Systems and methods for transferring items to containers

Abstract

A system having a pallet receiving area; a first robotic operator configured to transfer cases from the pallet receiving area, the cases containing individual items; a conveyor configured to receive cases from the first robotic operator and to transfer items in the cases to a container processing station where items are deposited in containers; and a first pusher element mounted adjacent the container processing station, the first pusher element configured to move a first set of items from the conveyor to a first container at the container processing station.

Description

Aty. Docket No. 1127P017425-WO (PCT)SYSTEMS AND METHODS FOR TRANSFERRING ITEMS TO CONTAINERSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is an international application of and claims the benefit of United States provisional patent application number 63 / 751,687 filed on January 30, 2025, the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND

[0002] This disclosure relates generally to storage and retrieval systems, and more particularly, to the transfer of items to containers in such systems.SUMMARY

[0003] Generally speaking, pursuant to various embodiments, systems, apparatuses and methods are provided herein useful to the transfer of items to containers. In some embodiments, an item transfer and assembly system includes: a pallet receiving area; a first robotic operator configured to transfer cases from the pallet receiving area, the cases containing individual items; a conveyor configured to receive cases from the first robotic operator and to transfer items in the cases to a container processing station where items are deposited in containers; and a first pusher element mounted adjacent the container processing station, the first pusher element configured to move a first set of items from the conveyor to a first container at the container processing station.

[0004] In some implementations, the system further includes a plurality of conveyor modules that may be assembled to form the conveyor, each conveyor module including a locomotion element configured to allow the conveyor module to move from a storage area to an operational location. In some implementations, the first robotic operator comprises a robotic arm disposed adjacent the pallet receiving area and adjacent the conveyor. In some implementations, the system further includes a decasing station adjacent the conveyor intermediate the pallet receiving area and the container processing station, wherein, at the decasing station, items are removed from an individual case on the conveyor and the removed items are placed on the conveyor. In some implementations, the system further includes a second robotic operator at the decasing stationAty. Docket No. 1127P017425-WO (PCT)configured to remove items from the individual case and place the removed items on the conveyor. In some implementations, the first pusher element includes a plurality of walls defining an open side facing the container processing station, the plurality of walls configured to surround the first set of items other than on the open side. In some implementations, the system further includes a first linear actuator disposed above the conveyor adjacent the container processing station, the first pusher element being mounted to the first linear actuator. In some implementations, the first linear actuator is configured to move the first pusher element in a direction substantially perpendicular to a direction of travel of items on the conveyor. In some implementations, the system further includes a second pusher element mounted adjacent the container processing station, the second pusher element configured to move a second set of items from the conveyor to a second container at the container processing station. In some implementations, the system further includes a second linear actuator disposed above the conveyor adjacent the container processing station, the second pusher element being mounted to the second linear actuator, wherein the second linear actuator is configured to move the second pusher element in the direction substantially perpendicular to the direction of travel of items on the conveyor. In some implementations, the first pusher element is disposed upstream of the second pusher element in the direction of travel of the conveyor; and the first pusher element is coordinated with the conveyor to avoid blocking the second set of items moving on the conveyor. In some implementations, the system further includes a third robotic operator at the container processing station configured to arrange the first set of items moved from the conveyor to the first container.

[0005] In another form, there is provided a method of transferring items from pallets to containers. The method includes: by a first robotic operator, transferring cases from a pallet receiving area, the cases containing individual items; by a conveyor, receiving cases from the first robotic operator and transferring items in the cases to a container processing station where items are deposited in containers; and by a first pusher element mounted adjacent the container processing station, moving a first set of items from the conveyor to a first container at the container processing station.

[0006] In some implementations, the method further includes at a decasing station adjacent the conveyor intermediate the pallet receiving area and the container processing station, removing items from an individual case on the conveyor and placing the removed items on the conveyor. In some implementations, a second robotic operator at the decasing station removes items from theAty. Docket No. 1127P017425-WO (PCT)individual case and places the removed items on the conveyor. In some implementations, the method further includes by a first linear actuator disposed above the conveyor adjacent the container processing station, the first pusher element being mounted to the first linear actuator moving the first pusher element in a direction substantially perpendicular to a direction of travel of items on the conveyor. In some implementations, the method further includes a second pusher element mounted adjacent the container processing station, the second pusher element configured to move a second set of items from the conveyor to a second container at the container processing station. In some implementations, the method further includes by a second linear actuator disposed above the conveyor adjacent the container processing station, the second pusher element being mounted to the second linear actuator, moving the second pusher element in the direction substantially perpendicular to the direction of travel of items on the conveyor. In some implementations, the first pusher element is disposed upstream of the second pusher element in the direction of travel of the conveyor, and the method further includes coordinating the first pusher element with the conveyor to avoid blocking the second set of items moving on the conveyor. In some implementations, the method further includes by a third robotic operator at the container processing station, arranging the first set of items moved from the conveyor to the first container.

