Material input system and material processing system

Abstract

To provide an article input system capable of increasing an article input capacity without depending on the number of lanes of a sorter.SOLUTION: An article input system according to an embodiment of the present invention includes a plurality of supply lanes, a plurality of input lanes, and an adjustment section. The plurality of supply lanes is a second predetermined number larger than the first predetermined number, and supplies articles toward the first predetermined number of sorter lanes of the article sorter system. The plurality of input lanes are the first predetermined number, and the articles from the second predetermined number of supply lanes are input to the first predetermined number of sorter lanes. The adjusting section adjusts the supply of the articles from the second predetermined number of supply lanes to the first predetermined number of input lanes. The first predetermined number is two or more. Furthermore, the second predetermined number is a natural number excluding multiples of the first predetermined number.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Embodiments of the present invention relate to an article input system and an article processing system.

Background Art

[0002] Article processing systems for automating the sorting of articles such as luggage or paper sheets are widespread. For example, an article processing system includes a main conveyance lane and a circulation conveyance lane, reads an image of an article conveyed by the main conveyance lane, recognizes destination information included in the image, and designates a sorting destination according to the destination recognition result. Further, the article processing system sends an article from the main conveyance lane to the circulation conveyance lane, and conveys the article circulated by the circulation conveyance lane to the designated sorting destination according to the destination recognition result of the article.

[0003] The circulation conveyance lane circulates a plurality of trays, and the main conveyance lane sends out each article toward each tray being circulated. The tray discharges the accommodated article toward the designated sorting destination at the timing when it reaches the position corresponding to the designated sorting destination.

[0004] High throughput and space saving are required for article processing systems. A dual sorter system in which two trays are arranged in parallel is known as a technology that achieves both of these. Since the dual sorter system can achieve high throughput at a relatively low conveyance speed, it is advantageous in terms of cost, energy efficiency, and noise.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] In a dual sorter system, items are fed into separate inner and outer lanes to achieve high throughput. When trying to increase the amount of items fed into a dual sorter system, one might consider increasing the number of feeders (or feeding mechanisms) in multiples of two. Typically, the work efficiency of a feeder is capped at around 4,000 PPH, and the feeding throughput can only be increased in multiples of that. Therefore, for example, if the sorter throughput is 5,500 PPH per lane (2 x 5,500 = 11,000), three feeders (3 x 4,000 = 12,000) would be sufficient, but it would be necessary to assign two feeders to each lane, resulting in an excess of one person's workload.

[0007] The problem that this invention aims to solve is to provide an item input system and an item processing system that can increase the amount of items input regardless of the number of lanes in the sorter. [Means for solving the problem]

[0008] The article input system according to the embodiment comprises a plurality of supply lanes, a plurality of input lanes, and an adjustment unit. The plurality of supply lanes are a second predetermined number greater than a first predetermined number, and supply articles to a first predetermined number of sorter lanes of the article sorter system. The plurality of input lanes are the first predetermined number, and input articles from the second predetermined number of supply lanes into the first predetermined number of sorter lanes. The adjustment unit adjusts the supply of articles from the second predetermined number of supply lanes to the first predetermined number of input lanes. The first predetermined number is 2 or more. The second predetermined number is a natural number excluding multiples of the first predetermined number. [Brief explanation of the drawing]

[0009] [Figure 1] Figure 1 shows an example of a schematic configuration of an article processing system according to the embodiment. [Figure 2] Figure 2 shows an example of the connection between the article input system and the article sorter system in the article processing system according to the embodiment. [Figure 3]Figure 3 is an enlarged view of the branching section and its surroundings in the article input system according to the embodiment. [Figure 4] Figure 4 is an enlarged view of the branching section and its surroundings in the article input system according to the embodiment. [Figure 5] Figure 5 is an enlarged view of the branching section and its surroundings in the article input system according to the embodiment. [Figure 6] Figure 6 is a control block diagram of the article processing system according to the embodiment. [Figure 7] Figure 7 shows an example of a tray status management list according to the embodiment. [Figure 8] Figure 8 is a flowchart showing an example of operation control by the sorter system control unit of an article sorter system according to an embodiment. [Figure 9] Figure 9 is a flowchart showing an example of operation control by the input system control unit of the article input system according to the embodiment. [Figure 10] Figure 10 shows an example of a sorter synchronization signal distribution criterion according to the embodiment. [Figure 11] Figure 11 shows a modified example of the connection section of the three supply lanes in the article input system according to the embodiment. [Modes for carrying out the invention]

[0010] The embodiments will be described below with reference to the drawings. [composition] Figure 1 is a diagram showing an example of the schematic configuration of the article processing system according to the embodiment. Figure 2 is a diagram showing an example of the connection between the article input system and the article sorter system in the article processing system according to the embodiment. Figures 3 to 5 are enlarged views of the branching section and its surroundings of the article input system according to the embodiment. Figure 6 is a control block diagram of the article processing system according to the embodiment.

[0011] As shown in Figures 1 and 2, the item processing system S comprises an item input system 1 and an item sorter system 2. As shown in Figure 2, the item input system 1 inputs items to be sorted into the item sorter system 2. For example, items are input from the item input system 1 to the item sorter system 2 by free fall. The item sorter system 2 reads an image of the item input from the item input system 1, recognizes the destination information contained in the image, specifies a sort destination according to the destination recognition result, and transports the item to the specified sort destination. The item sorter system 2 transmits a sorter synchronization signal to the item input system 1, and the item input system 1 inputs items into the item sorter system 2 at the timing based on the sorter synchronization signal. Note that the item input system 1 and the item sorter system 2 may be systems from the same manufacturer or systems from different manufacturers.

[0012] First, let me explain the general structure. The article sorter system 2 comprises a first predetermined number of sorter lanes 23. For example, the first predetermined number is an even number of 2 or more. In this embodiment, the first predetermined number will be described as 2. The first predetermined number of sorter lanes 23 includes a first sorter lane 23i on the inner circumference side of the circulating transport path and a second sorter lane 23o on the outer circumference side of the circulating delivery path.

