sort module (8). To make this transition, the sorter control system computer (3) communicates with the first sort module PLC (7) using the sort module I / O network (6) to request a "ready" message. If the first sort module (8) is clear, the PLC (7) responds with a "ready to transport" message, and the control system computer (3) activates the conveyor to move the package onto the first sort module (8). Simultaneously, the sorter control computer (3) uses the sort module I / O network (6) to send a package data set to the first sort module PLC (7) of the first sort module. The data set identifies key information about the package, including package ID, package length, and package final destination. Additional data may include width, height, weight, or any other relevant information.

[0216] Figure 4 illustrates inter-module handoff within the sorter subsystem. Details of the guidance subsystem are as described herein above, particularly in Figure 2. Further details of the guidance subsystem handoff to the sorter subsystem are as described herein above, particularly in Figure 3. As explained below, transitions between sort modules are performed with the same logic, and the basic transactions are the same between all sort modules. Each sort module has local, independent control to accept packages from upstream modules, transport packages in the travel direction (24), eject packages in the left or right sort direction (25), or coordinate with the next module to accept packages. When a package (26) is waiting on the first sort module (8) ready to move to the second sort module (27), the first sort module PLC (7) software sends a "ready for transport" signal from the second sort module PLC (28). If the package is not present on the second sort module (27), the second sort module PLC (28) sends a "clear for transport" message to the first sort module PLC (7) and the package moves to the second sort module (27). A package-specific data packet is sent from the first sort module to the second sort module PLC once the package is cleared for transport.

[0217] If the package is on the second sort module (27) or if it is unavailable, the package (26) waits on the first sort module (8) until the second sort module (27) clears and sends a "Ready for Transport" message to the first sort module PLC.

[0218] Figure 5 shows the sort module components. Each sort module (22) consists of a conveying surface (29) equipped with a conveying actuator (30), which moves packages in the conveying direction (31). A second conveying actuator (32) deflects packages off the conveyor at predetermined locations, "sorting" them into an adjacent conveyor or container. Each sort module is locally controlled by a sort module PLC (7), which is connected to adjacent sort modules via a sort module I / O network (6). Package sensors (33) are used to detect the leading and trailing edges of packages arriving at the sort module and determine when a package has arrived at the sort module. The leading and trailing edges can be used to determine package size and / or orientation; however, this information can be obtained during guidance, as packages move during transport and may effectively lengthen or shorten along the length of the conveyor surface. The passage of the leading and trailing edges can also be used to determine package speed, which is typically obtained from the sort module's motor encoder. Indicator lights (34) are provided to indicate status on the sort module, and push buttons (35) are provided for operator input (e.g., to stop the sort module or to return the sort module to operation after a jam has been cleared).

[0219] The sort module PLC (7) has a unique identifier number corresponding to the sort module's position in the overall sorter string. The sorter control computer can store these identifier numbers in association with their position in the sorter string. In some embodiments, the sorter control computer may have a layout of the sorter, which may be preloaded or operator-entered, and then pre-assigned module identifiers may be entered in association with each position in the layout. In other embodiments, the layout may include pre-generated numbers for each position in the layout, and the operator may then assign each number to the corresponding sort module based on its position in the sorter string via the PLC. In another embodiment, the sorter control computer can automatically configure the position-identifier relationship without operator involvement. Once the sort modules are set up and a setup button (e.g., a hard or soft button) is pressed by the operator, the sorter control computer may determine the position of each sort module (e.g., using the network connecting them) and automatically assign the appropriate identifier.

[0220] Each PLC has the same set of control programs for interfacing with the package sensor (33), transport actuator (30), and transport actuator (32). The transport actuator moves the package across the sort module (22) to the next module. This actuator can be a powered conveyor belt, a mechanically powered pusher, or other means of transporting packages. This actuator is activated when the PLC receives permission from the PLC of the next sort module, indicating that the next sort module is available to receive a package. Thus, in such an embodiment, each sort module will not have more than one package at any given time (barring a jam condition). Because the PLC will not allow the previous sort module to move forward until its conveyor surface is clear during normal operation, no more than half of the sort modules will have packages at any given time, and no more than half of the conveyor surface of the sort module will be active at any given time. When operating at less than full capacity, utilization is substantially less than 50%. As a result, sound levels are substantially lower than in conventional sort systems with a single, long conveyor belt that is essentially always running. For example, even at full capacity, total acoustic energy can be reduced by 50%. Hearing protection is not required, a significant improvement over conventional systems. An exception to this stop / start operating method is the purge / train mode, in which the sorting module does not wait for permission but simply operates all conveyor surfaces together to transport and discharge all packages from the end of the line, for example to clear a jam. Packages discharged from the end of the line can be reinserted into the guidance subsystem if necessary. Another exception occurs when packages accumulate behind a downstream jam in each module, such as in a traffic jam. Once the downstream jam is cleared, the sorting module operates to move the jammed packages forward one at a time, restoring normal spacing.