[0007] The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of example embodiments. Reference throughout this specification to “one embodiment,” “an embodiment,” “some embodiments”, “an implementation”, “some implementations”, “some applications”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “in some embodiments”, “in some implementations”, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0008] In one aspect, and without limitation, this disclosure may involve generally a facility, such as an order fulfillment facility, that may include multiple mobile robots that operate to pick and transfer containers in the context of an automated storage and retrieval system. In one form, mobile robots move about a storage structure and retrieve containers, or totes, of goods that are stored in specific storage locations in the facility, as part of the automated storage and retrieval system. TheAty. Docket No. 1127P017425-WO (PCT)facility may also include workstations, also referred to as container processing stations or tote processing stations, where containers, or totes, may be filled with items. These containers may be picked up at the workstations by the mobile robots.

[0009] In one aspect, and without limitation, this disclosure may involve generally an order fulfillment facility and system that may fulfill orders involving individual product units, which may also be referred to herein as “eaches” or items. Certain operations involve fulfilling orders with eaches at workstations, or container processing stations. These operations may be labor intensive because they may require manual action and may not be highly automated.

[0010] In one aspect, and without limitation, this disclosure relates to the partially or fully automated transfer of items from cases on pallets to container processing stations. In some forms, this transfer may have been manually performed at workstations to induct items into the system. This is a labor heavy process for individuals where they are required to remove items from cases and load them into containers received and staged at desired locations in the storage structure. In one aspect, this disclosure involves automating this procedure and making the work involved in this transfer process less burdensome for individuals.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The foregoing aspects and other features of the present disclosure arc explained in the following description, taken in connection with the accompanying drawings, wherein:

[0012] FIG. 1 shows parts of an order fulfillment facility (or storage facility) that utilizes and is part of an automated storage and retrieval system, in accordance with the present disclosure;

[0013] FIG. 2 shows a partial and simplified overhead view of an example of a level in the storage structure, in accordance with the present disclosure;

[0014] FIGS. 3-6 show an item transfer and assembly system that may be used at an order fulfillment facility and as part of an overall ASRS, in accordance with the present disclosure;

[0015] FIGS. 7-10 show an item transfer and assembly system that may be used at an order fulfillment facility and as part of an overall ASRS, in accordance with the present disclosure; andAty. Docket No. 1127P017425-WO (PCT)

[0016] FIG. 11 shows a process of transferring items from pallets to containers, in accordance with the present disclosure.DETAILED DESCRIPTION

[0017] FIG. 1 shows parts of an order fulfillment facility 100 (or storage facility) that utilizes and is part of an automated storage and retrieval system (ASRS). More specifically, as part of the ASRS, Figure 1 shows a storage structure 102 that is generally intended to store various items at a number of storage locations 104. In one form, the storage structure 102 may include a y-z array of storage locations 104 in horizontal rows and level changing towers (or vertical towers or climbing channels) along the rows. In some forms, mobile robots may travel between storage levels in the z-direction within the level changing towers. Rows of storage locations 104 may be arranged to face each other, separated by horizontal pathways or aisles 106.

[0018] The storage structure 102 may further include decks 108 (or transit planes or areas) spaced apart at different horizontal levels of the storage structure 102. The decks 108 may extend between the aisles 106 so that mobile robots can maneuver in the x-y plane of each deck 108 to travel between different aisles 106. Further details relating to the general structure and operation of embodiments of storage structures, workstations, and mobile robots, such as may be used in conjunction with this disclosure, are disclosed in U.S. Patent No. 9,139,363, issued September 22, 2015, entitled “Automated System for Transporting Payloads”; U.S. Patent No. 10,040,632, issued August 7, 2018, entitled” Automated System for Transporting Payloads”; U.S. Patent 10,435,241, issued October 8, 2019, entitled “Storage and Retrieval System”; U.S. Patent No. 10,952,533, issued March 23, 2021, entitled “Modular Structure for an Automated Storage and Retrieval System”; and U.S. Patent No. 11,142,398, issued October 12, 2021, entitled “Order Fulfillment System”; which patents are all incorporated by reference herein in their entirety.

