Robotic put wall systems and methods with dynamic gantry systems

Abstract

An object processing system includes an object induction station, at which an object is provided for processing, the object induction station includes an in-feed conveyor and at least one perception system for providing perception data regarding the object. A plurality of destination locations (104) are arranged in a vertically and horizontally extending array of destination locations. A first carrier system (106) includes a first transfer system (126) that is movable adjacent the plurality of destination locations (104) and a second carrier (138) system includes a second transfer system (136) that is movable adjacent the plurality of destination locations (104) independently of the first transfer system. Each of the first carrier system (106) and the second carrier system (138) are adapted to provide that both the first transfer system (106) and the second transfer system (138) are able to access the object induction station as well as each of the plurality of destination locations (104).

Description

ROBOTIC PUT WALL SYSTEMS AND METHODS WITH DYNAMIC GANTRY SYSTEMSPRIORITY

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63 / 685,595 filed August 21, 2024, the disclosure of which is hereby incorporated by reference in its entirety.BACKGROUND

[0002] The invention generally relates to object processing systems, and relates in particular to object processing systems such as e-commerce order fulfillment system, distribution center systems, and sortation systems that are used for processing a variety of objects.

[0003] Current object processing systems generally involve the processing of a large number of objects, where the objects are received in either organized or disorganized batches, and must be routed to desired destinations in accordance with a manifest or specific addresses on the objects (e.g., in a mailing / delivery system).

[0004] In current e-commerce order fulfillment systems objects are picked by human personnel from shelves and put into bins that hold multiple customer orders. These bins are then forwarded to manual cubbies, where they are sorted into customer orders. The human personnel at the cubbies will pick an object up, scan it with a barcode scanner, and a computerized system will tell them into which bin to put the object, or there will be a ‘put-to- lighf system where a light at the cubby lights up showing where the human personnel should put the object.

[0005] Current distribution center sorting systems, for example, generally assume an inflexible sequence of operations whereby a disorganized stream of input objects is first singulated into a single stream of isolated objects presented one at a time to a scanner that identifies the object. An induction element (e.g., a conveyor, a tilt tray, or manually movable bins) transport the objects to the desired destination or further processing station, which may be a bin, an inclined shelf, a chute, a bag or a conveyor etc.

[0006] In parcel sortation systems, human workers or automated systems typically retrieve parcels in an arrival order, and sort each parcel or object into a collection bin based on a set of given heuristics. For instance, all objects of like type might go to a collection bin, or all objects in a single customer order, or all objects destined for the same shipping destination, etc. The human workers or automated systems are required to receive objects and to move each to theirassigned collection bin. If the number of different types of input (received) objects is large, a large number of collection bins is required.

[0007] Current state-of-the-art sortation systems rely on human labor to some extent. Most solutions rely on a worker that is performing sortation, by scanning an object from an induction area (chute, table, etc.) and placing the object in a staging location, conveyor, or collection bin. When a bin is full or the controlling software system determines that it needs to be emptied, another worker empties the bin into a bag, box, or other container, and sends that container on to the next processing step. Such a system has limits on throughput (i.e., how fast can human workers sort to or empty bins in this fashion) and on number of diverts (i.e., for a given bin size, only so many bins may be arranged to be within efficient reach of human workers).

[0008] There remains a need for a more efficient and more cost-effective object processing systems that process objects of a variety of sizes and weights into appropriate collection bins or boxes, yet is efficient in handling objects of such varying sizes and weights.SUMMARY

[0009] According to an aspect of the invention, an object processing system is provided that includes an object induction station, a plurality of destination locations, a first carrier system and a second carrier system. At the object induction station, an object is provided for processing, the object induction station includes an in-feed conveyor and at least one perception system for providing perception data regarding the object. The plurality of destination locations are arranged in a vertically and horizontally extending array of destination locations. The first carrier system includes a first transfer system that is movable adjacent the plurality of destination locations and the second carrier system includes a second transfer system that is movable adjacent the plurality of destination locations independently of the first transfer system. Each of the first carrier system and the second carrier system are adapted to provide that both the first transfer system and the second transfer system are able to access the object induction station as well as each of the plurality of destination locations.

[0010] In accordance with another aspect of the invention, an object processing system is provided that includes an object induction station, two arrays of destination locations, a first carrier system and a second carrier system. At the object induction station, an object is provided for processing. The two arrays of destination locations are vertically and horizontally extending and are separated by an aisle with an aisle length. The first carrier system includes a first transfer system that is movable along the aisle. The second carrier system includes a second transfer system that is movable along the aisle independently of the first transfersystem. Each of the first carrier system and the second carrier system are adapted to provide that both the first transfer system and the second transfer system are movable along the full aisle length.

[0011] In accordance with yet another aspect of the invention, a method of processing objects is disclosed that includes: receiving an object at an object induction station that includes an in- feed conveyor; providing perception data regarding the object; providing a plurality of destination locations that are arranged in a vertically and horizontally extending array of destination locations; providing a first transfer system of a first carrier system that is movable adjacent the plurality of destination locations; providing a second transfer system of a second carrier system that is movable adjacent the plurality of destination locations independently of the first transfer system; and moving at least one of the first transfer system and the second transfer system past one another such that each of the first carrier system and the second carrier system is adapted to provide that both the first transfer system and the second transfer system are able to access the object induction station as well as each of the plurality of destination locations.

