Conveying arrangement

Abstract

A conveying arrangement (1) comprising a sorter (7) and at least one end point (6), in particular a multiplicity of end points (6); wherein at least one presence sensor (S1, S2) is located at the end point (6) and is configured to determine the presence of a conveyed material (9) at a predetermined position at the end point (6).

Description

[0001] Funding order

[0002] Description

[0003] The invention relates to a conveying arrangement.

[0004] At the terminal stations in a parcel distribution center, parcels are loaded onto delivery vehicles assigned to specific destination regions. A sorter, such as a crossbelt sorter as described in WO 2019 / 002048 A1, sorts the parcels and directs them to the individual destination stations. To overcome differences in elevation, inclined chutes are used between the sorter and the final destinations, allowing the parcels to slide down them due to gravity.

[0005] EP 1 868 923 B1 discloses an end-of-line chute with two rollers running transversely to the conveying direction of the chute and driven in the conveying direction. The speed of one roller is chosen to be higher than that of the other the closer the respective roller is to the discharge end.

[0006] German patent DE 102016 015 061 A1 describes an end-station device for sorting and order picking systems, in which at least one transport unit is movable between an upper and a lower level to temporarily store goods. Load height sensors are provided to detect the load status. These sensors detect the current load height and, via an electronic control unit, lower the transport unit to create a storage space. The sensors thus serve to dynamically adjust the storage geometry in case of imminent overfilling.

[0007] US Patent 2022 / 0297160 A1 describes a sorting system with a main sorting line and several chute discharges to different destination containers. Package detectors, designed as either photo-eye arrays or camera systems, are provided at the end points to monitor correct sorting. These sensors detect whether a package has entered the intended destination container and report any misassignments to a central control system. The sensors primarily serve for error detection and sorting control, not for storage control.

[0008] The object of the present invention is to provide an improved conveying arrangement. This object is achieved by a conveying arrangement and a method according to the main claims; embodiments are described in the dependent claims and the description.

[0009] - 1 -

[0010] 202501027 24045PWO text.docx The present invention relates to a conveying arrangement, which is intended in particular for use in parcel distribution centers. This arrangement comprises a sorter and at least one terminal station, wherein at least one presence sensor is arranged at the terminal station. This sensor is configured to detect the presence of conveyed goods at a predetermined position of the terminal station.

[0011] A key advantage of this conveying system is the precise control of the sorter. The terminal is equipped with a chute that takes the material from the sorter and transfers it to a storage area. The chute is inclined so that the material slides down under its own weight, ensuring efficient and reliable conveying.

[0012] The conveying system comprises several end points, each of which may have a conveying chute. These chutes are located between the sorter and the storage area of ​​the end point. The conveying system's control unit is configured to control the sorter, transporting goods from the sorter to a specific end point. This is achieved by precisely controlling, for example, the cross belt of a sorter carriage, so that the goods are accelerated laterally and conveyed accurately into the designated end point.

[0013] Presence sensors are installed at the receiving and / or transfer points. These sensors continuously monitor the position of the conveyed goods and ensure that the sorter only releases goods when the destination is ready to receive them. This prevents overloading and congestion that could disrupt operations.

[0014] Another design feature includes the integration of a buffer return system. This buffer return system receives conveyed goods that cannot be discharged to their designated destination due to overcrowding. Goods requiring buffering are held on the return system for a predetermined time and then returned to the sorter. This ensures smooth further processing and prevents blockages in the system.

[0015] The conveyor system's control unit is specifically designed to adjust the sorter's operation based on signals from the presence sensors. In case of overload, the conveyed material is not discharged into the overflowing end point but instead routed to the buffer return. The control unit can also send a signal to a service technician to empty the storage area and thus prevent the conveyor chute from becoming blocked.

[0016] - 2 -

[0017] 202501027 24045PWO text.docx The conveying arrangement according to the invention offers an efficient, reliable, and flexible solution for handling conveyed goods in parcel distribution centers. Precise control and monitoring by presence sensors, as well as the possibility of buffer return, contribute significantly to optimizing the entire conveying process. The arrangement enables continuous and trouble-free conveying, even with high conveying volumes and different conveyed goods.

[0018] A suitable conveying item, in particular a postal parcel, has a weight of 20 kg, although this does not preclude the use of lighter or heavier parcels. Specifically, the conveying system is designed for conveying an item, in particular a postal parcel, weighing 50 kg. Furthermore, so-called polybags can also be conveyed, i.e., items packaged in film, such as clothing.