[0019] FIG. 1 also shows workstations, or container processing stations 110, at the facility 100. In one form, operators (human individuals and / or robotic operators) work at the container processing stations 110 and may transfer eaches to containers. Various operations may be performed at container processing stations 110. Human or robotic operators, or pickers, may receive containers of eaches for transfer of the eaches into order containers. Mobile robots may perform transport operations, including moving containers of eaches between storage locationsAty. Docket No. 1127P017425-WO (PCT)and the workstations and including transporting order containers away from the workstations. Examples of workstations and picking and transfer operations, such as may be used in conjunction with this disclosure, are disclosed, for example, in U.S. Patent No. 11,845,610, issued December 19, 2023, entitled “Automated Decant System”; U.S. Patent Publication No. 2021 / 0380343, published December 9, 2021, entitled “Robotic Each Picking in a Micro-Fulfillment Center”; and U.S. Patent No. 10,984,375, issued April 20, 2021, entitled “Picking Workstation with Mobile robots and Machine Vision Verification of Each Transfers Performed by Human Operators,” all of which are incorporated by reference herein in their entirety.

[0020] FIG. 2 shows a partial and simplified overhead view of an example of a level 111 in the storage structure 102. This overhead view shows aisles 106 with storage locations 104 to either side of the aisle 106. It further shows mobile robot 140 that can traverse the aisles 106 and access the storage locations 104. The mobile robot 140 can also travel along decks 108 to allow it to turn and to allow it to exit one aisle 106 and enter a different one.

[0021] Two examples of operations that may be performed at the container processing station 110 are decanting and defragging. Decanting generally involves receiving cases of items at the facility and inducting items into the system by transferring these items into containers. In some forms, these operations may involve depalletizing, removing cases, and transferring items to containers. Defragging generally involves transferring items into partially occupied containers and / or the consolidation of items in multiple containers to more efficiently use those containers. In one aspect, this disclosure involves the performance of those operations at or near the container processing station 110. Another aspect is to streamline these operations to improve the experience of individuals at the facility 100 and to improve system efficiency.

[0022] FIGS. 3-6 show an item transfer and assembly system 112 that, in one form, may be used at an order fulfillment facility 100 and as part of an overall ASRS. It is generally contemplated that the item transfer and assembly system 112 facilitates the decanting and / or defragging process at the facility 100. In one form, the system 112 facilitates the inducting of newly-received cases containing eaches at the container processing stations 110.

[0023] As shown in FIG. 3, the item transfer and assembly system 112 may include a pallet receiving area 114, or platform. It is generally contemplated that a pallet 116 holding cases 118Aty. Docket No. 1127P017425-WO (PCT)may be transported to this pallet receiving area 114. For example, the cases 118 may be newly-arrived and delivered via truck and may then be moved from the delivery area to the pallet receiving area 114. This transport may be accomplished in any of various ways, such as, for instance, by forklift. Pallets can also be moved to this area 114 by autonomous vehicles, such as, for example, automated motorized robots (AMRs) and automated guided vehicles (AGVs). U.S. Publication No. 2021 / 0261335, published August 26, 2021, entitled “Automated Retail Supply Chain and Inventory Management System” discloses examples of transport and is incorporated herein by reference in its entirety.

[0024] The item transfer and assembly system 112 may also include a first robotic operator 120 that is configured to transfer the cases 118 from the pallet receiving area 114. It is generally contemplated that the cases 118 contain individual items, or eaches. In one form, the first robotic operator 120 may include a stationary robotic arm or articulated robot that is disposed adjacent to and sufficiently close to the pallet receiving area 114 to be able to grasp the cases 118. Although a robotic arm is one example of a first robotic operator 120, it should be understood that other types of robots and robotic devices may be used, such as, for example, gantry robots and autonomous vehicles.

[0025] Next, the system 112 may further include a conveyor 122 (or transfer belt) that receives cases 118 from the first robotic operator 120 and that transfers the items in the cases 118 to a container processing station 110 where items are deposited in containers 124. The conveyor 122 may be modular and composed of individual conveyor modules. It is generally contemplated that the first robotic operator 120 will transfer cases 118 individually from the pallet receiving area 114 to the conveyor 122. In addition, the first robot operator 120 is preferably disposed adjacent the conveyor 122 to allow for the transfer from pallet receiving area 114 to conveyor 122, although the disposition of the first robot operator 120 may depend on the nature and type of robot.