[0012] In accordance with still another aspect of the invention, a carrier system is provided that includes a horizontal gantry system for moving a transfer system in mutually opposing horizontal directions, the horizontal gantry system including at least two wheels for riding along upper sides of two horizontal rails, and at least two wheels for riding along undersides of the two horizontal rails; and a vertical gantry system that is attached to the horizontal gantry system for moving the transfer system in mutually opposing vertical directions, the horizontal gantry system and the vertical gantry system providing that the transfer system may access any of a plurality of destination locations that are provided in a vertical array of destination locations.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The following description may be further understood with reference to the accompanying drawings in which:

[0014] Figure 1 shows an illustrative diagrammatic front view of an object processing system in accordance with an aspect of the present invention;

[0015] Figures 2A and 2B show illustrative diagrammatic rear views of the induction station of the object processing system of Figure 1, showing an object about to be loaded onto a carrier system (Figure 2A) and showing the carrier system moving the object (Figure 2B);

[0016] Figures 3 A and 3B show illustrative diagrammatic views of the telescoping vertical gantry system of the object processing system of Figure 1 in an extended configuration (Figure 3 A), and in a retracted configuration (Figure 3B);

[0017] Figures 4A and 4B show illustrative diagrammatic partial cross-sectional views of the telescoping vertical gantry system of Figure 1, showing the telescoping vertical gantry system when collapsed (Figure 4A) and when extended (Figure 4B);

[0018] Figures 5A and 5B show illustrative diagrammatic views of the upper telescoping vertical system and the lower telescoping vertical gantry system of the object processing system of Figure 1 with each telescoping vertical gantry system in a partially extended position (Figure 5A) and a fully retracted position (Figure 5B);

[0019] Figures 6A and 6B show illustrative diagrammatic elevated perspective views of the telescoping vertical gantry systems of the object processing system of Figure 1 with each telescoping vertical gantry system in a fully retracted position (Figure 6A), and showing the lower telescoping vertical gantry system in a fully extended position (Figure 6B);

[0020] Figure 7 shows an illustrative diagrammatic plan view of the object processing system of Figure 1 showing a full aisle length between the arrays of destination locations;

[0021] Figure 8 shows an illustrative diagrammatic elevated front view of an object processing system in accordance with an aspect of the present invention that includes a programmable motion device at an induction station;

[0022] Figure 9 shows an illustrative diagrammatic side view of the induction station of Figure 8 showing a side view of the programmable motion device;

[0023] Figures 10A and 10B show illustrative diagrammatic rear views of an induction station of an object processing system in accordance with another aspect of the present invention that includes bypass mast vertical gantry systems, showing an object about to be loaded onto a transfer system of a downwardly extending bypass mast vertical gantry system (Figure 10 A) and showing the object on the transfer system of the downwardly extending bypass mast vertical gantry system and being moved (Figure 10B);

[0024] Figures 11 A and 1 IB show illustrative diagrammatic views of the upper carrier system of the object processing system of Figures 10A and 10B in a side view (Figure 11 A) and in an elevated end view (Figure 1 IB);

[0025] Figures 12A and 12B show illustrative diagrammatic enlarged views of the horizontal gantry system (Figure 12A) and the vertical gantry system (Figure 12B) of the upper carrier system of the object processing system of Figures 10A and 10B;

[0026] Figures 13 A and 13B show illustrative diagrammatic views of the upper and lower carrier systems of the object processing system of Figures 10A and 10B with the destination locations removed showing the transfer systems positioned to pass one another (Figure 13 A) and showing the transfer systems having passed one another (Figure 13B);

[0027] Figures 14A and 14B show illustrative diagrammatic views of the upper and lower carrier systems of the object processing system of Figures 10A and 10B with a portion of the destination locations removed showing each of the transfer systems approaching one another not in a passing condition (Figure 14A) and showing the respective transfer systems in each of the carrier systems in a passing condition (Figure 14B);

[0028] Figures 15A and 15B show illustrative diagrammatic views of the upper and lower carrier systems of the object processing system of Figures 10A and 10B with a portion of the destination locations removed showing each of the respective transfer systems having passed one another (Figure 15 A) and showing the respective transfer systems in each of the carrier systems having been moved by their respective vertical gantry systems (Figure 15B);

[0029] Figure 16 shows an illustrative diagrammatic view of a carrier system that includes a linear drive system with the horizontal gantry system in accordance with further aspects of the present invention;

[0030] Figure 17 shows an illustrative diagrammatic view of a carrier system that includes a telescoping vertical gantry system and a roller-mounted horizontal gantry system;

[0031] Figure 18 shows an illustrative diagrammatic plan view of a multi -gantry system in accordance with various aspects of the present invention that includes plural induction stations;

[0032] Figures 19A and 19B show illustrative diagrammatic views of carrier systems in accordance with further aspects of the present invention that include plural vertical gantry systems on each of upper and lower horizontal gantry systems, showing the vertical gantry systems separated (Figure 19 A) and mingled (Figure 19B);

[0033] Figure 20 shows an illustrative diagrammatic view of a functional representation of a robotic put wall system in accordance with various aspects of the present invention; and

[0034] Figures 21A and 21B show illustrative graphical representation of the relationship between metrics regarding discharge time and throughput (Figure 21A) and regarding discharge time and power (Figure 2 IB) in accordance with certain aspects of the present invention.

[0035] The drawings are shown for illustrative purposes only.DETAILED DESCRIPTION

[0036] In accordance with various aspects, the invention provides a robotic put-wall system that automates the sortation process. Any of a programmable motion device or human personnel may pick an object off of a conveyor or out of a bin at an induction station. The human personnel (or a programmable motion device) processes each object by retrieving the object, permitting it to be scanned, and places each object onto an in-feed conveyor that moves each object toward a carrier system. The carrier system moves the object to one of a plurality of destination locations (e.g., via any of a plurality of chutes, each of which leads to a destination location). Human personnel may then collect the objects from each destination location when completed and put the objects into, for example, shipping boxes for shipment.

[0037] An objective of the present invention is to move as many objects to their destination locations as quickly and efficiently as possible. Speed and efficiency involve consideration of not only time but also cost of materials, operational expenses and down-time costs. When the number of destination locations becomes larger, for example, with destination locations that extend horizontally and / or vertically over significant distances, inducting each object via a single induction station at one end and moving the objects via a single gantry system may become inefficient. Analyses of throughput may be used to establish cost justification of capital investment of automation, particularly since increases in throughput can increase significantly without increasing staffing levels. Other metrics include energy efficiency and utilization that factor in the capacity of the automation system. Precision can lead to reduced waste and errors. System down-time is an important factor and complexity of the automation system can be a significant factor.

[0038] In accordance with an aspect, the invention provides the use of varied gantry systems in an object processing system that provides higher throughputs without significantly negative impacts on cost of materials, operational expenses and down-time costs. The systems disclosed herein strike unexpected balances of throughput to identified costs that are applicable to various types of systems that may be used to distribute objects to destination locations as efficiently and economically as possible.