[0013] The article input system 1 has a second predetermined number of supply lanes, which is greater than the first predetermined number. The second predetermined number of supply lanes supply articles to the first predetermined number of sorter lanes 23 of the article sorter system 2. The second predetermined number is a natural number other than a multiple of the first predetermined number. In this embodiment, the second predetermined number is described as 3. The second predetermined number of supply lanes includes the first supply lane 11, the second supply lane 12, and the third supply lane 13.

[0014] In addition, the article input system 1 includes a first predetermined number of input lanes 15. The first predetermined number of input lanes 15 input articles from a second predetermined number of supply lanes to a first predetermined number of sorter lanes 23 via an input unit 16. The first predetermined number of input lanes 15 includes a first input lane 15i that inputs articles to the first sorter lane 23i on the inner peripheral side and a second input lane 15o that inputs articles to the second sorter lane 23o on the outer peripheral side.

[0015] The article input system 1 further includes an adjustment unit that adjusts the supply of articles from the second predetermined number of supply lanes to the first predetermined number of input lanes 15. The adjustment unit includes a first merging unit 115 that sends the articles in the first supply lane 11 to the first input lane 15i, a second merging unit 125 that sends the articles in the second supply lane 12 to the second input lane 15o, and a branching unit 14 that distributes and branches the articles in the third supply lane 13 to either the first input lane 15i or the second input lane 15o.

[0016] The first input lane 15i and the second input lane 15o convey articles from upstream to downstream. The branching unit 14 distributes the articles in the third supply lane 13 upstream of either the first input lane 15i or the second input lane 15o. The first merging unit 115 feeds the articles in the first supply lane 11 downstream of the first input lane 15i. The second merging unit 125 feeds the articles in the second supply lane 12 downstream of the second input lane 15o.

[0017] Note that while the number of lanes in the sorter lane 23 of the article sorter system 2 is 2, the number of lanes in the supply lanes of the article input system 1 may be increased to 5, 7, or 9 lanes.

[0018] Next, the detailed configuration will be described. As shown in FIGS. 1 and 2, the article input system 1 includes a first supply lane 11, a second supply lane 12, a third supply lane 13, a branching unit 14, an input lane 15, and an input unit 16. Further, as shown in FIG. 6, the article input system 1 includes an input system control unit 101, a memory 102, and an interface 103.

[0019] The input system control unit 101 operates based on a program stored in the memory 102. The input system control unit 101 controls the operation of the item input system 1 based on various signals from the item sorter system 2 (including the sorter synchronization signal SIG), the tray status management list (management information) 301, and item detection signals from multiple sensors installed at various points along the lane.

[0020] For example, the input system control unit 101 is one or more processors, and the processor is either a CPU (central processing unit) or an MPU (microprocessing unit). Alternatively, the input system control unit 101 is a PLC (Programmable Logic Controller). Furthermore, the input system control unit 101, memory 102, and interface 103 may be implemented using a general-purpose computer or the like.

[0021] Furthermore, as shown in Figures 1 and 2, the item sorter system 2 includes a passage detection unit 21, an item detection unit 22, a sorter lane 23, a tray state switching unit 24, and a destination detection unit 25. In addition, as shown in Figure 6, the item sorter system 2 includes a sorter system control unit 201, a memory 202, and an interface 203.

[0022] The sorter system control unit 201 is composed of one or more processors and operates based on a program stored in memory 202. The sorter system control unit 201 controls the operation of the item sorter system 2 based on the tray status management list 301 and item detection signals from multiple sensors installed at various points along the lane.

[0023] For example, the sorter system control unit 201 is one or more processors, and the processor is a CPU or MPU. Alternatively, the sorter system control unit 201 is a PLC. Furthermore, the sorter system control unit 201, memory 202, and interface 203 may be implemented using a general-purpose computer or the like. Alternatively, the input system control unit 101 and the sorter system control unit 201 may be implemented in a single control unit.

[0024] Furthermore, the item sorter system 2 includes n trays T1 to Tn arranged on a circular orbit of the sorter lane 23. Hereinafter, any tray will be referred to as tray T. The item sorter system 2 receives items falling from the input section 16 into tray T and transports the items in a circulating manner from upstream to downstream.

[0025] The input lane 15 includes a first input lane 15i for inputting articles into a first sorter lane 23i on the inner circumference side, and a second input lane 15o for inputting articles into a second sorter lane 23o on the outer circumference side. The input section 16 also includes a first input section 16i for inputting articles from the first input lane 15i into the first sorter lane 23i on the inner circumference side, and a second input section 16o for inputting articles from the second input lane 15o into the second sorter lane 23o on the outer circumference side.

[0026] The first supply lane 11, the second supply lane 12, the third supply lane 13, and the input lane 15 are a combination of conveyor mechanisms, such as a belt conveyor. In the article input system 1, articles are transported from upstream to downstream, the input lane 15 is located downstream of the branching section 14, and the input section 16 is located downstream of the input lane 15. The branching section 14 distributes the articles supplied from the third supply lane 13 to either the first input lane 15i or the second input lane 15o of the input lane 15.

[0027] As shown in Figures 3 to 5, the branching section 14 includes a branching mechanism 141, a first conveyor 142i, a second conveyor 142o, a first side conveyor 143i, and a second side conveyor 143o. The branching mechanism 141 branches the items to either the first conveyor 142i or the second conveyor 142o based on the sorter synchronization signal SIG distributed by the input system control unit 101.

[0028] For example, the branching mechanism 141 is a rotary conveyor, and as shown in Figure 4, it branches the items to the second conveyor 142o by rotating in the reverse direction (clockwise), and as shown in Figure 5, it branches the items to the first conveyor 142i by rotating in the forward direction (counterclockwise).

[0029] As shown in Figure 2, the first input section 16i of the input section 16 drops items from the first input lane 15i to the first sorter lane 23i on the inner circumference. The second input section 16o of the input section 16 drops items from the second input lane 15o to the second sorter lane 23o on the outer circumference.