[0221] The transport actuators 32 propel the packages left and right from the sorting module 22 to sort the packages into containers, chutes, or other types of discharge. Similarly, the actuators can be conveyor belts, mechanically powered pushers, or other means for propelling packages left and right.

[0222] The sort module PLC (7) also handles local communication with indicator lights (34) and push buttons (35) as well as network communication with upstream PLCs (36) and downstream PLCs (37) and the sorter control computer (3). The PLCs can communicate with the sorter control computer and adjacent PLCs. In some embodiments, all PLCs and the sorter control computer listen on a shared bus, so any communication can be sent to any device on the bus if properly addressed. For convenience, two sets of indicator lights and push buttons can be provided, one on each side of the sort module.

[0223] A data set for each package is generated by the sorter control computer and communicated from the upstream PLC (36) to the sort module PLC (7) when the package physically arrives at the sort module. Logic programmed into the sort module PLC (7) gives permission to send the package to the upstream module, determines the speed at which to run the conveyor belt, and determines whether the package should be diverted left or right or sent to the next module. If the package's sort point destination is further downstream in the sorter, the sort module PLC (7) communicates the data set to the downstream PLC (37) requesting permission to send the package to the next sort module.

[0224] In this embodiment, package data is sent from PLC to PLC with the package, including package identification, address data, size, sort point destination, etc. The speed of the package is determined according to pre-programmed rules. For example, a sort module may run at normal speed unless the package exceeds a threshold size and / or is sorted in that module or the next module, in which case the speed may be reduced, for example, to ¾ of the normal speed. In some embodiments, the speed may be increased from the normal speed, for example, if traffic is low and / or the package is not sorted until far down the line.

[0225] The sort module PLC (7) also turns indicator lights (34) on or off based on monitoring commands from the sorter control computer (3). By way of non-limiting example, an indicator light can be used to indicate that the sorter is on, a flashing light can indicate that a jam has been detected in the sort module, or a slow flashing light can indicate that a sort point destination bin should be full based on compiled dimensional data and may require operator attention.

[0226] In a similar manner, the sort module PLC (7) can interface with pushbuttons (35) to communicate operator input to a supervisory sorter control computer, which is not shown in FIG. 5 but could be, for example, the sorter control computer (3) as shown in any of FIGS. 1-4. As an example, an operator can stop the sorter from discharging to a particular location while changing out discharge containers, clearing jams, or performing maintenance functions. A module can be stopped completely, or it can run and pass packages to the next sort module but not discharge to the sort point where the discharge container is being changed. Any module can be turned on or off at any time. This provides a significant advantage over conventional sorting systems in which a single conveyor transports all packages and the entire system must be stopped to prevent package discharge during container changeout, maintenance, or jam clearance. In contrast, embodiments of the present invention allow such operations to be performed while the system remains substantially fully operational. Pressing the push button (35) provides an input to the sorting module PLC (7) which is communicated to the supervisory control computer (3) via the sorting module I / O network (6).

[0227] Figure 6 shows one exemplary module design (see U.S. Patent Application No. 15 / 916,248, filed March 3, 2018). This is one of many mechanical solutions that uses two actuators to transport and sort packages. In this design, two conveyor belts are mounted crosswise. The upper conveyor incorporates multiple rotating elements that transport packages on top, supported by a lower, crossing conveyor belt. The two conveyor belts move in unison, allowing packages to move in a straight line or be diverted left or right for discharge. The transport module frame (38) provides the structure to support the upper plastic conveyor belt (39) with its internal rotating elements (40) mounted on a flat transfer belt (41). The frame supports conveyor drive rollers (42) for the upper plastic belt and drive rollers (43) for the lower-mounted conveyor belt. The rotating elements of the upper plastic conveyor are in contact with the flat transport belt attached below, so that when the conveyor is moving, they rotate, propelling packages on the upper surface in the direction of belt movement. Furthermore, when the underlying transport belt (41) is driven by its drive rollers (43), the rotating elements (40) of the upper belt change direction, propelling packages on the conveyor from side to side for sorting. This is a particularly efficient mechanical solution and is the subject of the above-mentioned patent application. However, many other mechanical solutions are possible and contemplated.

[0228] Figure 7 illustrates the use of an angled through-beam array to detect even the smallest packages moving between sort modules. The control system for this modular sorter design requires accurate tracking of packages as they move from sort module to sort module, a challenging requirement for sorters that must handle a wide range of package sizes and types. Typically, this tracking is performed with simple sensors such as proximity sensors, through-beam sensors, ultrasonic sensors, or reflective sensors. However, each of these sensor types is limited in what types and sizes of packages they can detect.