[0039] With reference to Figure 1, an object processing system 100 in accordance with an aspect of the present invention includes an object induction station 102, a plurality of destination locations 104 on either side thereof, and a carrier system 106. The carrier system 106 includes a horizontal gantry system 113, a vertical gantry system 103 and a transfer system 126. The object induction station 102 includes a source conveyor system 108 on which objects to be processed (e.g., in bins 110) are presented. Generally, human personnel (or aprogrammable motion device as discussed below) picks an object (e.g., from a bin 110), holds the object under a scanner 112, receives feedback indicating the object is properly identified (e.g., via a light or status screen), and places the object onto an in-feed conveyor 114. Processed bins are returned along a return conveyor system 109.

[0040] The transfer system 126 is coupled to the vertical gantry system 103 for vertical movement thereof, and the vertical gantry system is coupled to the horizontal gantry system 113 for horizontal movement thereof. With reference to Figure 2 A (which shows a rear view of the object induction station 102), the transfer system 126 may be positioned (vertically and horizontally) to receive an object to be processed from a discharge end of the in-feed conveyor 114. The transfer system 126 is mounted on the distal end of the telescoping carrier 103, which raises and lowers as the telescoping vertical gantry system 103 retract and extends. The transfer system 126 is configured to receive an object thereon, such as object 111, from the in-feed conveyor 114 when the transfer system is aligned with a discharge end of the in-feed conveyor. The in-feed conveyor moves the object 111 past an additional perception system 107 that can acquire and evaluate images of the object 111 as it is moved in addition to, or in the replacement of the scanner 112. The speed of the in-feed conveyor 114 may be controlled by the control system 101 (Figure 1) to directly impact the processing time for each object. The transfer system 126 is adapted to move a transfer conveyor thereon in either of two opposing directions that are transverse to the horizontal direction movement of the first telescoping vertical gantry system 103, and such movement can be actuated to move an object thereon to any of the destination locations 104 when appropriately positioned by the vertical and horizontal gantry systems.

[0041] Figure 2B shows the rear view of the object induction station 102 with telescoping vertical gantry system 103 of the carrier system 106 in a retracted position that raises the elevation of the transfer system 126 above the level of the in-feed conveyor 114 with the object 111 thereon. The transfer system 126 is also moved horizontally by the horizontal gantry systems shown in Figures 1, 3 A and 3B. Characteristics of the object 111 may be acquired when the object 111 is being processed while on the transfer system 126. For example, the mass of the object may be acquired through the use of sensors disposed on the telescoping vertical gantry system 103. Physical characteristics, such as dimensions or overall height of the object 111 may be acquired by the perception system 107 as the object is being moved on the in-feed conveyor 114. Characteristics of the object 111 may also be acquired in a database lookup using the identifying indicia that may be read by the scanner 112 and / or the perception system 107. Characteristics may be used as an input in the determination of parameters tooptimize the overall efficiency and throughput of the object processing system 100, as will be described in more detail herein below.

[0042] Figure 3 A shows the telescoping vertical gantry system 103 of the carrier system 106 with the transfer system 126 (with the closer side of the destination locations omitted for clarity). The telescoping vertical gantry system 103 is shown positioned by the horizontal gantry system 113 and the vertical gantry system 103 such that the vertical gantry system 103 is in a fully extended position. In the fully extended position the telescoping vertical gantry system 103 may position the transfer system 126 at any one of the destination locations 104 including, for example, at the lowest level of the vertically and horizontally array or arrays of destination locations 104 as shown. When the transfer system 126 is positioned at a selected destination location, a transfer motor, e.g., a bidirectional transfer motor 132, is engaged to move any object thereon. The horizontal gantry system may include any of a linear screw drive or a pneumatic or hydraulic linear actuator.

[0043] Figure 3B shows the telescoping vertical gantry system 103 of the carrier system 106 with the object 111 disposed on the transfer system 126 and being moved along the horizontal gantry system with the telescoping vertical gantry system 103 in a fully retracted position (again with the closer side of the destination locations omitted for clarity). In the fully retracted position, the telescoping vertical gantry system 103 may position the carrier transfer system 126 at any one of the destination locations 104 including, for example, at the highest level of the object processing system 100, and horizontally positioned by the horizontal gantry system 113. One skilled in the art will appreciate that the telescoping vertical gantry system 103 may access any one of the destination locations 104 at any level of the object processing system 100 within the range of the fully extended position and fully retracted position by establishing the desired level of extension and subsequently activating the transfer system 126. When the transfer system 126 is positioned at a selected destination location, a transfer motor, e.g., a bidirectional transfer motor 132, is engaged to move any object thereon. The extension and retraction of the first telescoping carrier 103 may be performed while the telescoping vertical gantry system 103 is moving horizontally or it may be performed when the vertical gantry system 103 is not moving horizontally. Additionally, the activation of the carrier transfer system 126 may be initiated before the first telescoping vertical gantry system 103 has completed its translation to the desired destination location 104 by anticipating the arrival and factoring in the speed of the transfer system 126 and the inertia of the object 111 corresponding to its mass. In so doing, the time required for object processing can be further minimized.

[0044] Figures 4A and 4B show illustrative cross-sectional views of an example of an aspect of the telescoping vertical gantry system 103 of the carrier system 106. Figure 4A shows the telescoping vertical gantry system 103 collapsed and Figure 4B shows the telescoping vertical gantry system 103 extended. With reference to Figures 4A and 4B, the horizontal gantry system 113 includes a track that guides the horizontal movement of the assembly, and one or more horizontal drive motor(s) 159 (shown in Figure 7) operates in either clockwise or counterclockwise directions to rotate for example, a linear drive screw 155, to direct the horizontal motion of the first telescoping carrier 103 (e.g., using a linear screw drive that passes through nuts 117). In accordance with other aspects linear electromagnetic drives, or pneumatic or hydraulic systems may be used to provide the linear horizontal movement of the telescoping vertical gantry system 103. Encoders and / or revolution counters may be utilized to accurately track the horizontal position and rotational speed of the horizontal drive motor (e.g., 159 shown in Figure 7), which directly impacts the speed and acceleration of the horizonal motion.