[0030] The input section 16 has a slope inclined at a predetermined angle to the horizontal to drop items toward the sorter lane 23. Below the input section 16, the sorter lane 23 is positioned to transport the items. The input section 16 (slope) may be made movable by a movable mechanism (not shown) to prevent items transported by the sorter lane 23 from interfering with the slope of the input section 16. For example, the position of items transported by the sorter lane 23 is detected by sensors positioned along the sorter lane 23. Based on the item detection signal from the sensors, the input section 16 moves the slope horizontally or upward (away from the sorter lane 23) to avoid interference with the items being transported by the sorter lane 23.

[0031] The input lane 15 consists of belt conveyors connected in series and may include any curves and inclines depending on the installation layout.

[0032] The first input lane 15i is equipped with at least two post-branch buffer transport mechanisms 151i and a first pre-input buffer transport mechanism 153i for adjusting the transport pitch (input timing) of the articles. The first post-branch buffer transport mechanism 151i is located upstream of the first input lane 15i, and the first pre-input buffer transport mechanism 153i is located downstream of the first input lane 15i. The first input lane 15i transports articles from the upstream first post-branch buffer transport mechanism 151i to the downstream first pre-input buffer transport mechanism 153i.

[0033] Similarly, the second input lane 15o is equipped with a second post-branch buffer transport mechanism 151o and a second pre-input buffer transport mechanism 153o at least two locations for adjusting the transport pitch (input timing) of the articles. The second post-branch buffer transport mechanism 151o is located upstream of the second input lane 15o, and the second pre-input buffer transport mechanism 153o is located downstream of the second input lane 15o. The second input lane 15o transports articles from the upstream second post-branch buffer transport mechanism 151o to the downstream second pre-input buffer transport mechanism 153o.

[0034] The first post-branch buffer transport mechanism 151i and the first pre-feed buffer transport mechanism 153i are composed of one or more stages of conveyors with controllable transport speeds, and the transport pitch of the articles is adjusted by accelerating or decelerating the transport speed in an arbitrary waveform. In addition, the conveyors of the first post-branch buffer transport mechanism 151i and the first pre-feed buffer transport mechanism 153i are equipped with a detection unit (e.g., a transmission sensor) at the entrance (start end) to detect the passage of articles. The configuration of the second post-branch buffer transport mechanism 151o and the second pre-feed buffer transport mechanism 153o is the same as that of the first post-branch buffer transport mechanism 151i and the first pre-feed buffer transport mechanism 153i.

[0035] The first input lane 15i is equipped with a first post-branch buffer transport mechanism 151i, a first intermediate input lane 152i, and a first pre-input buffer transport mechanism 153i, in order from the upstream side where the goods are transported to the downstream side, and these are connected in series in this order.

[0036] Similarly, the second input lane 15o is equipped with a second post-branch buffer transport mechanism 151o, a second intermediate input lane 152o, and a second pre-input buffer transport mechanism 153o, in order from the upstream side where the articles are transported to the downstream side, and these are connected in series in this order. In this embodiment, a case in which buffer transport mechanisms are provided in two locations, either the first input lane 15i or the second input lane 15o, is described, but buffer transport mechanisms may be provided in three or more locations.

[0037] The first supply lane 11 comprises, in order from the upstream side where goods are transported to the downstream side, a first supply conveyor 111, first supply buffers 112, 113, 114, and a first merging section 115, all connected in series in this order. The first supply buffers 112, 113, and 114 adjust the transport pitch of the goods (the timing of the input of goods from the first supply lane 11 to the first input lane 15i). The first merging section 115 connects to the first intermediate input lane 152i from an oblique side such that the transport direction forms an acute angle, and the goods are transferred between them.

[0038] Similarly, the second supply lane 12 comprises a second supply conveyor 121, second supply buffers 122, 123, and 124, and a second junction 125, arranged in series from the upstream side to the downstream side where the goods are transported, in this order. The second supply buffers 122, 123, and 124 adjust the transport pitch of the goods (the timing of the input of goods from the second supply lane 12 to the second input lane 15o). The second junction 125 connects to the second intermediate input lane 152o from an oblique side such that the transport direction forms an acute angle, and the goods are transferred between them.

[0039] For example, the first merging section 115 has a trapezoidal conveying surface formed by the parallel arrangement of narrow belts of different lengths, and conveys articles from the conveying surface toward the first intermediate input lane 152i. Alternatively, the first merging section 115 is an inclined conveyor or a curved conveyor with a trapezoidal conveying surface. Furthermore, the first merging section 115 may have a conveying surface above the first intermediate input lane 152i, and articles may be dropped from the conveying surface toward the first intermediate input lane 152i.

[0040] Similarly, the second merging section 125 has a trapezoidal conveying surface formed by the parallel arrangement of narrow belts of different lengths, and conveys articles from the conveying surface toward the second intermediate input lane 152o. Alternatively, the second merging section 125 is an inclined conveyor or a curved conveyor with a trapezoidal conveying surface. Furthermore, the second merging section 125 may have a conveying surface above the second intermediate input lane 152o, and articles may be dropped from the conveying surface toward the second intermediate input lane 152o.

[0041] The third supply lane 13 comprises a third supply conveyor 131, and third supply buffers 132, 133, and 134, arranged in series from the upstream side to the downstream side where the goods are transported. The third supply buffers 132, 133, and 134 adjust the transport pitch of the goods (the timing of the input of goods from the third supply lane 13 to the first input lane 15i or the second input lane 15o). The third supply buffer 134 is located upstream of the branching section 14 and transports goods to the branching section 14.

[0042] For example, at least one worker W1 is assigned to the first supply lane 11. At least one worker W2 is assigned to the second supply lane 12. At least one worker W3 is assigned to the third supply lane 13.

[0043] Worker W1 takes an item from a container (such as a rack or bucket) placed in the first supply auxiliary section 110, which is provided in correspondence with the first supply lane 11, and places it on the first supply conveyor 111. Worker W2 takes an item from a container placed in the second supply auxiliary section 120, which is provided in correspondence with the second supply lane 12, and places it on the second supply conveyor 121. Worker W3 takes an item from a container placed in the third supply auxiliary section 130, which is provided in correspondence with the third supply lane 13, and places it on the third supply conveyor 131.

