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

Abstract

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

Description

Detailed Description of the Invention

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

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

[0003] [Background Art] Induction stations for material handling facilities are well known in the art. In conventional induction stations, the operator receives goods and then inducts them into a material handling device or system so that they can be further processed. Generally, as the sorting of goods becomes increasingly competitive and lead times to delivery continue to shorten, conventional induction stations have a bottleneck in that the operator at the induction station is time-limited by the maximum possible throughput (processing volume) of the goods. Furthermore, the volume of orders to be processed in a given time is increasing. This necessitates more space for order containers around the sorter. Adding additional levels for sorting operations can partially solve this problem. On the other hand, if these additional levels are spaced vertically, such vertical expansion often poses an ergonomic hazard to the operator, who needs to repeatedly reach higher to guide goods onto the sorting device. Thus, there is a need for ergonomic induction stations that enable higher throughput to multiple levels by a single operator.

[0004] 〔overview〕 This summary is provided to introduce, in a simplified form, the ideas further described in the detailed explanation below. This summary is not intended to identify any major or essential features of the claimed subject matter, nor should it be construed as limiting the scope of the claimed subject matter.

[0005] According to one or more embodiments, a multilevel guidance station includes a plurality of sorting levels arranged in a vertical stacking configuration. The multilevel guidance station further includes a mobile automatic lift having an article-carrying surface. The multilevel guidance station further includes a frame positioned adjacent to the plurality of sorting levels, extending to at least the same height as the highest sorting level among the plurality of sorting levels. The frame is configured to support the lift as it moves between the plurality of sorting levels. The multilevel guidance station may further include an information acquisition device positioned to read information from articles placed on the article-carrying surface of the lift. The multilevel guidance station further includes a plurality of transport devices, each of which has at least one transport device. The multilevel guidance station further includes a control system including a processor. The processor is configured to receive article data identifying articles placed on the article-carrying surface of the lift. The processor is further configured to determine the destination of the articles placed on the article-carrying surface of the lift based on the article data. The processor is further configured to direct the lift to one of the sorting levels, where the transport device is located at an article receiving position adjacent to the frame, at one of the sorting levels. The processor is further configured to direct the lift by operating the article-carrying surface of the lift, so that the articles placed on the article-carrying surface of the lift are placed onto the transport device at the article receiving position. The processor is further configured to direct the transport device to the destination. The processor is further configured to direct the lift to a guide height or guide level.

[0006] A control system for a multilevel guidance station is disclosed according to one or more embodiments. The control system includes a processor. The processor is configured to receive article data identifying articles placed on the article-carrying surface of an automatic lift moving along the frame of the multilevel guidance station. The processor is further configured to determine the destination of the articles placed on the article-carrying surface of the lift based on the article data. The processor is further configured to guide the lift to one of the sorting levels of the multilevel guidance station, where a transport device is waiting at an article receiving position adjacent to the frame, at the article receiving position on one of the sorting levels. The processor is further configured to guide the lift by operating the article-carrying surface of the lift to place the articles placed on the article-carrying surface of the lift onto the mobile transport device at the article receiving position. The processor is further configured to guide the mobile transport device to the destination. The processor is further configured to guide the lift to a guidance height or guidance level of the multilevel guidance station.

[0007] A multilevel guidance station is disclosed according to one or more embodiments. The multilevel guidance station includes a plurality of sorting levels arranged in a vertical stacking configuration. The multilevel guidance station further includes a mobile automatic lift having an article-carrying surface. The multilevel guidance station further includes a frame positioned adjacent to the plurality of sorting levels, extending to at least the same height as the highest sorting level among the plurality of sorting levels. The frame is configured to support the lift as it moves between the plurality of sorting levels. The multilevel guidance station includes a plurality of transport devices, each sorting level having at least one transport device. The multilevel guidance station further includes a control system. The control system includes a processor. The processor is configured to guide the lift to one of the plurality of sorting levels, where the transport device is an article receiving position adjacent to the frame, located at an article receiving position on one of the plurality of sorting levels. The processor is further configured to guide the lift so that the article placed on the article-carrying surface of the lift is placed onto the transport device at the article receiving position by operating the article-carrying surface of the lift. The processor is further configured to guide the transport device to the destination. The processor is further configured to guide the lift to a guide height or guide level.