[0045] The vertical drive mechanism 115 of the telescoping vertical gantry system shown in Figures 4 A and 4B includes a vertical drive motor 118 that drives a cog wheel 130 that advances or retracts a push-pull chain 116 into a plurality of coaxially oriented and nested sleeves, such as first sleeve 180, second sleeve 182, third sleeve 184, fourth sleeve 186 and fifth sleeve 188. In a retracted position, the range of retraction may be limited by limit stops 170 contacting the retraction stop 125 as shown in Figure 4A. In the fully extended position, the range of extension is limited by limit stops 170 contacting the extension stops 172 as shown in Figure 4B. In the retracted position the proximal end of the push-pull chain 116 may be spooled on a take-up reel or collected on a track that is affixed to the drive mechanism 115, not shown for clarity. The carrier transfer system 126 is affixed to the distal end of the innermost coaxially oriented nested sleeve 188 via a bracket 178. To resist rotation of the carrier transfer system 126 about the axis of the first telescoping carrier 103, the coaxially oriented and nested sleeves may be keyed with a keyway or may be constructed with a non-circular profile. In accordance with further aspects, actuation of the telescoping vertical gantry systems may involve any of such push-pull chains, pneumatic or hydraulic actuation.

[0046] The object processing system 100 herein described with reference to Figures 1 - 3B may be operated with the carrier system 106 only. The telescoping vertical gantry system 103 together with the horizontal gantry system may extend and retract to permit the transfer system 126 to address each of the destination locations 104 within the object processing system 100. In accordance with further aspects, the object processing system may include a secondindependently operable carrier system 138 as shown in Figures 5A and 5B. The carrier system 138 includes a lower horizontal gantry system 129 on which is mounted a telescoping vertical gantry member 134 with a transfer system 136 mounted on a distal end thereof. The lower horizontal gantry system 129 may include any of a linear screw drive or a pneumatic or hydraulic linear actuator similar to the system of the (upper) horizontal gantry system 113. The upper horizontal gantry system 113 is vertically aligned with the lower horizontal gantry system 129, and both transfer systems 126, 136 are able to access destination locations on either side of the horizontal gantry systems, and along the full height and full width of the array(s) of destination locations. Figure 5A shows the transfer systems 126, 136 not is a position to be moved past each other, but as shown in Figure 5B, when the telescoping vertical gantry systems 103, 134 are respectively collapsed, the transfer systems 126, 136 are no longer obstructed by the other carrier system.

[0047] The vertical gantry systems 103, 134 and the associated transfer systems 126, 136, may then move past one another to reach destination locations on the other side of the respective other carrier system. Figure 6A shows the transfer systems 126, 136 having moved past one another, and Figure 6B shows that the lower telescoping vertical gantry member 134 may then be extended such that the transfer system 136 may reach the higher levels of the destination locations.

[0048] Figure 5 A shows the object processing system 100 with the bypass carrier system 106 configured with the first telescoping carrier 103 and the second telescoping carrier 134. The second telescoping carrier 134 is functionally equivalent to the first telescoping carrier 103 but it traverses horizontally in the object processing system 100 on a second bypassing rails 129. As shown in Figure 5 A, the first telescoping carrier 103 is in a partially extended position traversing the object processing system on the first bypass rail 113. The second telescoping carrier 134 is in a partially extended position traversing the object processing system 100 on the second bypass rail 129. The first telescoping carrier 103 is moving right to left while the second telescoping carrier 134 is moving left to right. Figure 5B shows each of the first telescoping carrier 103 and the second telescoping carrier 134 retracting as each carrier continues its traversal of the object processing system 100. Figure 6A shows the first telescoping carrier 103 having moved past the second telescoping carrier 134 with each carrier continuing to proceed in a retracted position. Figure 6B shows the second telescoping carrier 134 extending the carrier transfer system 136 as necessary to align with an upper row of the destination locations 104 with the first telescoping carrier 103 remaining in the retracted position to be similarly aligned. With reference to Figure 7, the object processing system 100includes a first carrier system 106 and an optional second carrier system 138 that operate in the space between two arrays of destination locations 104. The transfer systems 126, 136 of the carrier systems 106, 138 permits the deposition of objects to any of destination locations 104 on either side and either end of the object processing system 100. The transfer system 126 of first telescoping carrier 103 cannot occupy the same space as the transfer system 136 of the second telescoping carrier 138. To avoid collision when the first carrier system 106 and the second carrier system 138 must traverse past the other, at least one of the first telescoping vertical gantry system 103 and the second telescoping vertical gantry system 134 must retract enough to clear the other. To avoid unnecessarily burdening of the overall throughput of the object processing system 100 the control system can minimize the amount of retraction and the corresponding time required to perform the retraction, accounting for a largest dimension of any object on each transfer system 126, 136. In particular, a largest dimension (or a measured height) of an object acquired by the perception system 107 at the induction station 102 may be used in determining the amount of retraction necessary to avoid collision.

[0049] Operation of the systems disclosed herein may be controlled by one or more computer processing systems 101 (also shown in Figure 1) that is in communication with the perception units 107 and scanner 112 as well as conveyor systems 108, 109, 116 and the carrier systems 106, 138. The one or more computer processing systems 101 provide the control processes for the functionality described herein. The use of the carrier systems 106, 138 discussed herein provides that Tset may be maintained to be approximately equivalent to two times TSOurce and approximately equivalent to Tdischarge. Tcycieis effectively optimized when T source Tdischarge wherein neither the induction station 102 nor the carrier systems 106, 138 is waiting for any other. Once optimized, the Tcycie metric can be further reduced by variation of parameters including conveyor speed, operating speed, bin assignment, relative bin assignment, etc.

[0050] The use of the induction station 102 along a mid-region of an extended put wall system provides flexibilities in the assignment of destination locations to dynamically assign destination locations that balance proximity with encounters (and frequency of encounters) with heavy (but processable) objects. While the system may generally favor assigning destination locations that are nearer to the induction station, the system may monitor the number and frequency of encounters with heavy objects, and responsive to this information determine whether to leave a small number (e.g., 1, 2, 3, 4) of destination locations near the inductions station freely available for use with heavier objects.