[0044] Articles placed on the third supply conveyor 131 are transported via the third supply buffers 132, 133, and 134 to the first post-branch buffer transport mechanism 151i or the second post-branch buffer transport mechanism 151o at the branching section 14. Articles placed on the first supply conveyor 111 are transported via the first supply buffers 112, 113, and 114 and the first merging section 115 to the first intermediate input lane 152i. Articles placed on the second supply conveyor 121 are transported via the second supply buffers 122, 123, and 124 and the second merging section 125 to the second intermediate input lane 152o.

[0045] Articles transported from the third supply conveyor 131 to the first post-branch buffer transport mechanism 151i are fed from the first input section 16i to the first sorter lane 23i of the article sorter system 2 via the first intermediate input lane 152i and the first pre-input buffer transport mechanism 153i. Articles transported from the third supply conveyor 131 to the second post-branch buffer transport mechanism 151o are fed from the second input section 16o to the second sorter lane 23o of the article sorter system 2 via the second intermediate input lane 152o and the second pre-input buffer transport mechanism 153o.

[0046] Articles transported from the first supply conveyor 111 to the first intermediate input lane 152i are fed from the first input section 16i to the first sorter lane 23i of the article sorter system 2 via the first pre-input buffer transport mechanism 153i. Articles transported from the second supply conveyor 121 to the second intermediate input lane 152o are fed from the second input section 16o to the second sorter lane 23o of the article sorter system 2 via the second pre-input buffer transport mechanism 153o.

[0047] The item sorter system 2 includes a passage detection unit 21, an item detection unit 22, a sorter lane 23, a tray state switching unit 24, and a destination detection unit 25. The item sorter system 2 also includes n trays T1 to Tn arranged on the circular orbit of the sorter lane 23. Hereinafter, any tray will be referred to as tray T. The item sorter system 2 receives items falling from the input unit 16 into tray T and transports the items in a circulating manner from upstream to downstream.

[0048] Trays T1 to Tn are connected in a ring shape, with tray T1 connected after tray Tn. Tray T is divided into two parts on the orbit: an inner tray Ti and an outer tray To. That is, trays T1 to Tn are composed of inner trays T1i to Tno and outer trays T1o to Tno.

[0049] The sorter lane 23 is a conveying means that circulates and conveys trays T1 to Tn. The first sorter lane 23i and the second sorter lane 23o circulate and convey the inner trays T1i to Tno and the outer trays T1o to Tno. As a result, the inner trays T1i to Tno and the outer trays T1o to Tno travel along a circular track.

[0050] The item sorter system 2 is equipped with chutes C1 to Cm below the sorter lane 23. Hereafter, any chute will be referred to as chute C.

[0051] Furthermore, the item sorter system 2 includes a tray state switching unit 24 located below the sorter lane 23, opposite the chutes C1 to Cm. For example, the tray state switching unit 24, through a tray state switching operation, contacts a predetermined position on the tray T, opening the bottom surface of the tray T and allowing the items on the tray T to fall into the chute C.

[0052] The passage detection unit 21 detects the timing of the tray T's passage at any position PS1 downstream of the last chute Cm on the orbital path of the article sorter system 2, and sends the detected passage timing to the sorter system control unit 201. However, the passage detection unit 21 is positioned sufficiently upstream of the position where articles are fed from the article input system 1 to the tray T. For example, the time required for articles transported from the first, second, and third supply buffers 114, 124, and 134 to pass through the input unit 16 is set to be shorter than the time it takes for the tray T detected by the passage detection unit 21 to reach the input unit 16.

[0053] In response to the passage detection unit 21 detecting the passage of tray T, the sorter system control unit 201 transmits a sorter synchronization signal SIG to the input system control unit 101. Since the travel speed and size of tray T are constant in principle, the timing of the detected passage of tray T will also be at regular intervals, and this can serve as a synchronization signal for controlling the item input system 1 in relation to the actual state of the item sorter system 2.

[0054] The item detection unit 22 detects whether or not there is an item on the tray T at any position PS2 downstream of the last chute Cm and upstream of the passage detection unit 21 on the orbital path of the item sorter system 2, and transmits the detection result to the sorter system control unit 201. Based on the detection result, the sorter system control unit 201 updates the tray status management list shown in Figure 7.

[0055] Figure 7 shows an example of a tray status management list according to the embodiment. As shown in Figure 7, the tray status management list 3 manages the tray numbers [T0] to [Tn], the inner tray status (presence or absence of items on the tray), and the outer tray status (presence or absence of items on the tray). The tray status management list 3 may be stored in external memory or in the memory of a higher-level system. Alternatively, the tray status management list 3 may be stored in the memory 102 of the item input system 1 or the memory 202 of the item sorter system 2.

[0056] For example, the sorter system control unit 201 updates the tray state management list 3 based on the detection results from the item detection unit 22. If the memory of the higher-level system stores the tray state management list 3, the higher-level system may update the tray state management list 3 based on the detection results from the item detection unit 22 transmitted from the sorter system control unit 201.

[0057] The sorter system control unit 201 may also detect when an item has been placed in tray T from input unit 16, or when an item on tray T has been released into chute C by the tray state switching unit 24, and update the tray state based on these detection results. However, both placing items into tray T and releasing items into chute C are physical phenomena involving free fall, and depending on the shape and material of the items, friction and air resistance may cause the item to fail to be placed or released, potentially leading to false detections. Therefore, the sorter system control unit 201 may record this update as reference information in the tray state management list 3.

[0058] [Operation] The operation of the item processing system S will be described below with reference to Figures 8 and 9. Figure 8 is a flowchart showing an example of operation control by the sorter system control unit of an article sorter system according to an embodiment. As shown in Figure 8, the sorter system control unit 201 controls the drive of the sorter lane 23, which drives the connected trays T1 to Tn to circulate and transport them (S1).

[0059] At position PS0, the item detection unit 22 detects the presence or absence of remaining items on tray T (S2), and the sorter system control unit 201 updates the tray status management list 3 by associating the tray number with the detection result (S3).

[0060] At position PS1, the item detection unit 22 detects the passage of tray T (S4), and the sorter system control unit 201 transmits a sorter synchronization signal SIG to the input system control unit 101 in response to the passage of tray T (S5YES, S6). The sorter synchronization signal SIG includes the serial number and time of passage of the tray that has passed, and the input system control unit 101 stores the passage information, including the serial number and time of passage of the tray, in the memory 102 based on the sorter synchronization signal SIG.