[0008] [Brief explanation of the drawing] To more clearly explain the technical solutions of the embodiments of the present invention, the following diagrams are briefly introduced as necessary for these embodiments. It should be noted that the following diagrams merely illustrate a part of the embodiments of the present invention and should therefore not be interpreted as limiting the scope of the invention. Furthermore, those skilled in the art should understand that they can obtain further related diagrams by following the drawings without requiring any ingenuity.

[0009] Figure 1 is a front perspective view of an exemplary embodiment of a multilevel induction station.

[0010] Figure 2 is a side perspective view of an exemplary embodiment of a multilevel induction station.

[0011] Figure 3 is a side view of an exemplary embodiment of a multilevel induction station.

[0012] Figure 4 is a top perspective view of an exemplary embodiment of a multilevel induction station.

[0013] Figure 5 is a top perspective view of an exemplary embodiment of a multilevel induction station.

[0014] Figure 6 is a top view of an exemplary embodiment of a multilevel induction station.

[0015] Figure 7 is a side perspective view of an exemplary embodiment of a multilevel induction station.

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

[0017] Figure 9 is a side perspective view showing an automatic lift according to one embodiment of the first position of a multilevel guidance station.

[0018] Figure 10 is a side perspective view showing an automatic lift according to one embodiment of the second position of a multilevel guidance station.

[0019] Figure 11A is a block diagram of an exemplary embodiment of a multilevel induction station.

[0020] Figure 11B is a block diagram of an exemplary embodiment of a multilevel induction station.

[0021] [Detailed description of the embodiment] Hereinafter, the technical solutions in embodiments of the present invention will be clearly and comprehensively described with reference to the drawings of embodiments of the present invention. Clearly, the embodiments shown herein are not all embodiments of the present invention, but merely a selection of embodiments. Generally, the components in embodiments of the present invention shown in the drawings herein can be arranged and designed according to various configurations. Therefore, the following detailed description of embodiments of the present invention provided in the drawings is not intended to limit the scope of the present invention as described in the claims, but merely to represent selected embodiments of the present invention. All other embodiments that can be obtained by a person skilled in the art without ingenuity based on embodiments of the present invention are within the scope of protection of the present invention.

[0022] The embodiments disclosed herein provide solutions to the problems of inefficient and ergonomically impractical induction stations. In particular, the embodiments disclosed herein provide a multilevel induction station, which enables a single operator to increase the throughput of items in a material handling facility. The multilevel induction station described herein is automated. This helps eliminate problems associated with human error and improves the efficiency of the induction station by allowing the operator to work more quickly. Furthermore, the multilevel induction station is more preferable for the operator because it provides a more ergonomic workspace, allowing the operator to use smaller movements and consequently reducing fatigue and / or strain. The multilevel induction station described herein enables induction stations to be higher than the operator's reach. This allows the induction station to be extended vertically (longitudinally) to increase throughput.