[0051] Figure 7 shows the object processing system 100 showing the full distance of the aisle length between ends that may include one or more horizontal drive motors 159. Thedestination locations 104 are fed from bins 110 on source conveyor system 108 via the induction station 102 to the in-feed conveyor 114 which is serviced by the bypass carrier system 106. Processed bins are returned along a return conveyor system 109. Again, the system may through processing recorded data, assign destination locations based in part on a weight of objects such that heavier objects are processed to closer destination locations. Similarly, very light objects may be selected for assignment to any of the destination locations that are most distant from the induction station 102. While any destination location may include a number of assigned objects (some heavier and some lighter), patterns may emerge that permit such dynamic assignment. Additionally, certain nearby destination locations may be additionally assigned to be linked with existing destination locations. For example, if a heavy object is assigned a destination location that is at least partially full, the system may add a further nearby destination location of the heavy object and the system will link the two destination locations together for a unified object removal process. In accordance with certain aspects, the each carrier system 106, 138 may traverse the entire span of the object processing system 100 and their movement may be independently and simultaneously controlled for delivering objects while avoiding collision.

[0052] The time between the first bypass carrier system leaving the in-feed conveyor 114 with the object transferred onto the carrier transfer system 126, 136, and the time of return to the central induction system 102 is monitored, and a running metric such as average time, or median time of this distribution time is maintained (Tdischarge). The weight of each object is recorded and data regarding any of a running average, median, mode and range of the weights of the objects is maintained (Wobjects). If an object is processed at the object induction station 102 that has a weight much higher than the running average, median or mode weight (Wobjects) or that is above a threshold weight of, for example 4 lb. or 5 lb., the system may utilize a close destination location that has been held open for heavy objects to be used to receive the object. The control system will then link the new utilized destination location with any previously assigned destination location associated with the heavy object.

[0053] Figures 8 and 9 show an elevational view of an object processing system 100’ similar to that of Figures 1 - 7 except that the human personnel operated induction station is replaced with a programmable motion device operated induction station 102’. The programmable motion device operated induction station 102’ includes a programmable motion device 160 with an end-effector 162 (shown as a side view in Figure 9), as well as a robotic controller 166 and a vacuum source 164, for example, to provide vacuum to the vacuum end-effector 162. In accordance with various aspects, each of the object processing systems disclosed herein may beused with either a human personnel operated induction station or a programmable motion device operated induction station, and further, where more than one induction station is provided (such as disclosed below with reference to Figure 18), any combination of human personnel operated induction stations and programmable motion device operated induction stations may be employed.

[0054] Figure 10A shows an object processing system 200 that includes an object induction station 102 from a rear perspective. The system 200 includes a carrier system 206 with a horizontal gantry system 208, a bypass mast vertical gantry system 210 and a transfer system 204. The transfer system 204 raises and lowers along the bypass mast vertical gantry system 210, which moves along rails 208 of the horizontal gantry system 208 to adjust the vertical and horizontal positions of the transfer system 204, as will be described in further detail herein below to reach each of the destination locations 104. The transfer system 204 is configured to receive and move an object thereon, such as object 211, from the in-feed conveyor 114. The in- feed conveyor 114 moves the object 211 past the perception system 107 that can acquire and evaluate images of the object 211 as it is moved in addition to, or in the replacement of the scanner 112. The speed of the in-feed conveyor may be controlled by the control system 101 (discussed above) to directly impact the processing time for each object. The carrier transfer system 204 is adapted to move an object thereon in either of two opposing directions that are transverse to the horizontal direction movement of the carrier system 206, and such movement can be actuated at any of the vertical positions at which the bypass mast vertical gantry system 210 adjusts the vertical position of the transfer system 204.

[0055] Figure 10B shows the transfer system 204 of the carrier system 210 in a raised position that raises the elevation of the transfer system 204 with the object 211 thereon. Characteristics of the object 211 may be acquired when the object 211 is being processed while on the transfer system 204. Further, the mass of the object may be acquired through the use of sensors disposed on the transfer system 204. Physical characteristics, such as dimensions or overall height of the object 211 may be acquired by the perception system 107 as the object is being moved on the in-feed conveyor 114. Characteristics of the object 211 may also be acquired in a database lookup using the identifying indicia that may be read by the scanner 112 and / or the perception system 107. Characteristics may be used as an input in the determination of parameters to optimize the overall efficiency and throughput of the object processing system 200. Figure 10B shows the transfer system 204 of the carrier system 206 in an elevated position that raises the elevation of the transfer system 204 with the object 211 thereon.

[0056] Figure 11 A shows a front side view of the bypass mast vertical gantry system 210 with the transfer system 204 mounted thereto. The transfer system 204 is mounted to brackets 212 that are attached to a slider 214 that slides within a guide slot 216 on the mast 226 as further shown in an enlarged view in Figure 12B. An idler pulley 218 is also attached to the slider 214, and a belt (or cable) 220 loops around the idler pulley 218. The belt is fixed at one end and is attached at the other end to a drive spool 224. A bi-directional vertical drive motor 222 drives the drive spool 224 to raise or lower the slider 214 and transfer system 204. In particular, the raising of the slider 214 is achieved by rotating the drive spool such that the belt or cable 220 spools onto the drive spool 224, and the lowering of the slider 214 may be achieved by unwinding the drive spool 224 to release the collected portion of the belt or cable, with gravity or by using a biasing spring to urge the slider 214 and transfer system 204 downward.

[0057] Figure 1 IB shows a perspective view of the horizontal gantry system 230 that includes upper wheels 232 and lower wheels 234 that are positioned in contact with the rails 208 above and below the rails 208. The wheels 232, 234 include at least one driven wheel, with the remaining wheels being non driven, and the driven wheels may be powered by one or more bidirectional motors 236 as further shown in Figure 12 A. The wheel assembly 238 of the horizontal gantry system 230 provides stable support of the vertical gantry system 210 on the rails 208. The (drive) wheels 232, 234 are individually and simultaneously actuated to bidirectionally drive the vertical gantry system 206 in a horizontal direction, while constrained to mitigate wobble, deflection, or undesirable oscillation. The independent control of the horizontal drive motors 236 permit control of horizontal position, acceleration and operational interruption for safety matters.

[0058] Figure 12B shows an enlarged view of the transfer system 204 mounted on the bracket 212 that is attached to the slider 214 that travels along the guide slot 216. Again, when the belt or cable 220 is wound around the drive spool 224 (shown in Figure 11 A), the idler pulley 218 is raised pulling the slider 214 and transfer system 204 upward. Either under the force of gravity or a spring in compression or tension, when the drive spool 224 is unwound, the sider 214 and transfer system 204 are lowered.