[0026] In some forms, the item transfer and assembly system 112 may include a decasing station 126 (or unpacking station). The decasing station 126 is preferably adjacent the conveyor 122 and intermediate the pallet receiving area 114 and the container processing station 110. The decasing station 126 is generally at some point along the conveyor 122 between where cases 118 have been placed on the conveyor 122 but before they would arrive at the container processing station 110.Aty. Docket No. 1127P017425-WO (PCT)At the decasing station 126, items are removed from an individual case 118 on the conveyor 122 and the removed items are placed on the conveyor 122.

[0027] The decasing station 126 may include a transfer belt 127 (or a second conveyor) disposed, in part, beneath the first conveyor 122. The transfer belt 127 may move empty cases 118 away from the decasing station 126 to a designated case pickup area or location. After items have been removed from the cases 118, it may be desirable to have a mechanism to remove the empty cases 118 to avoid accumulation and congestion at the work area or otherwise hinder operation at the work area.

[0028] In some forms, a human operator may be at the decasing station 126. The human operator may remove items from the individual case 118 and place the removed items on the conveyor 122. In other forms, however, it is contemplated that a second robotic operator may be present at the decasing station 126 to remove items from the cases 118 and place them on the conveyor 122.

[0029] The item transfer and assembly system 112 also preferably includes a first pusher element 128 that is mounted at a transfer station / area adjacent the container processing station 110. This first pusher element 128 is configured to move a first set of items from the conveyor 122 to a first container 124A at the container processing station 110. In some forms, this first pusher element 128 may include multiple walls 130 that define an open side facing the container processing station 110 such that the walls 130 configured to surround the first set of items other than on the open side. In this example, the walls 130 from a U-shape with the open side of the U being at the container processing station 110. In this manner, the walls 130 can enclose and capture the first set of items and push them to the container processing station 110.

[0030] In some forms, as can be seen in FIGS. 4 and 5, the system 112 includes a first linear actuator 132, or first linear displacer, that is disposed above the conveyor 122 at the transfer station / area adjacent the container processing station 110. The first pusher element 128 is mounted beneath the first linear actuator 132. In this form, the linear actuator 132 may be any of various types such that the linear actuator 132 exerts a pushing force against the first pusher element 128 in a direction toward the container processing station 110. In other forms, the linear actuator 132 may be any of various types configured in a different manner so as to exert a pulling force on the first pusher element 128 and toward the container processing station 110. As shown in FIG. 5, theAty. Docket No. 1127P017425-WO (PCT)first linear actuator 132 moves the first pusher element 128 in a direction substantially perpendicular to the direction of travel of items on the conveyor 122.

[0031] As shown in FIGS. 4 and 5, there may be more than one pusher element and linear actuator disposed along the conveyor 122. FIGS. 4 and 5 show two pusher elements and linear actuators disposed adjacent each other along the conveyor 122. It is generally contemplated that the additional pusher elements and linear actuators may be generally the same type as the first pusher element 128 and first linear actuator 132, although this is not required.

[0032] In other words, the item transfer and assembly system 112 may include a second pusher element 134 mounted at the transfer station / area adjacent the container processing station 110 with this second pusher element 134 configured to move a second set of items from the conveyor 122 to a second container 124B at the container processing station 110. Further, the system 112 may include a second linear actuator 136, or linear displacer, disposed above the conveyor 122 at the transfer station / area adjacent the container processing station 110 with the second pusher element 134 being mounted to the second linear actuator 136. The second linear actuator 136 is preferably configured to move the second pusher element 134 in the direction substantially perpendicular to the direction of travel of items on the conveyor 122.