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

[0024] The multilevel guidance station 101 is configured to guide articles 133, 135, 137, 145, and 147. Each article may include an identifier 151, 159, 161, 163, and 165. In various embodiments, the identifier may take the form of a barcode, QR code, text label, RFID, etc. Articles may be delivered to the multilevel guidance station using an article delivery device 129. The article delivery device 129 may be a manual rolling cart (shown in Figure 1), an automated mobile transport device, a conveyor, a pick port from an automated storage system, etc. The article delivery device 129 may carry one or more articles 133, 135, and / or 137 directly on the delivery device, or the article delivery device 129 may carry one or more articles 133, 135, and / or 137 in a bin (container) 127. Articles may be manually loaded from the article delivery device 129 onto lifts such as lifts 131, 141, and 143, and then automatically loaded onto the transport device by intelligently controlling the lifts through a control system. In one embodiment, an operator may select one or more articles from the article delivery device 129 or bin 127 and place the articles onto the lift with identifiers on the articles positioned so that they can be read by an information acquisition device (e.g., information acquisition devices 153, 155, 157). The information acquisition device automatically interacts with the identifiers to recognize the articles. One or more information acquisition devices (e.g., information acquisition devices 153, 155, 157) may be positioned above the articles to read the article identifiers from above. Instead of being positioned above the articles, or in addition to being positioned above the articles, one or more information acquisition devices may be positioned to the side of the articles or otherwise positioned close to the articles. The scope of the present invention is intended to include any configuration that enables one or more information acquisition devices to read the identifier of an article either before or after the article is placed on a lift.For example, in at least one embodiment, the identifier of an article may be read by an information acquisition device in the form of a handheld scanner (either before or after the article is placed on the lift). In one example, a human operator may scan the identifier of an article using an information acquisition device in the form of a handheld scanner (either before or after the article is placed on the tray of the lift). The information acquisition device then communicates the identifier information associated with the article to the control system. For example, in one embodiment, the information acquisition device communicates with a sorter execution system (e.g., execution system 1164) (e.g., shown in Figure 11B), and the sorter execution system then communicates with a lift and sorter control server (e.g., sorter control server 1152). In at least one embodiment, the height of the article delivery device may be established, adjusted, or calibrated by the execution system 1164 so that the article is at approximately the same height as the guide height or guide level. This allows the operator to work at the optimal guide height or guide level (e.g., an adjustable guide height that is dynamically calculated to suit the specific operator's anatomical structure) in an ergonomic manner, avoiding unnecessary or unergonomic hand flexion, extension, and / or vertical movement.

[0025] In at least one embodiment, the multi-level guidance station 101 allows two or more articles to be placed on the lift, thereby enabling multiple guidances to a single lift by lifts 131, 141, or 143. In such an embodiment, the identifier of each article may be scanned (by either an information acquisition device or a human operator) before the articles are placed on the lift, simultaneously with the articles being placed on the lift, or after the articles have been placed on the lift. In one embodiment, the control system may correspondingly be configured to communicate to the operator about specific articles that need to be guided to a single lift among lifts 131, 141, or 143, and the control system may further require the operator to acknowledge that all of the specific articles have been guided to that single lift before the next step of the process begins.

[0026] The multi-level guidance station 101 further includes one or more mobile automatic lifts, such as lifts 131, 141, and 143. Each lift has an article-carrying surface. In some embodiments, the lifts may be configured to move vertically (longitudinally). In some embodiments, the lifts may be configured to move in three dimensions. In various embodiments, the article-carrying surface may be configured to carry or otherwise support articles of unusual shapes, such as clothing on hangers. The article-carrying surface may be operated to place (lower) articles from the lift onto a transport device located at an article receiving position in one of the multiple sorting levels. In one embodiment, the article-carrying surface may be or include an inclined tray. In an inclined tray, the tray tilts to one side, and articles are pulled away from the tray by gravity. The articles slide onto the transport device at the article receiving position in the sorting level. The tray then straightens up to prepare to receive another article. Inclined trays can typically handle a variety of articles. The various articles may be small or large, irregular or regular in shape, light or heavy. The tilting motion of the tilting tray may include forward motion (i.e., motion toward transport devices such as transport devices 109, 111, 113, 115, 117, or 119) concurrent with the tilting motion, so that the leading edge of the tray on the lift (i.e., the edge closest to the transport device) covers at least a portion of the transport device at the article receiving position at the sorting level when tilted, allowing for smoother delivery of articles from the tray on the lift to the transport device. In another embodiment, the article-carrying surface may be a cross belt including a belt conveyor powered by a small motor, or may include such a cross belt. The motor moves the conveyor to lower articles to the side of the cross belt onto the transport device at the article receiving position at the sorting level. Cross belt sorters can typically handle articles of irregular shape. In another embodiment, the lift or article-carrying surface may include a non-tilting tray having an article-pushing mechanism.In another embodiment, the lift or the article-carrying surface may include a cross belt, or an article pushing mechanism, or an article diverting mechanism.