[0229] The angled through-beam array shown in Figure 7 is a series of individual through-beam sensors mounted within a common housing. Each through-beam array has a light emitter (44) and a light receiver (45). The light beam array (46) is a screen of light beams spaced very close together, in this case approximately 12 beams spaced 1 / 4 inch apart. The light emitters and receivers are mounted at angles (47) to cover the area between the sensors with a diagonal pattern of light beams. The diagonal pattern of light beams greatly improves the system's performance in detecting very thin packages (48) moving between conveying surfaces (49). Packages thinner than the spacing between the light beams will break multiple angled beams (50) and be detected. This capability greatly expands the sorter's versatility in handling a wide variety of package sizes, from large boxes to flat envelopes to single business cards. If it is known that objects of a certain thinness will never encounter the system, less expensive sensors with fewer, more widely spaced beams can be used. For example, for shoebox-sized items, a simple single through beam is typically sufficient. Sensors are placed between sorting modules to detect when a package (or other object) transitions from one sorting module to the next.

[0230] Figure 8 shows one adaptive speed control logic function of the sort module PLC programming when handling larger package sizes. The sorter must precisely position each package before it exits the sort module. The appropriate position and timing vary depending on the size of the package being processed. The larger the package relative to the sort module, the more precise the position control must be to ensure the package is properly delivered to its sort point destination and not, for example, on the floor. Package position may be determined using the package's leading or trailing edge and / or conveying surface speed, combined with the elapsed time from package entry (leading or trailing edge), based on the sensor shown in Figure 7 that detects package entry onto the sort module. In some embodiments, a single sort module can supply multiple sort points / containers on a side, in which case package position on the conveyor surface is important, but many embodiments have only one sort point on either side of a given sort module. Sorters are designed to operate as fast as possible to maximize their throughput. However, larger packages have less available space for detouring or stopping at a given module size. In normal operation, a stop is required when a downstream module is not clear, i.e., contains a package. Attempting to bypass or stop a large package in an insufficient distance or time frame can cause the package to slide on the conveying surface, overrun its sorting module, miss its sort point destination, or leave the sorting system entirely. To accommodate these packages, the PLC is programmed to accommodate larger packages and automatically slows the conveyor speed when a larger package is encountered.

[0231] What constitutes a larger package and how much speed reduction is necessary may be preprogrammed, or operational adjustments may be determined empirically. Size measurements may be captured in the guidance subsystem by an imaging-type dimensioner or supplemented by calculating the package's length as it traverses a through-beam sensor array in the guidance subsection from leading edge to trailing edge while traveling at a known speed. Calculating the appropriate speed reduction can be complex, as it depends on many factors, including the package's mass, the coefficient of friction of the conveyor material, irregularities between the conveyor material and contact points, differences in longitudinal and lateral motion, and the behavior of a particular package when subjected to a shunting force. Such calculations are known, and while more or less precise calculations can be performed based on available information and computing resources, they are largely unnecessary. Alternatively, the system may be programmed to reduce speed to a predetermined threshold, e.g., 3 / 4, of the normal operating speed, if the package length is greater than a threshold ratio of the module length. Multiple length ratios and corresponding deceleration thresholds may be programmed, e.g., a ½ length ratio results in a ¾ speed, a ¾ length ratio results in a ½ speed, etc. The system then records jam / reliability rates and determines whether deceleration at a given length ratio is appropriate (e.g., using a programmed reliability threshold, e.g., a threshold for 95% accurate jam-free sorting), adjusting if necessary or based on operator input. The appropriate speed at a given package length ratio to achieve the desired reliability in a given implementation may be empirically determined by the sorter control computer as speeds, length ratios, and jam frequency / reliability are recorded. The operating speed, which correlates with the length ratio, may be automatically adjusted when reliability is detected to vary from the desired level.

[0232] As previously described herein, package dimension data is collected during the package guidance process and communicated by the sort module I / O network (6) to the individual sort module PLCs along with data packets traveling from sort module to sort module with the physical package. If a large package (51) exceeds a preprogrammed value, the sort module PLC (52) on the sort module (53) may decrease the conveying speed (54), which is automatically reset to a default speed after the package leaves the sort module. When the package moves to the next sort module (55), the next PLC (56) programs the conveying speed (57) within that sort module for that package as well, which may be automatically reset to a default value when the package leaves that sort module.

[0233] For example, each sort module starts when a sensor located in the gap immediately preceding the sort module detects the leading edge of the package. The package passes through the sort module without stopping if the next sort module is clear and ready to accept the next package. The sort module continues to run and transport the package to the downstream sort module and stops when the sensor at the beginning of the downstream sort module detects the trailing edge of the package.

[0234] However, if the next module is not clear, the package must be stopped before entering the next module. In this case, the first sort module starts as before when the inlet sensor detects the leading edge of the package. However, the sort module must stop the package before blocking the inlet sensor of the downstream zone. To stop the package in time, the same sensor that detects the leading edge of the package is used to detect the trailing edge of the package and signal the zone to stop.

[0235] If a sort module is 40 inches long and transports 10-inch packages at 40 inches per second, the package will have 30 inches, or 3 / 4 second, after its trailing edge passes the entrance sensor to a zone before its leading edge is detected by the entrance sensor to the next sort module. However, if the same sort module transports a larger 20-inch package, the package will only have 20 inches, or 1 / 2 second, after its trailing edge passes the entrance sensor.

[0236] In some cases, this may not be enough time or distance for the package to stop if it needs to before triggering the inlet sensor of the next sort module and causing a jam condition.