[0059] The mast 226 is suspended from the wheel assembly 238 but is not centered under the wheel assembly 238. Rather the mast 226 is positioned below but closer to one of the two upper rails 208 as shown in Figure 12A. With reference to Figure 13A, another carrier system 240 may also be provided that includes lower rails 242 along which another a wheel assembly 244 rides and supports a vertical gantry system 246. The wheel assembly 244 and verticalgantry system 246 are the same as the wheel assembly 238 and vertical gantry system 206 but are inverted. In the vertical gantry system 246 a spring is provided in the slot to bias the position of the slider and transfer system 248 upward. The mast of the lower vertical gantry system 246 is positioned closer to the other of the rails than the mast of the upper vertical gantry system 206 such that when the transfer system 204 is fully raised and the transfer system 246 is fully lowered, the vertical gantry systems 206, 246 may be moved past one another as shown in Figure 13B.

[0060] In accordance with further aspect, the vertical drive of the vertical gantry systems 206, 246, may be alternatively provided by a serpentine or toothed belt that runs the full extent of the mast with the slide affixed to the belt. Similarly, a linear drive may be configured to raise and lower the carrier transfer system with the slide affixed to a bearing through which a threaded rod is rotated by the vertical drive motor. The respective transfer systems are located in the center of the aisle space between opposing faces of the destination locations 104 (as shown in Figure 18) with the respective mast offset from the center of the aisle. Accordingly, when the first carrier system 206 and the second carrier system 246 pass each other a clearance exists between the respective masts. The vertical position of the transfer system must be above (or below) the elevation of the distal end of the respective other mast.

[0061] Figure 14A shows the object processing system with the carrier system 206 configured with the first transfer system 204 and a second carrier system 246 with the second transfer system 248. As shown in Figure 14A, the first transfer system 204 is in a partially raised position traversing the object processing system on the first set of rails 208, and the second carrier system 248 is in a partially raised position traversing the object processing system on the second set of rails 242. The first carrier system 206 is moving left to right while the second carrier system 246 is moving right to left. Figure 14B shows each of the transfer system 204 of the first carrier system 206 and the transfer system 248 of the second carrier system 246 moving to the fully raised / lowered positions respectively to avoid contact with each other and the masts as described above as each carrier systems continues its traversal of the object processing system. Figure 15A shows the first carrier system 206 having moved past the second carrier system 246 with each carrier continuing to proceed in their respective fully raised and lowered positions. Figure 15B shows the first transfer system 204 of the first carrier system 206 in a partially lowered position to align the transfer system 204 as may be needed, and the second transfer system 248 of the second carrier system 246 is shown raised as may be needed. The system may dynamically determine whether to move the transfer systems to theirrespective retracted positions so that the carrier systems 206, 246 may be moved past one another to access the destination locations 104.

[0062] In accordance with further aspects, the horizontal gantry system may include a linear drive (as discussed above with reference to Figures 1 - 9) together with a non-powered roller wheel assembly that rides on two rails. Figure 16 shows an elevated view of a horizontal gantry system 300 that includes a linear drive screw 302 positioned between rails 308. A wheel assembly 304 includes non-driven wheels that capture the rails 308 above and below the rails 308 as discussed above, and rotation of the linear drive screw 302 causes the threaded block 306 to move bidirectionally in horizontal directions. A transfer system 324 is provided on a vertical gantry system 326 as discussed above, and a similar lower carrier system may also be provided that includes linear drive screw 312 and rails 318.

[0063] Carrier system with the telescoping vertical gantry systems of Figures 1 - 9 may also be used with the horizontal gantry systems of Figures 10A - 16. Figure 17 shows a horizontal gantry system 400 that includes two upper rails 408 that are captured by wheels 402, 403, and from the wheel assembly, a telescoping vertical gantry system 406 as discussed above with reference to Figures 1 - 9 is provided. A transfer system 404 is mounted on the distal end of the telescoping vertical gantry system 406. The horizontal gantry system 400 may include any of powered wheels or a linear drive system as also discussed above with reference to Figures 10A - 16.

[0064] The object processing system may further include additional induction stations as shown in Figure 18. The object processing system 500 of Figure 18 includes induction stations 502, 504 (again either manually operated or programmable motion device operated) that both feed two transfer systems 506, 508 of two carrier systems that each transverse the fill aisle length of the object processing system between ends 510, 512 to access all destination locations 104. The object processing system 500 may dedicate each induction station to one of the carrier systems, or may dynamically choose with carrier system to use for each object as it is being inducted, based, for example, on where the assigned destination location is positioned. If the carrier systems need to be moved past each other, this is accomplished as discussed above, and this may be done either prior to receiving new objects on the transfer systems 506, 508 or after receiving one or more objects depending on the known largest diameter of the object(s) and the known clearance during passing.

[0065] In accordance with further aspects, object processing systems of the invention may include plural vertical gantry systems on a single horizontal gantry. Figure 19A shows a system 550 that includes two vertical gantry systems 552, 554 mounted on a single upperhorizontal gantry system 556, as well as two vertical gantry systems 562, 564 mounted on a single lower horizontal gantry system 566. Figure 19A shows the vertical gantry systems 552, 554 adjacent each other and the vertical gantry systems 562, 564 adjacent each other. Figure 19B shows the vertical gantry systems 552, 562 having passed each other such that the gantry systems 552, 554, 562, 564 are mingled. The vertical gantry systems 552, 554, 562, 564 may be any of the telescoping or bypass mast vertical gantry systems discussed above, and the horizontal gantry systems 556, 566 may include any of the linear screw drive, powered wheel assembly drive, or linear screw drive with passive wheel assembly drive systems discussed above. By using plural vertical gantry systems on one horizontal gantry system, the object processing system may efficiently process objects from one centrally-located induction station as shown in Figure 1 or from plural centrally-located induction stations as shown in Figure 18. If an end-located induction station is used, the horizontal gantry system must permit both vertical gantry systems to access the discharge area(s) of the in-feed conveyors unless end- located induction stations are provided at both ends.