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

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

[0029] The multi-level guidance station 101 includes frames 121, 123, and 125 positioned adjacent to a plurality of sorting levels, the frames extending to at least the same height as the highest sorting level among the plurality of sorting levels. Each frame is configured to support the lift as it moves vertically between the plurality of sorting levels. Each frame may include a plurality of support rails. The lift may be moved vertically by a belt, worm drive, pulley, rack and pinion, or other such mechanism. In various embodiments, the frames may form a square or rectangular shape, for example, as shown in Figure 1. The support rails of the frames may be engaged by the lift, thereby supporting the lift, which is able to move vertically and optionally laterally and horizontally as well. In one embodiment, each frame occupies a footprint slightly larger than the footprint occupied by the transport device. For example, in one embodiment, each frame may be 19'' (width) × 19'' (depth) × 82'' (height). The frame height may be adjusted or customized depending on the height of the top platform and ceiling, as well as other relevant features. In various embodiments, the multi-induction station includes multiple frames arranged in close proximity to one another.

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

[0031] The information acquisition devices 153, 155, and 157 of the multi-level guidance station 101 are each positioned on the frame so that they read information from articles placed on the article-carrying surface of the lift. In one embodiment, as shown in Figure 1, each information acquisition device is positioned on or near the back surface of each frame (e.g., of the support rail) so as to read identifiers on the articles beneath it. The information acquisition devices 153, 155, and 157 are configured to capture images or other identifiers of articles, or otherwise examine them, in order to identify the articles and / or determine their destination. In various embodiments, the information acquisition devices may be barcode readers, QR code readers, text readers, RFID readers, etc. The information acquisition devices are configured to acquire article information of articles, which may include the destination of the articles. The information acquisition devices interact with identifiers on the articles or with the articles themselves.

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

[0033] In some embodiments, the multilevel guidance station further includes multiple transport systems, each system including multiple transport devices. The multilevel guidance station may operate in conjunction with other sorting systems and therefore may be used, for example, to guide three stacked bomb bay sorters.

[0034] The multi-level guidance station 101 further includes a sorter control system (see Figures 11A and 11B) which includes a processor. The sorter control system, and its processor, are configured to receive article data that identifies articles placed on the article-carrying surface of the lift. The processor is further configured to determine the destination of the articles placed on the article-carrying surface of the lift based on the article data. The processor is further configured to guide the lift to one of a plurality of sorting levels, where the transport device is located at an article receiving position adjacent to the frame, at an article receiving position at one of the plurality of sorting levels. In one embodiment, the processor selects a specific transport device from a plurality of transport devices located at an article receiving position adjacent to the frame, at an article receiving position at a specific sorting level among the plurality of sorting levels. The processor is further configured to guide the lift with articles placed on its article-carrying surface so that articles are placed on the transport device located at the article receiving position by operating the article-carrying surface of the lift (for example, Figures 8 to 10 show articles being placed by the lift). The processor is further configured to guide the transport device to its destination. The processor is further configured to guide the lift to a guided height or guided level.

[0035] In one embodiment, as shown in Figures 1 to 7, the sorting levels may include multiple platforms, and the transport device may include an automated mobile transport device (e.g., a robot) that moves on the platform. In one embodiment, the automated mobile transport device is positioned at or near the edge of the platform at an item receiving position adjusted relative to the lift.

[0036] In at least one embodiment, the information acquisition device is optional. For example, in a sorting system where the same type of articles are always guided to a predetermined guidance station, or a certain quantity of the same type of articles are guided, or where an upstream system provides article information, it is not necessary to use an information acquisition device to individually identify the articles. In such embodiments, the multilevel guidance station includes a plurality of sorting levels arranged in a vertical stacking configuration. The multilevel guidance station further includes a vertically moving automatic lift having an article-carrying surface. The multilevel guidance station further includes a frame positioned adjacent to the plurality of sorting levels, the frame extending to at least the same height as the highest sorting level among the plurality of sorting levels. The frame is configured to support the lift as it moves vertically between the plurality of sorting levels. The multilevel guidance station further includes a plurality of transport devices, with at least one transport device located at each sorting level. The multilevel guidance station further includes a control system including a processor. The processor is configured to guide the lift to one of the plurality of sorting levels. Here, the transport device is located at an item receiving position adjacent to the frame, at an item receiving position in one of a plurality of sorting levels. The processor is further configured to guide the lift by operating the item-carrying surface of the lift so that the items placed on the item-carrying surface of the lift are placed onto the transport device at the item receiving position. The processor is further configured to guide the transport device to the destination. The processor is further configured to guide the lift (again) to the guide height.