[0237] Adaptive programming on the sort module's PLC can be used to slow the sort module's conveying speed and increase package stop time to avoid jam conditions. In this example, the sort module's PLC knows the package is 20 inches long (determined during package induction and / or by sensors). Based on preprogrammed values ​​or machine learning, the PLC knows that 40 inches / second is too fast to stop the package if a package occupying the next downstream module needs to stop. Therefore, the PLC slows the module's conveying speed to 20 inches / second, giving a 20-inch package 20 inches, or a full second, to stop before a jam occurs. These adaptive features allow the sorter to operate at its maximum throughput rate and dynamically adjust the conveying speed to improve reliability across a wide range of package sizes.

[0238] Figure 9 illustrates another important application of adaptive speed control: slowing down the conveyor speed in anticipation of an upcoming sort point destination. Package types vary widely, and so do their mechanical interactions with the conveying surface. As a purely non-limiting example, some packages are slippery and take a long time to prevent slipping on the conveyor surface and turn or eject from the sort point. Overshooting the sort point can cause a jam condition, requiring operator intervention.

[0239] Dynamically slowing the transport conveyor, assuming the package will be sorted in the next sort module, increases the tolerance for timing the start of discharge and significantly improves package sorting reliability. The ability to predict and automatically adjust the conveyor module speed during package transport significantly improves the accuracy and reliability of both the transport and sorting functions, avoiding unnecessary jams from missed stops or missed discharges within the available time and length of the sort module. The decision to slow the transport conveyor can also be programmed as a function of the package. Small packages may not require speed adjustments to bypass downstream packages. However, larger packages have less tolerance and often require speed adjustments to maintain maximum reliability.

[0240] Figure 9 shows the control logic by which packages (58) in a sorting module (59) are sorted (60) in a subsequent sorting module (61). The PLC (62) may reduce the conveying speed (63) so that the packages enter the subsequent module (61) more slowly, thus reducing the chance of sliding or overshooting as they are rotated and sorted (60).

[0241] Each sort module PLC has a similar adaptive function in its control program to slow down the conveying speed in anticipation of the packages on that module being sorted in the next downstream sort module. This logic follows each package as it moves downstream through the sorter based on a data set prepared by the sort computer, which is not shown in FIG. 9 but may be, for example, a sorter control computer (3) such as that shown in any of FIGS. 1-4, and is relayed to the sort modules via the sort module I / O network (6). No further control is required from the sort computer.

[0242] Similarly, the sort module PLC program can look ahead and increase package transport speed based on the knowledge that the next few zones are clear of traffic and there are no impending transport / sort events.

[0243] In summary, an adaptive speed correction program running independently in each of the sort modules can improve the throughput and reliability of the entire sorter without burdening the sorter control computer with calculating the local conditions in each sort module.

[0244] Jam detection is an important function of a sorter. Stopping the sorter when a jam is detected avoids missorting and provides a timely warning to the operator to clear the jam and resume full operational throughput. When a jam is detected, it is reported to the sorter control computer, and only the sort module associated with the jam stops processing and its indicator light is illuminated to notify the operator. A jam may be detected based on the through-beam sensor detecting a package when it is not expected (i.e., the sort module preceding the sensor has not been instructed to go forward, which may indicate a package sliding into the sensor area when it should have stopped or been diverted from the sorter), or not detecting a package when it is expected (i.e., the sort module preceding the sensor has been instructed to go forward, which may indicate the package is stuck or has fallen off the conveyor surface). Until the jam is cleared, the sort module associated with the jam does not send a ready signal to the previous sort module, and therefore no further packages are transported onto the previous sort module.

[0245] Figure 10 shows the jam detection logic running in each of the sort module PLCs, separate from the sorter control computer in the guidance subsystem. This diagram shows a package 63 arriving on sort module 65 just after passing sensor 64. However, the next downstream package sensor 66 has just detected package 67 moving into sort module 61 much earlier than expected based on the expected package 63 length and sort module transport speed 68.

[0246] An unexpected early arrival is communicated as an "unknown package" to the sorter control computer (not shown in Figure 10 but shown, for example, as sorter control computer (3) in any of Figures 1-4), and the package transport actuators (30) are stopped in the affected sort module. The sort module PLC (69), connected to the sorter control computer via the sort module I / O network (6), flashes indicator lights (34), and the operator is instructed to simply remove the package in that area and restart the sorter by pressing push button (35).

[0247] Several different jam detection routines are implemented in each sort module PLC based on predicting the detection of package arrival at a particular module. Some non-limiting examples of such routines are provided below.

[0248] A package did not arrive when expected. Similar to the "unknown package" jam described above, this jam is based on a package not being seen when expected. If a package is not detected by the package sensor when expected, the PLC will report a package transport jam and the sorter control system will stop the conveyor module and raise an alarm, indicating that the package could not be transported.