[0061] At position PS2, an item is placed into tray T, which is transported from input unit 16 (S7). At position PS3, the destination detection unit 25 reads an image of the item on tray T and detects the destination from the image (S8).

[0062] Based on the destination detection result, the sorter system control unit 201 outputs an operation signal to operate the tray state switching unit 24 above the chute C corresponding to the destination. The tray state switching operation of the tray state switching unit 24 opens the bottom of the tray T and releases the items on the tray T into the chute (S9).

[0063] The sorter system 2 continues to process items by repeatedly performing the operations S1 to S9 described above. While the processing at positions PS0, PS1, PS2, and PS3 is basically performed in parallel, it may also be executed sequentially.

[0064] Figure 9 is a flowchart showing an example of operation control by the input system control unit of the article input system according to the embodiment. The interface 103 of the item input system 1 receives various signals from the sorter system control unit 201. For example, the sorter system control unit 201 transmits a sorter synchronization signal SIG based on the detection of the passage of tray T by the passage detection unit 21, and the input system control unit 101 receives the sorter synchronization signal SIG via the interface 103.

[0065] As shown in Figure 9, the input system control unit 101 checks for the presence or absence of the sorter synchronization signal SIG received via interface 103 (S11), and outputs a forward-filling drive signal to forward-fill items when the sorter synchronization signal SIG is not received. The first supply lane 11, the second supply lane 12, and the third supply lane 13 perform forward-filling drive based on the forward-filling drive signal (S12NO, S13).

[0066] The algorithm for front-filling drive is arbitrary. For example, the first supply buffers 112, 113, and 114 each control the acceleration and deceleration of the transport speed so that the goods are filled from downstream in the transport direction (so that the goods come to a stop on the transport surface of the conveyor). The same applies to the second supply buffers 122, 123, and 124, and the third supply buffers 132, 133, and 134.

[0067] An example of a front-filling drive algorithm for the first supply lane 11 will be described. The first supply buffer 114 slows down and stops so that the leading edge of the item is at a predetermined position, for example, at the end of the conveyor. The first supply buffer 113 drives at a steady speed if there are no items on the conveying surface of the first supply buffer 114, the first supply buffer 112 accelerates and decelerates while monitoring the state of the first supply buffer 113, and the first supply conveyor 111 accelerates and decelerates while monitoring the state of the first supply buffer 112. By performing the above operations, it is possible to create a state in which the first supply buffers 112 to 114 are filled with items.

[0068] The forward-shifting drive algorithms in the second supply lane 12 and the third supply lane 13 are the same as the forward-shifting drive algorithm in the first supply lane 11.

[0069] When the input system control unit 101 receives the sorter synchronization signal SIG, it supplies items to one of the first supply lane 11, the second supply lane 12, or the third supply lane 13 based on the sorter synchronization signal SIG. In other words, the input system control unit 101 supplies items to one of the first supply lane 11, the second supply lane 12, or the third supply lane 13 based on the sorter synchronization signal SIG, which is based on the detection of the passage of tray T in the sorter lane 23, and the detection result of the items being transported by tray T in the sorter lane 23 (tray state management list 3).

[0070] In other words, when the input system control unit 101 receives the sorter synchronization signal SIG, it distributes the sorter synchronization signal SIG to any two of the first supply lane 11, the second supply lane 12, and the third supply lane 13 according to the distribution criteria based on the tray state management list 3 (S12YES, S14), and supplies items through any two of those lanes. For example, the input system control unit 101 controls the number of items to be input per unit time from the first supply lane 11 and the third supply lane 13 to be the same as the number of items to be input from the second supply lane 12 and the third supply lane 13, based on the sorter synchronization signal SIG. Based on the sorter synchronization signal SIG, the input system control unit 101 inputs two items from the first supply lane 11 and one item from the third supply lane 13 per unit time, and inputs two items from the second supply lane 12 and one item from the third supply lane 13. Several criteria can be considered for distributing the sorter synchronization signal SIG to achieve the predetermined number of items to be loaded per unit time mentioned above, but here we will explain one example.

[0071] Figure 10 shows an example of a sorter synchronization signal distribution criterion according to the embodiment. Assuming that workers W1, W2, and W3 supply goods at roughly the same pace, the goods supplied to the third supply lane 13 will branch in two directions, so the amount of goods supplied from the third supply lane 13 to the first input lane 15i will be half the amount of goods supplied from the first supply lane 11 to the first input lane 15i. Similarly, the amount of goods supplied from the third supply lane 13 to the second input lane 15o will be half the amount of goods supplied from the second supply lane 12 to the second input lane 15o.

[0072] Therefore, as shown in Figure 10, for the inner tray of the first input lane 15i, two items in a row (the first and second items) are initially distributed to the first supply lane 11, and the next item (the third item) is distributed to the third supply lane 13. As a result, for example, two items are transported in a row with tray numbers [T1] and [T2], and the next item is transported with tray number [T3].

[0073] Furthermore, for the outer trays of the second input lane 15o, one item is initially distributed to the third supply lane 13, and then two consecutive items are distributed to the second supply lane 12. As a result, for example, one item is transported under tray number [T1], and then two consecutive items are transported under tray numbers [T2] and [T3].

[0074] The sorter synchronization signals are then distributed repeatedly using the same criteria, but if there are remaining items on a tray, the sorter synchronization signal SIG corresponding to the tray containing the remaining items is ignored. In other words, trays with remaining items are excluded from the sorting process.

[0075] Of the first supply lane 11, the second supply lane 12, and the third supply lane 13, the supply lane to which the sorter synchronization signal SIG is assigned performs supply drive (S15). For example, if supply drive occurs in the first supply lane 11, the items accumulated in the first supply buffers 112, 113, and 114 are released downstream. The same applies to supply drive in the second supply lane 12 and the third supply lane 13.

[0076] The input system control unit 101 may calculate backward from the time required for the items to arrive at the input section 16 and wait for a predetermined time (after setting a delay time) before starting the conveyor acceleration control. Furthermore, if the input system control unit 101 receives the next sorter synchronization signal SIG during this delay time, it may control the system to release two items consecutively from the first supply lane 11 and the second supply lane 12.