[0037] In various embodiments, the multilevel guidance station 101 may be portable. For example, the multilevel guidance station 101 may be equipped with wheels 149. This allows the multilevel guidance station to be moved to the optimal position or location within the material handling facility where it can be used most effectively. Furthermore, the addition of wheels makes it easy to add additional multilevel guidance stations during busy periods such as holidays.

[0038] In various embodiments, the multilevel guidance station 101 may be modular. For example, each of the sorting levels or sorting platforms may be assembled from parts, thereby allowing the multilevel guidance station 101 to be easily reconfigured to fit any material handling facility. Also in various embodiments, the multilevel guidance station 101 may be reconfigurable to various dimensions, thereby allowing the length, width, area, and other attributes of each sorting level or sorting platform to be reconfigured.

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

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

[0041] Figure 9 is a side perspective view showing an automatic lift according to one embodiment at a first position of a multi-level guidance station. Meanwhile, Figure 10 is a side perspective view showing an automatic lift according to the same embodiment at a second position of the multi-level guidance station. Referring to Figures 9 and 10, the motor 167 moves the frame of the lift 131 (e.g., vertically up or down) to a position close to the transport device or close to the guidance height or guidance level (e.g., the height shown in Figure 3 or Figure 7). The tilting mechanism 169 tilts the tray forward (e.g., to the position where the articles are placed) and / or backward (e.g., back to the article carrying position) by rotating, extending and / or retracting the arm 171. In at least one embodiment, as the arm 171 extends, the tray slides forward or moves forward along the track 173. As a result, the tray first slides forward or moves forward (for example, towards the transport device, in a forward direction), and then the tray rotates at a downward angle, so that the items 145 slide off the tray (as shown in Figure 10) into the transport device located at the item receiving position of one of the sorting levels.

[0042] Figure 11A is an exemplary block diagram of an exemplary embodiment of a multilevel guidance station described herein. Referring to Figure 11A, the multilevel guidance system 1101 includes a sorter control server 1102, an information acquisition device 1104, a lift 1106, and a transport device 1108, a wireless access point 1110, and a host management system server 1112. These are shown representatively as blocks representing a general descriptor of the art.

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

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

[0045] As used herein, the term “cloud” refers to a set of Internet-connected servers that can be leased as part of a software or application service. Cloud-based services may include web hosting, data hosting and sharing, and the use of software or applications. The term “cloud” also refers to cloud computing, which involves the coordinated use of multiple servers to share the load. This means that instead of using a single powerful machine, complex processing can be distributed across multiple smaller computers. In various embodiments, the sorter control servers 1102 / 1152, the host management servers 1112 / 1162, and the cloud server 1166 may be servers in which the term “server” is understood in its broadest sense, or may include servers in which the term “server” is understood in its broadest sense in other ways. As used herein, the term “server” includes any computer that provides data to other computers. It may provide data to systems on a local area network (LAN) or to systems on a wide area network (WAN) over the Internet. In various embodiments, the sorter control servers 1102 / 1152 may be or include a cloud server (e.g., cloud server 1166). As used herein, the term “cloud server” includes any pooled and centralized server resources that are hosted and delivered over a network (typically the Internet) and accessed on demand by multiple users. A cloud server may be located remotely (e.g., in a remote cloud server configuration). A cloud server may be a virtual server operating in a cloud computing environment (rather than a physical server). A cloud server may be built, hosted, and delivered over the Internet and through a cloud computing platform and may be accessed remotely. A cloud server may include all the software necessary for execution and may function as a standalone unit.Cloud servers can perform all the same functions as traditional physical servers, including processing power, storage, and application delivery. One of the advantages of cloud storage is that there are many distributed resources that behave as a single entity. This is often referred to as a federated storage cloud. This makes the cloud extremely resilient to failures because the data is distributed. By using the cloud, access to documents, files, and data is shared, reducing the need to create multiple versions of files.