[0249] A package or debris has jammed on the conveyor. If a package detection sensor, such as a through beam sensor as described herein, is blocked and remains blocked between sort modules, the module PLC will report a transport jam. Similarly, the control system will stop the conveyor module and sound an alarm, indicating that a package is jammed on the conveyor.

[0250] In all cases, the sorter control system notifies the operator where the jam was detected. This notification is available on the sorter control screen or with indicator lights located on each sort module. When a jam is reported, the sorter control system stops the sort module where the jam was detected and flashes a light to indicate to the operator where the problem was detected. Additional notification is shown on the control system screen. The operator clears the jam in the affected area and removes the package. The operator notifies the control system that the package has been removed and the jam is cleared by pressing a push button located with an indicator light. Depending on the sorter and operator configuration, a secondary push button located at the operator station can be used to clear all jam conditions from one location. Once the jam is cleared, the affected sort module resumes operation.

[0251] It is important to note that independent PLC control of the sorting modules allows portions of the sorter outside the area where a sort is detected to continue processing packages until package flow is reversed by the module where it has stopped. This is an important feature as jams are often cleared before the sorter can stop from the reverse flow of stopped packages.

[0252] The sorter control system tracks the number and type of jams for each sorter module. Diagnostic logs are maintained to identify problematic sorter sections that require additional maintenance monitoring. Diagnostic log records are also used by the sorter control system to provide input for dynamic speed control of the sort modules and automatically compensate for degradation in sort module performance when mechanical wear or contamination changes the performance of the transport or movement mechanisms.

[0253] Figure 11 shows the sorter's ability to continuously sort in areas unaffected by localized jams. This is an important capability because maximum throughput is always a key consideration for a sorter system. The modular architecture allows the sorter to continue sorting packages into output bins that are not affected by localized jams or full bin conditions. This capability allows the sorter to continue productive operation for a period of time until the jam or full bin condition is cleared. These conditions are often cleared before package flow reverses and prevents the induction of new packages. In these cases, jams or bin changes do not affect the sorter's overall throughput.

[0254] Figure 11 shows sort module 69 detecting a jam and stopping the module. The sort module PLC in module 70 is not getting a "clear to transport" signal, so package 71 stops in module 72 and waits for module 69 to clear. Package 73 is directed further downstream in the sorter, but must wait until module 72 clears. However, modules 74 and 75 can continue to transport and sort packages without interruption.

[0255] Figure 12 shows how the sorter control computer, without any inter-module communication or control, can override the local sort module PLC to turn on the transport actuators of multiple sort modules, operating all at once to move all packages simultaneously. This function is used to purge the sorter of packages or to clear multiple jams when it is easier to purge a zone of modules and re-run the packages on the sorter. This purge function can be performed only on zones where only a selected group of modules operates as a group to the end of the sorter. Packages upstream and downstream of the reject zone are sorted normally, and once the affected section has flown out the end, the overall sorter operation returns to normal.

[0256] FIG. 12 illustrates this purge function with one set of modules identified as the purge zone (76), which includes the sort module PLC in module (70), among other sort module PLCs. These sort modules operate together as one large zone, and the entire zone operates as one, transporting all packages together. The local PLC logic in the module is overridden by the sorter computer to move the entire group of packages to the end of the sorter and into the reject bin (77). The sort modules in the purge zone (76) continue to transport packages forward, but do not attempt to sort packages to the side to avoid sorting errors. Other packages on sort modules outside the purge zone operate normally, passing packages from module to module and sorting accordingly. Package (78) in the illustration moves to the next module as package (79) is sorted from the module. Package (80) bypasses and is sorted normally. The purge zone (76) follows any stuck packages along the line of sort modules. When a jammed package reaches a sort module 74, the purge zone 76 includes the sort module 74 and the previous sort module, but not the sort module before that, and there are no sort modules in the purge zone 76 at that point until the jammed package enters a reject bin (unless a new jam condition and a new purge zone are established).

[0257] While preferred embodiments and examples for the production and testing of the invention have been shown and described, it will be apparent that the invention is not limited thereto. Numerous modifications or variations, changes, variations, substitutions, and equivalents will occur to those skilled in the art without departing from the spirit and scope of the invention and are considered part and parcel of the invention disclosed herein.

[0258] Furthermore, the present invention should be considered to include all possible combinations of any and all features described in this specification, the appended claims and / or the drawings, which may be novel, inventive and industrially applicable.

[0259] Numerous variations and modifications are possible in the embodiments of the invention described herein. While specific exemplary embodiments of the invention have been shown and described herein, a wide range of modifications, variations, and substitutions are contemplated in light of the above disclosure. While the above description contains many specifics, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of one or more preferred embodiments of the invention. In some instances, some features of the invention may be used without the corresponding use of other features.

[0260] Accordingly, the foregoing description is appropriately construed and understood broadly as being given by way of illustration and example only, the spirit and scope of the invention being limited only by the claims ultimately issued.