[0066] Figure 20 shows at 600 a functional processing representation of a system in accordance with an aspect of the present invention that includes a processor 602 (included, for example, in any of the processing systems 101, 164 discussed above). The processor 602 receives TSOurce, Tobject and Tdischarge information as discussed above, as well as Wobjects information that may include any of an average, median, mode or range of weights over a period of time (AT) as shown. The processor 602 also includes in-feed conveyor velocity data (Vconveyor) as well as carrier velocity data (Vcamer), both of which may be adjusted during operation. The system may periodically test whether using one or more transfer systems is most efficient (e.g., maximizes throughput or minimizes power) by using different combinations of induction stations for a set period and then comparing the results with results while using other combinations of induction stations. As further shown in Figure 20, the results of the throughput using, a single induction station or two induction stations is collected by data collection module 604 and the data is fed back to the processor 602 as shown at 606. Various additional combinations of induction stations may be used for gathering data, both using either human personnel operated induction stations and / or programmable motion device operated induction stations as discussed herein. For example, the induction station of Figure 18 may include alternating human personnel operated induction stations and programmable motion device operated induction stations.

[0067] Additionally, the travel distance of each object from the discharge end of an in-feed conveyor to its assigned destination location (Dobj-to-DL) is maintained as well as the identity ofeach scanned object waiting to be distributed (Idscanned). The system also maintains information regarding the assigned destination location (DLassn d) as well as the fullness or completeness of each destination location (DLtuiiness). As discussed above with reference to the various system described herein, the system (where appropriate) will provide object sequencing data (Obj-Seq- data) that directs a sequence controller 608 to select any of an object to be processed next (Obj selected), a discharge end of a conveyor on which to present the object (Dischargeseiected) where more than one is present, and a carrier to be used (CarrierSeiected) where more than one is present. The amount of time that the in-feed conveyor is idle during AT is also collected and feed back to the processor as is the amount of time that the carrier is idle during AT as shown. Similarly, when more than one induction station (e.g., two, three or four) are used during a similar time period (AT) the system records the data at the corresponding data collection module and feeds it back to the processor 602.

[0068] Systems of various aspects of the present invention therefore may adjust whether to use one or two, or if available, more induction station responsive to collected metrics regarding any of weight of products being processed, power used, and the number of destination locations being used. In this way, system throughput may be maximized by adjusting the number of induction stations to use in any of the systems discussed herein during operation by electing whether to use one or all of the induction stations available, as well as whether to use plural vertical gantry systems on one horizontal gantry as discussed above. The systems may also elect to use fewer than the full number of available destination locations available in order to keep the used destination locations close to the discharge end of the in-feed conveyor; the system may elect to increase the number of destination locations responsive to a desired throughput and collected metrics regarding weight of products being processed and power being used.

[0069] Figure 21 A shows a graphical representation of system throughput verses the discharge time (Tdischarge), and as shown as the discharge time increases (e.g., if the number of destination locations increases or the distance to the destination locations otherwise changes), the throughput may decrease as shown at 700 when the system uses two carrier systems that do not cross each other, but as shown at 702 the throughput may increase with greater discharge times. If dual induction stations are used (as shown in Figure 18), then the throughput may increase as shown at 704 with longer discharge times, but as shown at 710 in Figure 2 IB this comes at the cost of greater power consumption as compared to using a single induction station both without having carrier systems pass one another (as shown at 708) and with having carrier systems pass one another (as shown at 710). The use of carrier systems that may pass one another providesimproved benefits where the discharge time is relatively high for certain applications. In this example (e.g., for a period time AT), the system with the dual induction stations at opposite ends may be efficient at shorter discharge times, but the system with two middle induction stations may have higher throughput then the discharge times become larger. Again, these analyses may be compared over similar periods of time AT.

[0070] Where power consumption is of a concern, Figure 2 IB shows a graphical representation of system power used verses the discharge time (Tdischarge), and as shown as the discharge time increases, the power consumption may increase as shown at 706 when carrier systems do not cross each other, but where carrier systems do cross each other, the power consumption may be relatively lower as shown at 708. Again, the use of an additional induction station may increase power consumption for certain application as shown at 710. Again, these data may be used by the processing system to optimize for any of throughput and power consumption.

[0071] Those skilled in the art will appreciate that numerous modifications and variations may be made to the above disclosed embodiments without departing from the spirit and scope of the present invention.

Claims

CLAIMS1. An object processing system comprising: an object induction station at which an object is provided for processing, the object induction station including an in-feed conveyor and at least one perception system for providing perception data regarding the object; a plurality of destination locations that are arranged in a vertically and horizontally extending array of destination locations; and a first carrier system that includes a first transfer system that is movable adjacent the plurality of destination locations and a second carrier system that includes a second transfer system that is movable adjacent the plurality of destination locations independently of the first transfer system, each of the first carrier system and the second carrier system being adapted to provide that both the first transfer system and the second transfer system are able to access the object induction station as well as each of the plurality of destination locations.

2. The object processing system of claim 1, wherein the plurality of destination locations are provided as two arrays of vertically and horizontally extending arrays of destination locations that are separated by an aisle along which the first carrier system and the second carrier system are positioned.

3. The object processing system of claim 2, wherein each of the first transfer system and the second transfer system is adapted to transfer any object thereon bidirectionally into any of the destination locations of the two arrays of vertically and horizontally extending arrays of destination locations.

4. The object processing system of claim 1, wherein the first carrier system includes a first horizontal gantry system that is positioned above the plurality of destination locations, and wherein the second carrier system includes a second horizontal gantry system that is positioned below the plurality of destination locations.

5. The object processing system of claim 4, wherein the first transfer system of the first carrier system is elevated on the first carrier system and the second transfer system of the second carrier system is lowered on the second carrier system when the first transfer system and the second transfer system are movable past one another.

6. The object processing system of claim 1, wherein the first carrier system includes a downwardly extending first telescoping vertical gantry system that is coupled to an upper horizontal gantry system and the second carrier system includes an upwardly extending second telescoping vertical gantry system that is coupled to a lower horizontal gantry system.

7. The object processing system of claim 6, wherein a first transfer system is mounted at a distal end of the downwardly extending first telescoping vertical gantry system of the first carrier system and a second transfer system is mounted at a distal end of the upwardly extending second telescoping vertical gantry system of the second carrier system.