[0077] Of the first supply lane 11, the second supply lane 12, and the third supply lane 13, the supply lane to which the sorter synchronization signal SIG has not been assigned performs forward-shifting drive as if the sorter synchronization signal SIG had not been received (S16).

[0078] When the sorter synchronization signal SIG is assigned to the third supply lane 13, the input system control unit 101 switches the transport direction of the branching unit 14 toward the tray T to be fed (S17YES, S18). That is, when feeding into the tray T of the inner first input lane 15i, the branching unit 14 switches its transport direction toward the inner first post-branch buffer transport mechanism 151i, and when feeding into the tray T of the outer second input lane 15o, it switches its transport direction toward the outer second post-branch buffer 151o.

[0079] Furthermore, the input system control unit 101 updates the reference passage time t for all conveyors constituting the buffer transport mechanisms included in the input lane 15 based on the sorter synchronization signal SIG (S19). All buffer transport mechanisms included in the input lane 15 are the first post-branch buffer transport mechanism 151i, the first pre-input buffer transport mechanism 153i, the second post-branch buffer transport mechanism 151o, and the second pre-input buffer transport mechanism 153o. Based on the reference passage time t, the input system control unit 101 controls the timing so that items are fed from the conveyors constituting the buffer transport mechanisms into the target trays. The reference passage time t may be determined by referring to a predefined parameter table from the arrival time of the sorter synchronization signal SIG, or it may be determined based on a predetermined mathematical formula.

[0080] For example, the reference passage time t may be calculated using the following formula, with respect to the time t0 required to pass through the conveyor constituting the buffer transport mechanism at a steady speed, the scheduled time t1 from when the tray leaves the conveyor until it is fed into the tray T via the input section 16, the time t2 for the tray to reach the input position PS2 from PS1, the transport speed v of the tray by the sorter lane, and the pitch p between trays.

[0081] t=(t2-t0-t1)%(p / v)+t0 Next, if the input system control unit 101 detects the entry of a new item into the conveyor constituting the buffer transport mechanism (S20) (S21YES), it updates the conveyor transport speed pattern so that the item passes through the conveyor by the reference passage time t (S22). For example, the input system control unit 101 determines the conveyor transport speed pattern based on the acceleration and deceleration time, which is set to be constant acceleration and deceleration, resulting in uniformly accelerated linear motion.

[0082] Subsequently, the input system control unit 101 counts down the reference passage time t by the control clock (S23) and drives all conveyors, including those other than the buffer conveyor (S24).

[0083] As described above, the article feeding system 1 of this embodiment makes it possible to efficiently feed articles from three lanes (first supply lane 11, second supply lane 12, and third supply lane 13) into trays T of two lanes (first sorter lane 23i and second sorter lane 23o).

[0084] Here, I will add some information about degenerate mode. The input system control unit 101 detects an abnormality if any of the first supply lane 11, the second supply lane 12, or the third supply lane 13 cannot operate normally due to some abnormality (for example, equipment failure or jamming of items), and executes a degraded mode. The input system control unit 101 changes the control of the lanes in degraded mode.

[0085] For example, the input system control unit 101 monitors the passage of items using multiple sensors positioned along each of the first supply lane 11, the second supply lane 12, and the third supply lane 13, and detects (determines) any abnormalities based on the presence and timing of detection signals from each sensor.

[0086] If the first supply lane 11 is not functioning properly, the input system control unit 101 detects the abnormality in the first supply lane 11, controls the branching mechanism 141 of the branching unit 14 to the first branching mode, and sends the items to the first conveyor 142i. For example, the input system control unit 101 controls the branching mechanism 141 of the branching unit 14 to the first branching mode for the duration that it receives an abnormality signal from the first supply lane 11. As a result, the items supplied from the third supply lane 13 are sent to the first post-branching buffer transport mechanism 151i via the first conveyor 142i.

[0087] If the second supply lane 12 is not functioning properly, the input system control unit 101 detects the abnormality in the second supply lane 12, controls the branching mechanism 141 of the branching section 14 to the second branching mode, and sends the items to the second conveyor 142o side. For example, the input system control unit 101 controls the branching mechanism 141 of the branching section 14 to the second branching mode while it is receiving an abnormality signal from the second supply lane 12. As a result, the items supplied from the third supply lane 13 are sent to the second post-branching buffer transport mechanism 151o via the second conveyor 142o.

[0088] The input system control unit 101 may temporarily execute a degraded mode not only when an anomaly is detected. For example, the input system control unit 101 may tolerate a certain amount of deviation from the sorter synchronization signal SIG, allowing for a slight timing delay (e.g., up to about 0.5 seconds) and oversupply of items. Even if items are oversupplied to the first input lane 15i and the second input lane 15o, the timing of item input will be appropriately adjusted by the first post-branch buffer transport mechanism 151i and the first pre-input buffer transport mechanism 153i, as well as the second post-branch buffer transport mechanism 151o and the second pre-input buffer transport mechanism 153o, so there will be no problem, and it will be possible to maximize the output throughput.

[0089] [Differentiation] The input system control unit 101 monitors the passage of items using a plurality of sensors positioned along each of the first supply lane 11, the second supply lane 12, and the third supply lane 13. The input system control unit 101 may also distribute the sorter synchronization signal SIG to one of the first supply lane 11, the second supply lane 12, or the third supply lane 13 based on the number of items in each lane.

[0090] For example, the input system control unit 101 monitors the number of items in the first supply buffers 112, 113, 114, the second supply buffers 122, 123, 124, and the third supply buffers 132, 133, 134. When the number of items in the first supply buffers 112, 113, 114 is at its maximum, the sorter synchronization signal SIG is preferentially distributed to the first supply lane 11. Similarly, when the number of items in the second supply buffers 122, 123, 124 is at its maximum, the sorter synchronization signal SIG is preferentially distributed to the second supply lane 12. Furthermore, when the number of items in the third supply buffers 132, 133, 134 is at its maximum, the sorter synchronization signal SIG is preferentially distributed to the third supply lane 13. Alternatively, the input system control unit 101 may compare the number of items in each lane and distribute the sorter synchronization signal SIG to the two lanes that have more items. In this case, the input system control unit 101 can perform operations equivalent to the degenerate mode without applying the degenerate mode.