Claims

1. a plurality of sort modules configured to transport the package to one of a plurality of sort points corresponding to the package's sort point destination; a distributed control architecture having a plurality of controllers; each of the plurality of controllers is associated with one of the plurality of sort modules; each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers, including sending and receiving electronic data packets, and to use information contained in the electronic data packets to determine, based on the package's sort point destination, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module; the electronic data packet includes a sort point destination for the package; each of the plurality of controllers is capable of controlling a corresponding sort module; each of the plurality of sorting modules includes a conveyor surface configured to move articles on the conveyor surface forward and to either side; A modular package sorting system, wherein each controller of the plurality of controllers is programmed to reduce the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module exceeds a size and / or weight threshold or has a sort point destination located adjacent to the immediately succeeding sort module.

2. 2. The modular package sorting system of claim 1, wherein the plurality of sort modules comprises a series of sort modules physically connected end-to-end and configured to transport articles from a first sort module to a last sort module through the series, and wherein a controller associated with each sort module is configured to communicate with controllers associated with the immediately preceding and succeeding sort modules in the series, if present.

3. 3. The modular package sorting system of claim 2, wherein each controller of the plurality of controllers is programmed to perform the same operations, including receiving the sort point destination from a guidance subsystem or from a controller of a immediately preceding sort module, using the sort point destination to determine whether to move the package to the side of the associated sort module toward the sort point or to transport the package to the immediately succeeding sort module, and when transporting the package to the immediately succeeding sort module, sending the sort point destination to the controller associated with the immediately succeeding sort module.

4. 10. The modular package sorting system of claim 1, wherein each controller is configured to control the mechanical operation of the conveyor surface of a corresponding sort module, the plurality of sort point destinations are located on one or more sides of the plurality of sort modules, and the plurality of sort modules are configured to transport packages to the sort point destinations by transporting the packages to one or more sides of the sort modules.

5. 2. The modular package sorting system of claim 1, wherein each controller of the plurality of controllers is programmed to increase the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module has a sort point destination located beyond the immediately succeeding sort module and a predetermined number of subsequent sort modules do not have articles on their respective conveyor surfaces.

6. The modular package sorting system of claim 1 , wherein each controller is configured to provide status information regarding an associated sort module.

7. 2. The modular package sorting system of claim 1, wherein the plurality of controllers are configured to, before moving each package from one sort module to the next sort module, determine whether another package is located on the next sort module, and if so, wait to move the package to the next sort module until the other package is no longer located on the next sort module.

8. 2. The modular package sorting system of claim 1, wherein each of the plurality of controllers has its own rule set, and wherein the rule set includes at least a rule that, before moving each package from one sort module to the next sort module, determines whether another package has been placed in the next sort module, and if so, waits to move the package to the next sort module until no other packages have been placed in the next sort module.

9. The modular package sorting system of claim 1 , wherein the distributed control architecture is configured to distribute control of the plurality of sort modules among the plurality of controllers.

10. 10. The modular package sorting system of claim 1, wherein the electronic data packet further includes information related to the physical dimensions of the package, information identifying the package, and / or information identifying the dimensions of the package and / or the weight of the package.

11. 2. The modular package sorting system of claim 1, wherein each of the plurality of controllers is configured to receive the electronic data packet from a previous controller in the sequence and then communicate the electronic data packet to a next controller in the sequence.

12. 2. The modular package sorting system of claim 1, wherein the transmission of the electronic data packets occurs simultaneously with the transport of the package from an associated sort module to a subsequent sort module or to a sort point associated with the associated sort module.

13. 10. The modular package sorting system of claim 1, wherein each of the plurality of controllers is further configured to determine one of a plurality of speeds at which to convey the packages to a subsequent sort module.

14. 14. The modular package sorting system of claim 13, wherein the velocity determination depends at least on whether the package is discharged to a sort point associated with a subsequent sort module or to a sort point associated with a sort module downstream of the subsequent sort module.

15. 14. The modular package sorting system of claim 13, wherein the determined rate is different from the rate at which an associated sort module receives packages.

16. 14. The modular package sorting system of claim 13, wherein the plurality of speeds are pre-installed in each of the plurality of controllers.

17. 14. The modular package sorting system of claim 13, wherein the speed determination depends at least on the physical dimensions of the package.

18. a first controller of the plurality of controllers is associated with a first sort module of the plurality of sort modules, a second controller of the plurality of controllers is associated with a second sort module of the plurality of sort modules, and a third controller of the plurality of controllers is associated with a third sort module of the plurality of sort modules, the first, second, and third sort modules being connected in series; 2. The modular package sorting system of claim 1, wherein the second controller is configured to receive a query from the first controller regarding whether the second sort module is empty, and to send a response to the query from the first controller when the second sort module is empty; select a speed from among a plurality of speeds pre-installed in the second controller to send the package to the third sort module when a package received on the second sort module is to be transported to the third sort module; send a query to the third controller regarding whether the third sort module is empty; and send the package to the third controller only after receiving a response to the query to the third controller from the third controller.