[0019] An end point is, in particular, a functional section of a conveying system designed to receive conveyed goods from an upstream sorter, especially for temporary storage and to hold them ready for further distribution. The end point may, in particular, include a conveying chute and a storage area.

[0020] "Permanent" within the meaning of this application refers in particular to a presence duration that exceeds the typical time span for a normal passage of an object and indicates a stationary state, i.e., that the conveyed material remains within the sensor's range. This serves to distinguish it from a short-term presence signal, such as that generated when a conveyed material passes by.

[0021] The invention is explained in more detail below with reference to the figure, which shows:

[0022] Figure 1 schematically shows a side view of a conveying arrangement according to the invention in conjunction with a diagram of presence signals in a first state;

[0023] Figure 2 schematically shows the side view in conjunction with the diagram of presence signals according to Figure 1 in a second state;

[0024] Figure 3 schematically shows parts of the conveyor arrangement according to Figure 1 in a top view.

[0025] Figure 1 shows a conveying arrangement 1. A conveyed item 9, e.g., a postal parcel, is fed by a sorter 7, in particular a cross-belt sorter. From the sorter 7, the conveyed item 9 reaches a terminal 6, the terminal 6 comprising a conveying chute 61 and one of the

[0026] - 3 -

[0027] 202501027 24045PWO text.docx The conveyor chute has a downstream storage point 62. At storage point 62, the conveyed material 9 is temporarily stored in order to be transferred from there, for example, to a delivery van 63.

[0028] The conveyor chute 61 comprises a transfer area A1, where the conveyed material 9 is transferred from the sorter ? to the conveyor chute 61. A chute section A2 adjoins the transfer area A1 in the conveying direction F. In chute section A2, the conveyed material 9 slides downwards, at least in sections, to reach a transfer area A3, where the conveyed material 9 is transferred to the downstream storage location 62. In chute section A2, significant height differences are overcome in some sections. For space optimization purposes, chute section A2 can be very steep.

[0029] The length of the conveyor chute 61 is defined by the distance between the receiving area A1 and the transfer area A3. An average angle of inclination can be defined by the average gradient between the receiving area A1 and the transfer area A3.

[0030] Sorter 7 can be a sorter as described in WO 2020 / 025329 A1. This sorter 7 has a multitude of sorter carriages that carry the conveyed material and, when required, deliver the conveyed material to one of a multitude of end points 6.

[0031] The conveying arrangement 1 according to the invention therefore comprises in particular

[0032] - a sorter 7 with a large number of sorter trolleys 71 ,

[0033] - a large number of terminals 6

[0034] - an end point can have a conveying chute 61, wherein the conveying chute 61 is arranged between the sorter 7 and the storage point 62 of the end point 6.

[0035] The conveying arrangement 1 has a control unit 1C, which controls the following function. The control unit 1C controls the sorter such that conveyed goods 9 are transported by the sorter to a specific end point 6 from among the multiple end points 6. For example, in a cross-belt sorter, the cross belt of a sorter carriage 71 is driven at a specific time such that the conveyed goods are accelerated laterally and transported precisely to the specific end point 6.

[0036] A first presence sensor S1 is located at the transfer area A1. A second presence sensor S2 is located at the transfer area A3.

[0037] - 4 -

[0038] 202501027 24045PWO text.docx The respective presence sensors S1 and S2 are configured to detect whether a conveyed item 9 is located in the receiving area A1 or the transfer area A3. The presence sensors are, in particular, light barriers or light switches.

[0039] During a normal operating state (first state), the first presence sensor S1 outputs a first presence signal P1 when a conveyed item 9 passes the transfer area A1.

[0040] During normal operating conditions (first condition), the second presence sensor S2 outputs a second presence signal P2 when the conveyed item 9 passes the transfer area A3.

[0041] The presence duration t1, t2 of the respective presence signal P1, P2 is essentially defined by the length and speed of the conveyed material 9 at the respective sensor position. The presence duration t1, t2 of the respective presence signal P1, P2 is typically less than one second or at most slightly more (see diagram in Figure 1).

[0042] Figure 2 shows the arrangement from Figure 1 in a second state. It can be seen that storage location 62 is now so full that it can no longer accept any further conveyed goods 9. In such a situation, the conveyed goods 9 gradually pile up on the conveyor chute 61 as well.