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

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

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

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

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

[0051] During operation, the operator receives one or more items at a multi-level guidance station. The one or more items may be transported to the operator by an item delivery device. The operator takes one of the items from the item delivery device and places it on the item-carrying surface (e.g., a tray) of a lift waiting at guidance height or guidance level. As can be seen in Figure 1, for example, the operator loads the item onto the lift's tray from the back of the tray (i.e., the side of the tray facing the operator). In at least one embodiment, the lift's tray can be rotated at least 90 or 180 degrees. As a result, the front or side of the tray faces the operator, allowing the operator to load the item onto the lift's tray from the front of the tray. The tray is then rotated back to its original position so that the back of the tray faces the operator before the next step of the process begins. An information acquisition device reads the identifier on the item on the lift's item-carrying surface (e.g., from above, from the side, or near the lift). The information acquisition device transmits the identifier information to the control system. The control system identifies the articles and their destinations. Next, the control system assigns the articles on the lift's tray to a specific transport device and transmits the location of the selected transport device to the lift. The lift then moves its frame as appropriate (e.g., up or down) to the appropriate height relative to the selected transport device. Once the lift reaches the appropriate height, it places the articles on the assigned transport device at the article receiving position. In one embodiment, the tray on the lift tilts forward, causing the articles to slide off the front of the tray onto the assigned transport device. The tilting motion of the lift's tray may include a simultaneous forward movement (see Figures 9 and 10) such that the front edge of the lift's tray covers the transport device when tilted, allowing for smoother delivery of articles from the lift's tray to the transport device. After delivery of the articles to the assigned transport device, the lift returns to the guided height or guided level to be ready to receive the next articles from the operator.

[0052] It should be understood that various frame configurations are possible depending on the number of operators and the reach of each operator. For example, with two frames placed side-by-side on a 3-level station, a single operator can ergonomically (efficiently) load items onto six different robot positions. Similarly, with two frames placed side-by-side on a 4-level station, a single operator can ergonomically load items onto eight different robot positions.

[0053] Furthermore, as shown in Figure 1, for example, with three frames placed at the corners of a three-level system, the operator can ergonomically load items onto nine different robot positions.

[0054] The above are merely specific embodiments of the present invention. However, the scope of protection of the present invention is not limited to these, and any modifications or substitutions that are readily conceivable by those skilled in the art, as long as they fall within the disclosed technical scope of the present invention, should also fall within the scope of protection of the present invention. In other words, the scope of protection of the present invention should be determined by the scope of protection of the appended claims. [Brief explanation of the drawing]

[0055] [Figure 1] This is a front perspective view of an exemplary embodiment of a multilevel induction station. [Figure 2] This is a side perspective view of an exemplary embodiment of a multilevel induction station. [Figure 3] This is a side view of an exemplary embodiment of a multilevel induction station. [Figure 4] This is a top perspective view of an exemplary embodiment of a multilevel induction station. [Figure 5] This is a top perspective view of an exemplary embodiment of a multilevel induction station. [Figure 6] This is a top view of an exemplary embodiment of a multilevel induction station. [Figure 7] This is a side perspective view of an exemplary embodiment of a multilevel induction station. [Figure 8] This is a side perspective view of an automatic lift according to one embodiment of a multi-level guidance station. [Figure 9] This is a side perspective view showing an automatic lift according to one embodiment of the first position of a multilevel guidance station. [Figure 10] This is a side perspective view showing an automatic lift according to one embodiment of the second position of a multilevel guidance station. [Figure 11A] This is a block diagram of an exemplary embodiment of a multilevel induction station. [Figure 11B] This is a block diagram of an exemplary embodiment of a multilevel induction station.