19. 2. The modular package sorting system of claim 1, wherein each of the plurality of controllers is further configured to communicate only with the controllers associated with the sort modules immediately preceding and immediately succeeding the associated sort module, the communication including responding to a request from the controller associated with the immediately preceding sort module, receiving a data packet including a sort point destination for the package from the immediately preceding sort module when the package is transported from the immediately preceding sort module to the associated sort module, and if the sort point destination of the package is not the sort point associated with the sort module, sending a request to the controller associated with the immediately succeeding sort module, and sending a data packet to the immediately succeeding sort module when the package is transported to the immediately succeeding sort module.

20. 20. The modular package sorting system of claim 19, further comprising a second plurality of sorting modules, each of the second plurality of sorting modules having only an immediately preceding sorting module or an immediately succeeding sorting module but not both, the immediately preceding sorting module or the immediately succeeding sorting module being one of the plurality of sorting modules.

21. a plurality of sort modules configured to transport the package to one of a plurality of sort points corresponding to the package's sort point destination; a distributed control architecture having a plurality of controllers; each of the plurality of controllers is associated with one of the plurality of sort modules; each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers and to determine, based on a sort point destination of the package, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module; each of the plurality of controllers is capable of controlling a corresponding sort module; further comprising a guidance subsystem configured to receive and transport the packages toward the plurality of sort modules; the guidance subsystem is configured to prevent the package from being conveyed to the plurality of sorting modules until information is successfully read from a label on the package; the directing subsystem is configured to acquire information about the received package, determine a sort point destination for the received package based on the acquired information, and send the sort point destination to the plurality of sort modules; a sorter control computer configured to determine the sort point destination based on information about the received package; and wherein the sorter control computer is configured to, in response to a jam being detected and / or user input, remove control of two or more sort modules from the controller and operate the two or more sort modules together to purge the two or more sort modules of packages in the modular package sorting system.

22. 22. The modular package sorting system of claim 21, wherein the sorter control computer, in controlling two or more sort modules, is configured to place one or more other sort modules under the control of its controllers.

23. a plurality of sort modules configured to transport a package to one of a plurality of sort points corresponding to a sort point destination of the package, each of the plurality of controllers being associated with one of the plurality of sort modules; each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers and to determine, based on a sort point destination of the package, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module; each of the plurality of controllers is configured to receive a request for a first ready message; when the corresponding sort module is determined to be empty, send the first ready message; determine whether the package received on the corresponding sort module will be ejected in a right or left sorting direction or transported to another sort module; if the package received on the corresponding sort module is to be transported to another sort module, send a request for a second ready message to a controller corresponding to the other sort module; receive a second ready message from the controller corresponding to the other sort module; and send the package received from the corresponding sort module to the other sort module in response to receiving the second ready message from the controller corresponding to the other sort module.

24. a plurality of self-controlling sort modules configured to transport packages to one of a plurality of sort points, the plurality of controllers each associated with one of the plurality of sort modules; A modular package sorting system, wherein each of the plurality of controllers is configured to determine, when a package is received by a corresponding sort module, whether to transport the package to a subsequent sort module or to a sort point associated with the corresponding sort module, and when the package is to be transported to the subsequent sort module, to communicate with the controller associated with the subsequent sort module by sending a request for a ready message to the controller corresponding to the subsequent sort module and by receiving a ready message from the controller corresponding to the subsequent sort module, and to send the package to the subsequent sort module after receiving the ready message from the controller corresponding to the subsequent sort module.

25. 25. The modular package sorting system of claim 24, wherein a message received from a controller associated with a subsequent sort module indicates that the subsequent sort module is ready to receive a package.

26. 25. The modular package sorting system of claim 24, wherein each of the plurality of controllers is configured to enable self-control of its respective sorting module, each of the plurality of controllers being autonomous from a central operator supervisory control.

27. 25. The modular package sorting system of claim 24, wherein each of the plurality of controllers includes the same standard protocol for communicating with a sort module adjacent to an associated sort module, the standard protocol configured to enable delivery of a package to a subsequent sort module.

28. 25. The modular package sorting system of claim 24, wherein the plurality of sorting modules comprises a series of sorting modules physically connected end-to-end and configured to transport articles across the series from a first sorting module to a last sorting module, and wherein a controller associated with each sorting module is configured to communicate with controllers associated with the immediately preceding and succeeding sorting modules in the series, if present.

29. 29. The modular package sorting system of claim 28, wherein each controller of the plurality of controllers is programmed to perform identical operations, including receiving a sort point destination for the package from a guidance subsystem or from a controller of a immediately preceding sort module, and using the sort point destination to determine whether to move the package to the side of the corresponding sort module toward a sort point associated with the corresponding sort module or to transport the package to a immediately succeeding sort module, and when transporting the package to the immediately succeeding sort module, sending the sort point destination to a controller associated with the immediately succeeding sort module.

30. 25. The modular package sorting system of claim 24, wherein each of the plurality of sorting modules comprises a conveyor surface configured to move articles on the conveyor surface forward and to either side.

31. 31. The modular package sorting system of claim 30, wherein each controller is configured to control the mechanical operation of the conveyor surface of a corresponding sort module, the multiple sort point destinations are located on one or more sides of the multiple sort modules, and the multiple sort modules are configured to transport packages to the sort point destinations by transporting them to one or more sides of the sort modules.