[0091] Figure 11 shows a modified example of the connection section of the three supply lanes in the article input system according to the embodiment. Among the reference numerals attached to each part of the article input system shown in Figure 11, the same reference numerals attached to each part of the article input system shown in Figures 1 and 2 have the same function.

[0092] As shown in Figure 11, the article input system 1 includes a first supply lane 11, a second supply lane 12, and a third supply lane 13. Furthermore, the article input system 1 includes a branching section 14, an input lane 15, and an input section 16.

[0093] The first supply lane 11 comprises a first supply conveyor 111 and first supply buffers 112, 113, and 114 in order from the upstream side to the downstream side where goods are transported, and these are connected in series in this order. Downstream of the first supply buffer 114 of the first supply lane 11, an input lane 15 (first input lane 15i) is connected, and further downstream of the first input lane 15i, an input section 16 (first input section 16i) is connected.

[0094] The second supply lane 12 is equipped with a second supply conveyor 121 and second supply buffers 122, 123, and 124 in order from the upstream side to the downstream side where the goods are transported, and these are connected in series in this order. Downstream of the second supply buffer 124 of the second supply lane 12, an input lane 15 (second input lane 15o) is connected, and further downstream of the second input lane 15o, an input section 16 (second input section 16o) is connected.

[0095] The third supply lane 13 comprises a third supply conveyor 131 and third supply buffers 132, 133, and 134, arranged in series from the upstream side to the downstream side where goods are transported, and these are connected in this order. A branching section 14 is connected downstream of the third supply buffer 134 of the third supply lane 13.

[0096] The branching section 14 is equipped with a conveyor 142 for transporting articles from upstream to downstream. Furthermore, the branching section 14 is equipped with an extrusion mechanism 141o and a second post-branch buffer transport mechanism 151o on the upstream side opposite the conveyor 142, and an extrusion mechanism 141i and a first post-branch buffer transport mechanism 151i on the downstream side opposite the conveyor 142.

[0097] The push mechanism 141o pushes the articles on the upstream side of the conveyor 142 toward the second branch buffer transport mechanism 151o based on the sorter synchronization signal SIG distributed by the input system control unit 101. The pushed articles are transported to the second input lane 15o via the second branch buffer transport mechanism 151o, then to the second input section 16o via the second input lane 15o, and finally fed from the second input section 16o into the second sorter lane 23o of the article sorter system 2.

[0098] Furthermore, the push mechanism 141i pushes the articles downstream of the conveyor 142 toward the first post-branch buffer transport mechanism 151i based on the sorter synchronization signal SIG distributed by the input system control unit 101. The pushed articles are transported to the first input lane 15i via the first post-branch buffer transport mechanism 151i, then transported to the first input section 16i via the first input lane 15i, and finally fed from the first input section 16i into the first sorter lane 23i of the article sorter system 2.

[0099] As a result, we can provide an item input system and an item processing system that can increase the amount of items input regardless of the number of lanes in the sorter. By providing three supply lanes to the dual sorter described in this embodiment, an item processing system that can be operated with a sufficient number of operators is realized. This allows the advantages of high throughput and space saving to be utilized with minimal operating costs. Furthermore, by distributing the three supply lanes, a robust system can be realized that is resistant to variations in operator work time and variations in transport time for each item.

[0100] While several embodiments of the present invention have been described, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These novel embodiments can be carried out in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims of the invention and its equivalents. The invention described in the original claims of this application is listed below. [Note 1] A second predetermined number of supply lanes, greater than the first predetermined number, that supply articles to a first predetermined number of sorter lanes of the article sorter system, The first predetermined number of input lanes that input articles from the second predetermined number of supply lanes into the first predetermined number of sorter lanes, An adjustment unit that adjusts the supply of articles from the second predetermined number of supply lanes to the first predetermined number of input lanes, Equipped with, The aforementioned first predetermined number is 2 or more. An item input system in which the second predetermined number is a natural number excluding multiples of the first predetermined number. [Note 2] The first predetermined number of sorter lanes includes the first and second sorter lanes, The first predetermined number of input lanes includes the first and second input lanes, The second predetermined number of supply lanes includes the first, second, and third supply lanes, in the article input system as specified in Appendix 1. [Note 3] The adjustment unit is, A first merging section that sends articles from the first supply lane to the first input lane, A second merging section that sends articles from the second supply lane to the second input lane, A branching section that branches the items from the third supply lane to either the first or second input lane, The article loading system described in Appendix 2, which includes the features of the article loading system described in Appendix 2. [Note 4] The first input lane includes a first post-branch buffer that adjusts the timing of input of articles from the third supply lane, and transports articles from the upstream first post-branch buffer downstream. The article input system described in Appendix 3, wherein the second input lane is equipped with a second post-branch buffer that adjusts the timing of article input from the third supply lane, and articles are transported from the upstream second post-branch buffer downstream. [Note 5] The branching section distributes the articles in the third supply lane toward either the first or second post-branching buffer. The first merging section merges the articles in the first supply lane downstream of the first post-branch buffer. The second merging section is the article feeding system described in Appendix 4, which merges the articles from the first supply lane downstream of the second post-branch buffer. [Note 6] An interface for receiving synchronization signals based on the detection of the passage of trays in the first predetermined number of sorter lanes, A control unit that supplies an article to one of the first, second, and third supply lanes based on the aforementioned synchronization signal, An article loading system as described in Appendix 3, comprising the features of the article loading system described in Appendix 3. [Note 7] The interface receives the detection results of items being transported by the first predetermined number of sorter lanes, The control unit supplies articles through one of the first, second, and third supply lanes based on the synchronization signal and the detection result, as described in Appendix 6. [Note 8] The item feeding system as described in Appendix 6, wherein the control unit controls the number of items fed from the first and third supply lanes per unit time to be the same as the number of items fed from the second and third supply lanes per unit time, based on the synchronization signal. [Note 9] The item feeding system as described in Appendix 6, wherein the control unit, based on the synchronization signal, causes two items to be fed from the first supply lane and one item from the third supply lane, and two items to be fed from the second supply lane and one item from the third supply lane per unit time. [Note 10] In an article processing system comprising an article sorting system and an article input system, The aforementioned article sorting system is A first predetermined number of sorter lanes are provided, The aforementioned article input system is A second predetermined number of supply lanes, which are greater than the first predetermined number, supply articles to the first predetermined number of sorter lanes, The first predetermined number of input lanes that input articles from the second predetermined number of supply lanes into the first predetermined number of sorter lanes, An adjustment unit that adjusts the supply of articles from the second predetermined number of supply lanes to the first predetermined number of input lanes, Equipped with, The aforementioned first predetermined number is 2 or more. An article processing system in which the second predetermined number is a natural number excluding multiples of the first predetermined number. [Explanation of symbols]