[0043] Initially, the transfer area A3 is permanently blocked by a conveyed item 9a. Accordingly, the second presence sensor S2 permanently outputs a second presence signal P2.

[0044] Subsequently, the receiving area A1 is also permanently blocked by a conveyed item 9b. Accordingly, the first presence sensor S1 also permanently outputs a first presence signal P1.

[0045] Accordingly, the presence durations t1 and t2 are now permanent until the blockage caused by the conveyed goods 9 is removed. This can be achieved, in particular, by manually removing conveyed goods from the end point.

[0046] If the second presence duration t2 of the second presence signal P2 is above a second threshold value G2, but the first presence duration t1 of the first presence signal P1 is below a first threshold value G1, this indicates an intermediate state in which storage location 62 is overfilled and conveyor chute 61 is gradually filling up. In this intermediate state, the controller 1C can issue a signal to a service person requesting that the storage location be emptied to prevent conveyor chute 61 from becoming blocked.

[0047] - 5 -

[0048] 202501027 24045PWO text.docx If the first presence duration t1 of the first presence signal P1 is also above the first threshold value G1, this is an indicator of a condition in which the conveyor chute 61 is also overloaded.

[0049] It is evident that in the second operating state, conveyed material can no longer be reliably discharged from the sorter carriage 71. There is now a risk that the conveyed material will not completely leave the movement area 7B of the sorter 7 and will consequently protrude into this movement area 7B, thus obstructing the following sorter carriages and, in extreme cases, potentially causing damage.

[0050] In this second state, the sorter 7 is controlled by the controller 1C in such a way that no more goods are discharged to the respective endpoint with its associated blocked chute, whose chute 61 is full. The conveyor car then passes the designated receiving area without discharging any goods, even if these are destined for the respective endpoint with the blocked chute. The undischarged goods can then be transferred to a collection point or complete additional cycles on the sorter until the blockage is cleared. Alternatively, the goods to be discharged can be discharged to another collection point before reaching the endpoint, or the goods may not be conveyed to the sorter at all.

[0051] To achieve this purpose, it is evident that the position of the first presence sensor S1 at the transfer area A1 is to be interpreted broadly and therefore encompasses areas in the conveying direction below the immediate interface between sorter 7 and conveyor chute 61. It is important to note that if a conveyed item is detected at the first presence sensor S1, it is not critical with regard to the movement area 7B of the sorter 7, but any further conveyed item cannot be tolerated. The sorter 7 should therefore be able to continue operating without concern, even if an overload of a single end point is detected.

[0052] The foregoing description also applies to a variant according to the invention in which no conveying chute is arranged between the sorter carriage 71 and the storage point 62.

[0053] Figure 3 shows parts of the conveying arrangement according to the invention schematically in a top view.

[0054] The goods 9 are initially fed to the sorter 7 via an infeed conveyor E. Subsequently, the goods are usually transported individually onto a conveyor car, which then travels to the individual sorting stations. Each item 9 is intended to be discharged at a specific conveyor station.

[0055] - 6 -

[0056] 202501027 24045PWO text.docx If, as described above, a conveyed item cannot be discharged into the designated destination due to overfilling, the conveyed item initially remains on the conveying car. The conveyed item is then transferred from the conveying car to a buffer return R (hereinafter referred to as "the conveyed item 9P to be buffered"). The conveyed item 9P to be buffered remains on the buffer return R for at least a predetermined time and is then transferred from the buffer return R back onto a feed conveyor E. The feed conveyor E can be the same one used for the initial feed, or a different feed conveyor E can be used for this purpose.

[0057] - 7 -

[0058] 202501027 24045PWO text.docx List of reference symbols

[0059] 1 Conveyor arrangement 6 End point 61 Conveyor chute 62 Storage point

[0060] 63 delivery vans, 7 sorters

[0061] 71 Sorter trolley 7B Movement area 9 Goods to be conveyed (postal parcel)

[0062] 9P material to be buffered

[0063] A1 Takeover area

[0064] A2 Slide area A3 Transfer area F Conveyor direction S1 First presence sensor

[0065] S2 second presence sensor

[0066] P1 first presence signal

[0067] P2 second presence signal t1 first presence duration t2 second presence duration R buffer feedback

[0068] - 8 -

[0069] 202501027 24045PWO text.docx

Claims

Claims 1. Conveyor arrangement (1) comprising a sorter (7) and at least one terminal (6), in particular a plurality of terminals (6); characterized in that at least one presence sensor (S1, S2) is arranged at the terminal (6), which is configured to determine the presence of a conveyed item (9) at a predetermined position of the terminal (6).