32. 31. The modular package sorting system of claim 30, wherein each controller of the plurality of controllers is programmed to reduce the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module exceeds a size and / or weight threshold or has a sort point destination located adjacent to the immediately succeeding sort module.

33. 31. The modular package sorting system of claim 30, wherein each controller of the plurality of controllers is programmed to increase the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module has a sort point destination located beyond the immediately succeeding sort module and a predetermined number of subsequent sort modules do not have articles on their respective conveyor surfaces.

34. 25. The modular package sorting system of claim 24, wherein each controller provides status information for a corresponding sort module.

35. 25. The modular package sorting system of claim 24, wherein the plurality of controllers are configured to, before moving each package from one sort module to the next sort module, determine whether another package is located on the next sort module, and if so, wait to move the package to the next sort module until the other package is no longer located on the next sort module.

36. a plurality of sort modules configured to transport a package to one of a plurality of sort points corresponding to a sort point destination of the package, each of the plurality of controllers being associated with one of the plurality of sort modules; each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers and to determine, based on a sort point destination of the package, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module; a sorter control computer configured to determine a sort point destination based on information obtained about the received package; and wherein the sorter control computer is configured to, in response to a jam being detected and / or user input, remove control of two or more sort modules from the controller and operate the two or more sort modules together to purge the two or more sort modules of packages in the modular package sorting system.

37. 37. The modular package sorting system of claim 36, wherein the sorter control computer, in controlling two or more sort modules, is configured to place one or more other sort modules under the control of its controllers.

38. A method for transporting a package to one of a plurality of sort points corresponding to a sort point destination of the package, the method comprising: a plurality of self-controlled sort modules having a plurality of controllers, each of the plurality of controllers being associated with one of the plurality of sort modules; Each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers and to determine, based on the sort point destination of the package, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module. a sorter control computer configured to determine a sort point destination based on information obtained about the received package; each of the plurality of controllers is configured to receive a request for a first ready message; when the corresponding sort module is determined to be empty, send the first ready message; determine whether the package received on the corresponding sort module will be ejected in a right or left sorting direction or transported to another sort module; if the package received on the corresponding sort module is to be transported to another sort module, send a request for a second ready message to a controller corresponding to the other sort module; receive a second ready message from the controller corresponding to the other sort module; and send the package received from the corresponding sort module to the other sort module in response to receiving the second ready message from the controller corresponding to the other sort module.

39. A method for transporting a package to one of a plurality of sort points corresponding to a sort point destination of the package, the method comprising: a plurality of self-controlled sort modules having a plurality of controllers, each of the plurality of controllers being associated with one of the plurality of sort modules; Each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers and to determine, based on the sort point destination of the package, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module. a sorter control computer configured to determine a sort point destination based on information obtained about the received package; each of the plurality of sorting modules comprising a conveyor surface configured to move articles on the conveyor surface forward and to either side; A modular package sorting system, wherein each controller of the plurality of controllers is programmed to reduce the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module exceeds a size and / or weight threshold or has a sort point destination located adjacent to the immediately succeeding sort module.

40. A method for transporting a package to one of a plurality of sort points corresponding to a sort point destination of the package, the method comprising: a plurality of self-controlled sort modules having a plurality of controllers, each of the plurality of controllers being associated with one of the plurality of sort modules; Each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers and to determine, based on the sort point destination of the package, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module. a sorter control computer configured to determine a sort point destination based on information obtained about the received package; each of the plurality of sorting modules comprising a conveyor surface configured to move articles on the conveyor surface forward and to either side; A modular package sorting system, wherein each controller of the plurality of controllers is programmed to increase the speed of the conveyor surface of the corresponding sort module when an article on the conveyor surface of the corresponding sort module has a sort point destination located beyond the immediately succeeding sort module and a predetermined number of subsequent sort modules do not have articles on their respective conveyor surfaces.

41. A method for transporting a package to one of a plurality of sort points corresponding to a sort point destination of the package, the method comprising: a plurality of self-controlled sort modules having a plurality of controllers, each of the plurality of controllers being associated with one of the plurality of sort modules; Each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers and to determine, based on the sort point destination of the package, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module. a sorter control computer configured to determine a sort point destination based on information obtained about the received package; A modular package sorting system, wherein each controller is configured to provide status information regarding an associated sort module.

42. A method for transporting a package to one of a plurality of sort points corresponding to a sort point destination of the package, the method comprising: a plurality of self-controlled sort modules having a plurality of controllers, each of the plurality of controllers being associated with one of the plurality of sort modules; Each of the plurality of controllers is configured to communicate with one or more other controllers of the plurality of controllers and to determine, based on the sort point destination of the package, whether to transport the package from an associated sort module to a subsequent sort module or to a sort point associated with the sort module. a sorter control computer configured to determine a sort point destination based on information obtained about the received package; The modular package sorting system, wherein the communication with the one or more other controllers includes a request for readiness message.

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