[0101] 1…Item input system 2…Item sorting system 11…First supply lane 12…Second supply lane 13…Third supply lane 14... Branching point 15… Input lane 15i…First input lane 15o...Second input lane 16…Insertion section 16i...First input section 160...Second input section 21...Passage detection unit 22...Item detection unit 23...Sotarane 23i... The first Sortarane 23o... The second Sortarane 24...Tray state switching section 25...Destination detection unit 101... Input System Control Unit 102...memory 103… Interface 110...First supply support unit 111...First supply conveyor 112, 113, 114... First supply buffer 115...First junction 120...Second supply support unit 121, 122, 123... Second supply conveyor 124...Second supply buffer 125...Second merging point 130... Third Supply Support Department 131...Third supply conveyor 132, 133, 134... Third supply buffer 141... Branching mechanism 141i... Extrusion mechanism 141o...Extrusion mechanism 142... Conveyor 142i...First conveyor 142o... Second conveyor 143i... First side conveyor 143o...Second side conveyor 151i...First post-branch buffer transport mechanism 151o...Second post-branch buffer transport mechanism 152i...First intermediate input lane 152o...Second intermediate input lane 153i...First pre-insertion buffer transport mechanism 153o...Second pre-feed buffer transport mechanism 201... Sorter System Control Unit 202...Memory 203… Interface 301...Tray Status Management List C, C1, Cm... Shoot T...Tray T1i...Inner tray T1o... Outer tray

Claims

1. A second predetermined number of supply lanes, greater than the first predetermined number, that supply articles to a first predetermined number of sorter lanes of the article sorter system, The first predetermined number of input lanes that input articles from the second predetermined number of supply lanes into the first predetermined number of sorter lanes, An adjustment unit that adjusts the supply of articles from the second predetermined number of supply lanes to the first predetermined number of input lanes, Equipped with, The first predetermined number is 2 or more. The second predetermined number is a natural number excluding multiples of the first predetermined number. The first predetermined number of sorter lanes includes the first and second sorter lanes, The first predetermined number of input lanes includes the first and second input lanes, The second predetermined number of supply lanes includes the first, second, and third supply lanes, The adjustment unit is, A first merging section that sends articles from the first supply lane to the first input lane, A second merging section that sends articles from the second supply lane to the second input lane, A branching section that branches the items from the third supply lane to either the first or second input lane, Equipped with, The first input lane is equipped with a first post-branch buffer that adjusts the timing of input of articles from the third supply lane, and transports articles from the upstream first post-branch buffer downstream. The article input system comprises a second input lane equipped with a second post-branch buffer that adjusts the timing of article input from the third supply lane, and transports articles from the upstream second post-branch buffer downstream.

2. The branching section distributes the items in the third supply lane toward either the first or second post-branching buffer. The first merging section merges the articles in the first supply lane downstream of the first post-branch buffer. The article feeding system according to claim 1, wherein the second merging section merges the articles in the first supply lane downstream of the second post-branch buffer.

3. An interface for receiving synchronization signals based on the detection of the passage of trays in the first predetermined number of sorter lanes, A control unit that supplies an article to one of the first, second, and third supply lanes based on the aforementioned synchronization signal, The article loading system according to claim 1, comprising:

4. The interface receives the detection results of items being transported by the first predetermined number of sorter lanes, The article feeding system according to claim 3, wherein the control unit causes the article to be supplied through any of the first, second, and third supply lanes based on the synchronization signal and the detection result.

5. The article feeding system according to claim 3, wherein the control unit controls the number of articles fed from the first and third supply lanes per unit time to be the same as the number of articles fed from the second and third supply lanes per unit time, based on the synchronization signal.

6. The article feeding system according to claim 3, wherein the control unit, based on the synchronization signal, causes two articles to be fed from the first supply lane and one article from the third supply lane, and two articles to be fed from the second supply lane and one article from the third supply lane per unit time.

7. In an article processing system comprising an article sorting system and an article input system, The aforementioned article sorting system is A first predetermined number of sorter lanes are provided, The aforementioned article input system is A second predetermined number of supply lanes, which are greater than the first predetermined number, supply articles to the first predetermined number of sorter lanes, The first predetermined number of input lanes that input articles from the second predetermined number of supply lanes into the first predetermined number of sorter lanes, An adjustment unit that adjusts the supply of articles from the second predetermined number of supply lanes to the first predetermined number of input lanes, Equipped with, The first predetermined number is 2 or more. The second predetermined number is a natural number excluding multiples of the first predetermined number. The first predetermined number of sorter lanes includes the first and second sorter lanes, The first predetermined number of input lanes includes the first and second input lanes, The second predetermined number of supply lanes includes the first, second, and third supply lanes, The adjustment unit is, A first merging section that sends articles from the first supply lane to the first input lane, A second merging section that sends articles from the second supply lane to the second input lane, A branching section that branches the items from the third supply lane to either the first or second input lane, Equipped with, The first input lane is equipped with a first post-branch buffer that adjusts the timing of input of articles from the third supply lane, and transports articles from the upstream first post-branch buffer downstream. The article processing system comprises a second input lane equipped with a second post-branch buffer that adjusts the timing of article input from the third supply lane, and transports articles from the upstream second post-branch buffer downstream.

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