2. Conveyor arrangement (1) according to the preceding claim, characterized in that the end point (6) has a conveying chute (61) downstream of the sorter (7); the conveying chute (61) is configured to - Transfer of a conveyed item (9) at a transfer area (A1) from the upstream sorter (7); - Transfer of the conveyed goods (9) to a transfer area (A3), in particular for transfer to a storage location (62); - Transfer of the conveyed material (9) in a chute area (A2) from the receiving area (A1) to the transfer area (A3), wherein the conveying chute (61) is inclined downwards in the conveying direction (F) so that the conveyed material (9) is conveyed by gravity in a sliding manner.

3. Conveyor arrangement (1) according to claim 2, characterized in that a first presence sensor (S1) is arranged at the transfer area (A1).

4. Conveyor arrangement (1) according to claim 2 or 3, characterized in that a second presence sensor (S2) is arranged at the transfer area (A3).

5. Conveyor arrangement (1) according to one of the preceding claims, characterized in that the conveyor arrangement has a control unit (1C) which is configured to control the operation of the sorter (7), wherein the control unit (1C) is configured to control the operation of the sorter (7) depending on a presence signal (P1 , P2) of the presence sensor (S1 , S2). - 9 - 202501027 24045PWO text.docx 6. Conveyor arrangement (1) according to the preceding claim, characterized in that the control (1C) is configured to control the sorter in such a way that, in the event of an overload, which has been detected on the basis of the at least one presence signal (P1, P2), the conveyed material is not thrown from the sorter carriage (71) into the designated end point.

7. Conveyor arrangement (1) according to one of the preceding claims, characterized in that the conveying arrangement (1) comprises a buffer return (R), wherein the buffer return (R) is arranged, - to receive a conveyed material (9P) to be buffered from the sorter (7), which in particular was previously discharged from a sorter wagon (71), - and to transfer the material to be buffered (9P) to an infeed conveyor (E), wherein the infeed conveyor (E) is set up to feed the material back onto the sorter (7).

8. Conveyor arrangement (1) according to claim 7 and one of claims 5 or 6, characterized in that the control (1C) is configured to control the sorter (7) in such a way that the conveyed material (9P) to be buffered is fed to the buffer return (R).

9. Conveying arrangement (1) according to one of claims 7 or 8, characterized in that the conveying arrangement (P) is configured to buffer the conveyed material to be buffered on the buffer return (R) for at least a predetermined buffer period.

10. Method for controlling a conveying arrangement (1), in particular a conveying arrangement according to one of the preceding claims, wherein the conveying arrangement (1) comprises a sorter (7) and at least one terminal station (6) downstream of the sorter (7); the method comprises the following process steps: - Determination of the presence of at least one conveyed item (9) at the terminal (6); - Controlling the function of the sorter (7) based on the determined presence. - IQ - 202501027 24045PWO text, docx 11. Method according to the preceding claim, characterized in that, based on the determined presence, at least partial, permanent overcrowding of the terminal (6) is detected.

12. Method according to one of claims 10 to 11, characterized in that, based on the determined presence of the sorter (7), it is controlled as required in such a way that, in particular in a second operating state, no further conveyed material (9) is transferred to the overloaded end point, in particular the receiving area (A1) of the conveying chute (61).

13. Method according to the previous claim, characterized in that a conveyed item (9P) is transferred from the sorter to a buffer return (R), in particular the buffer return according to claim 7, instead of to the overloaded end point; and that the conveyed item (9P) is subsequently transferred again to the sorter (7).

14. Method according to one of claims 10 to 13, characterized in that the sorter (7) is controlled as required based on the determined presence, - that, particularly in an intermediate state, a request signal is issued to a service person to empty the corresponding terminal (6); and / or - that in an intermediate state the sorter (7) is controlled in such a way that further conveyed material is transferred to the final destination (6).

15. Conveying arrangement (1) according to one of claims 1 to 9, comprising a controller (1C) wherein the controller (1C) is configured to control the method according to one of claims 10 to 14. - 11 - 202501027 24045PWO text.docx

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