8. The object processing system of claim 1, wherein the first carrier system includes a downwardly extending first bypass mast vertical gantry system that is coupled to an upper horizontal gantry system and the second carrier system includes an upwardly extending second bypass mast vertical gantry system that is coupled to a lower horizontal gantry system.

9. The object processing system of claim 8, wherein a first transfer system of the first carrier system is movable along the downwardly extending first bypass mast vertical gantry system of the first carrier system, and a second transfer system is movable along the upwardly extending second bypass mast vertical gantry system of the second carrier system.

10. The object processing system of claim 1, wherein a vertical gantry system of the first carrier system is coupled to a roller assembly that travels along a pair of rails of a horizontal gantry system of the first carrier system.

11. An object processing system comprising: an object induction station at which an object is provided for processing; two arrays of vertically and horizontally extending destination locations that are separated by an aisle with an aisle length; a first carrier system that includes a first transfer system that is movable along the aisle; and a second carrier system that includes a second transfer system that is movable along the aisle independently of the first transfer system, each of the first carrier system and the second carrier system being adapted to provide that both the first transfer system and the second transfer system are movable along the full aisle length.

12. The object processing system of claim 11, wherein the first carrier system includes a first horizontal gantry system that is positioned above the plurality of destination locations, and wherein the second carrier system includes a second horizontal gantry system that is positioned below the plurality of destination locations.

13. The object processing system of claim 12, wherein the first transfer system of the first carrier system is elevated on the first carrier system and the second transfer system of the second carrier system is lowered on the second carrier system when the first transfer system and the second transfer system are movable past one another.

14. The object processing system of claim 11, wherein the first carrier system includes a downwardly extending first telescoping vertical gantry system that is coupled to an upper horizontal gantry system and the second carrier system includes an upwardly extending second telescoping vertical gantry system that is coupled to a lower horizontal gantry system.

15. The object processing system of claim 14, wherein a first transfer system is mounted at a distal end of the downwardly extending first telescoping vertical gantry system of the first carrier system and a second transfer system is mounted at a distal end of the upwardly extending second telescoping vertical gantry system of the second carrier system.

16. The object processing system of claim 12, wherein the first carrier system includes a downwardly extending first bypass mast vertical gantry system that is coupled to an upper horizontal gantry system and the second carrier system includes an upwardly extending second bypass mast vertical gantry system that is coupled to a lower horizontal gantry system.

17. The object processing system of claim 16, wherein a first transfer system of the first carrier system is movable along the downwardly extending first bypass mast vertical gantry system of the first carrier system, and a second transfer system is movable along the upwardly extending second bypass mast vertical gantry system of the second carrier system.

18. The object processing system of claim 11, wherein a vertical gantry system of the first carrier system is coupled to a roller assembly that travels along a pair of rails of a horizontal gantry system of the first carrier system.

19. A method of processing objects comprising: receiving an object at an object induction station that includes an in-feed conveyor;providing perception data regarding the object; providing a plurality of destination locations that are arranged in a vertically and horizontally extending array of destination locations; providing a first transfer system of a first carrier system that is movable adjacent the plurality of destination locations; providing a second transfer system of a second carrier system that is movable adjacent the plurality of destination locations independently of the first transfer system; and moving at least one of the first transfer system and the second transfer system past one another such that each of the first carrier system and the second carrier system is adapted to provide that both the first transfer system and the second transfer system are able to access the object induction station as well as each of the plurality of destination locations.

20. The method of claim 19, wherein the plurality of destination locations are provided as two arrays of vertically and horizontally extending arrays of destination locations that are separated by an aisle along which the first carrier system and the second carrier system are positioned.

21. The method of claim 20, wherein each of the first transfer system and the second transfer system is adapted to transfer any object thereon bidirectionally into any of the destination locations of the two arrays of vertically and horizontally extending arrays of destination locations.

22. The method of claim 19, wherein the first carrier system includes a first horizontal gantry system that is positioned above the plurality of destination locations, and wherein the second carrier system includes a second horizontal gantry system that is positioned below the plurality of destination locations.

23. The method of claim 22, wherein the first transfer system of the first carrier system is elevated on the first carrier system and the second transfer system of the second carrier system is lowered on the second carrier system when the first transfer system and the second transfer system are movable past one another.

24. The method of claim 19, wherein the first carrier system includes a downwardly extending first telescoping vertical gantry system that is coupled to an upper horizontal gantrysystem and the second carrier system includes an upwardly extending second telescoping vertical gantry system that is coupled to a lower horizontal gantry system.

25. The method of claim 24, wherein a first transfer system is mounted at a distal end of the downwardly extending first telescoping vertical gantry system of the first carrier system and a second transfer system is mounted at a distal end of the upwardly extending second telescoping vertical gantry system of the second carrier system.

26. The method of claim 19, wherein the first carrier system includes a downwardly extending first bypass mast vertical gantry system that is coupled to an upper horizontal gantry system and the second carrier system includes an upwardly extending second bypass mast vertical gantry system that is coupled to a lower horizontal gantry system.

27. The method of claim 26, wherein a first transfer system of the first carrier system is movable along the downwardly extending first bypass mast vertical gantry system of the first carrier system, and a second transfer system is movable along the upwardly extending second bypass mast vertical gantry system of the second carrier system.

28. A carrier system comprising: a horizontal gantry system for moving a transfer system in mutually opposing horizontal directions, the horizontal gantry system including at least two wheels for riding along upper sides of two horizontal rails, and at least two wheels for riding along undersides of the two horizontal rails; and a vertical gantry system that is attached to the horizontal gantry system for moving the transfer system in mutually opposing vertical directions, the horizontal gantry system and the vertical gantry system providing that the transfer system may access any of a plurality of destination locations that are provided in a vertical array of destination locations.

29. The carrier system of claim 28, wherein the transfer system includes a bi-directional conveyor.

30. The carrier system of claim 28, wherein the vertical gantry system includes a telescoping vertical gantry system.

31. The carrier system of claim 28, wherein the vertical gantry system includes a bypass mast vertical gantry system.

32. The carrier system of claim 28, wherein carrier system includes a second vertical gantry system that is attached to the horizontal gantry system for moving a second transfer system in mutually opposing vertical directions.

Images