Claims

1. It is a multilevel guidance station, Multiple sorting levels arranged in a vertical stacking configuration, A vertically moving automatic lift having an article-carrying surface, A frame positioned in close proximity to a plurality of sorting levels, extending to at least the same height as the highest sorting level among the plurality of sorting levels, and configured to support the lift as the lift moves between the plurality of sorting levels, A plurality of transport devices which are self-powered and self-guided automated guided vehicles (AGVs) operating on a platform, wherein each sorting level has at least one transport device, A control system including a processor, Includes, The aforementioned processor, The lift receives article data that identifies an article placed on the article-carrying surface of the lift, Based on the aforementioned item data, the destination of the item placed on the item-carrying surface of the lift is determined. The lift is guided to one of the sorting levels, where a transport device is wirelessly communicating with the control system at an item receiving position adjacent to the frame in one of the sorting levels. By operating the article-carrying surface of the lift, the lift is guided to place the article placed on the article-carrying surface of the lift onto the transport device at the article receiving position. The transport device is guided to the destination. Guide the aforementioned lift to the guide height It is configured in such a way, The platform is a multilevel induction station having a continuous, flat surface on which no openings are formed.

2. The present invention further includes an information acquisition device arranged to read information from an article placed on the article-carrying surface of the lift, The multilevel guidance station according to claim 1, wherein the item data is received from the information acquisition device.

3. The multilevel guidance station according to claim 1, wherein the multilevel guidance station is portable.

4. The multilevel guidance station according to claim 3, wherein the multilevel guidance station is equipped with wheels.

5. The multilevel induction station according to claim 1, wherein the multilevel induction station is modular.

6. The multilevel guidance station according to claim 1, wherein the multilevel guidance station is reconfigurable.

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

8. The multi-level guidance station according to claim 7, wherein the inclined tray is configured to tilt so as to cover the transport device and move forward toward the transport device.

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

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

11. The multilevel guidance station according to claim 1, wherein the guidance height is set to a predetermined height determined by the processor.

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

13. The multilevel guidance station according to claim 1, wherein the multilevel guidance station includes at least two sorting levels arranged vertically.

14. The multilevel guidance station according to claim 1, wherein the multilevel guidance station includes a plurality of frames arranged in close proximity to each other.

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

16. The multilevel guidance station according to claim 15, wherein the frame further includes a sensor that prevents the lift from moving before the operator's arm is withdrawn from the guidance opening.

17. A control system for a multilevel guidance station, The system receives article data that identifies an article placed on the article-carrying surface of an automatic lift moving through the frame of the multi-level guidance station. Based on the aforementioned item data, the destination of the item placed on the item-carrying surface of the lift is determined. The lift is guided to one sorting level where a mobile transport device, which is a self-powered and self-guided automated guided vehicle (AGV) operating on a platform, is waiting at an item receiving position close to the frame at one of the sorting levels of the multi-level guidance station. By operating the article-carrying surface of the lift, the lift is guided to place the article placed on the article-carrying surface of the lift onto the movable transport device at the article receiving position. The movable transport device is guided to the destination. The lift is guided to the guidance height of the multilevel guidance station. It has a processor configured as follows: The platform is a continuous, flat surface on which no openings are formed. The transport device is a control system that communicates wirelessly with the control system.

18. The control system according to claim 17, wherein item data is received from an information acquisition device located on the frame of the multilevel guidance station.

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

20. It is a multilevel guidance station, Multiple sorting levels arranged in a vertical stacking configuration, A mobile automatic lift having an article-carrying surface, A frame positioned in close proximity to a plurality of sorting levels, extending to at least the same height as the highest sorting level among the plurality of sorting levels, and configured to support the lift as the lift moves between the plurality of sorting levels, A plurality of transport devices which are self-powered and self-guided automated guided vehicles (AGVs) operating on a platform, wherein each sorting level has at least one transport device, A control system including a processor, Includes, The aforementioned processor, The lift is guided to one of the sorting levels, where a transport device is wirelessly communicating with the control system at an item receiving position adjacent to the frame in one of the sorting levels. By operating the article-carrying surface of the lift, the lift is guided to place the article placed on the article-carrying surface of the lift onto the transport device at the article receiving position. The transport device is guided to its destination. Guide the aforementioned lift to the guide height It is configured in such a way, The platform is a multilevel induction station having a continuous, flat surface on which no openings are formed.

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