[0033] As can be seen from FIGS. 4 and 5, the system 112 may coordinate the operation of the two pusher elements 128 and 134, such as, for example, by staggering the operation of the two pusher elements 128 and 134. In FIG. 5, the first (or top) pusher element 128 is in a retracted position (or in a direction away from the container processing station 110). The first set of items are on the conveyor 122, and the pusher element 128 has not yet been moved to push the first set of items toward the first container 124A at the container processing station 110. In contrast, the second (or bottom) pusher element 134 is in an extended position (toward the container processing station 110). The second pusher element 134 has already pushed the second set of items toward the second container 124B at the container processing station 110. Further, as shown in FIGS. 5 and 6, the system 112 may include one or more chutes 137 (such as ramps with sidewalls in one form) to support the pusher elements 128 and 134 when they are positioned to dispense items into the containers 124.Aty. Docket No. 1127P017425-WO (PCT)

[0034] In this form, the first pusher element 128 is disposed upstream of the second pusher element 134 in the direction of travel of the conveyor 122. Further, the first pusher element 128 is coordinated with the conveyor 122 to avoid blocking the second set of items moving on the conveyor 122. For example, the first and second pusher elements 128 and 134 may generally be held in an elevated position with respect to the conveyor 122 when not in use. Then, when in use, they may each be lowered to engage the conveyor 122 and encircle a set of items, and then be urged toward the container processing station 110 to move the items to the respective containers 124. Alternatively, one or both pusher elements 128 and 134 may be raised as a set of items is approaching that pusher element 128 and 134. Another example might be to retract the first and second pusher elements 128 and 134 further in a direction away from the container processing station 110 when these pusher elements 128 and 134 are not in use. In other words, one or both of the first and second pusher elements 128 and 134 may be in a fully retracted position so as not to block the conveyor 122 when not in use.

[0035] FIGS. 5 and 6 show mobile robots 140, or bots, interacting with the container processing station 110. In one form, it is contemplated that mobile robots 140 may carry the containers 124 to and from the container processing station 110. In this example, there are two levels along which the mobile robots 140 may travel to and from the container processing station 110. At one level, mobile robots 140 may be transporting empty or partially-empty containers 124 to the container processing station 110, while at the other level, mobile robots 140 may be transporting fdled or partially-filled containers 124 away from the container processing station 110.

[0036] FIGS. 5 and 6 show a third robotic operator 142 at the container processing station 110. In one form, the system 112 may include a third robotic operator 142 at the container processing station 110 that arranges the first set of items that have been moved from the conveyor 122 to the first container 124A. In other words, the third robotic operator 142 may arrange the items in the first conveyor 124A in an ordered fashion, rather than haphazardly and randomly arranged in the first container 124A. The third robotic operator 142 may make sure that everything that was pushed into a container 124 is low enough and that eaches are positioned correctly in the container 124. The third robotic operator 142 may organize and act as a fine discriminator. The third robotic operator 142 may make sure that nothing protrudes from the containers 124 and that the eaches are well-situated within the containers 124. It is contemplated that mobile robots 140 travel in twoAty. Docket No. 1127P017425-WO (PCT)lanes to bring containers 124 into the container processing station 110. In this form, the third robotic operator 142 arranges items in two different containers 124A and 124B corresponding to the first and second pusher elements 128 and 134. Further, it should be understood that, in other forms, it is contemplated that a human individual may manually perform the actions and operations at the container processing station 110.

[0037] FIGS. 7-10 show a second embodiment of an item transfer and assembly system 212 that may be used at an order fulfillment facility 100 and as part of an overall ASRS. It is generally contemplated that this embodiment is generally similar to the previous embodiment (item and transfer assembly system 112), but this second embodiment has more portability. The description of the previous embodiment and its components are incorporated herein. It should be understood that the embodiments are generally the same, except for the differences noted below.

[0038] FIG. 7 shows components of the item transfer and assembly system 212 in a stored condition. It is generally contemplated that certain components, including, for example, the first robotic operator 220, the conveyor 222, and / or the transfer belt 227, may include wheels 244, such as casters with locks for limiting movement, or some other sort of locomotion features. In this way, the components can be easily moved from a storage area or location when not in use to a position adjacent the container processing station 210 when in use. As can be seen, in this form, the conveyor 222 may be modular and may include several conveyor modules 248 that may be assembled to form the conveyor 222. Although the components are shown stored on the open floor of the facility 100, it is contemplated that the components may be stored at a designated storage area / location, which may, for example, be enclosed and / or which may be in an area that is away from heavy traffic areas of the facility 100. In addition, locating features may be used, such as markings on the floor of the facility 100 to indicate where the components should be positioned. Also, the system may include features, such as, for example, a guide or docking rail 246, that may allow certain components to be docked and clamped in place once in position.

[0039] As shown in FIG. 7, other components may also be stored with the wheeled components. For instance, it is contemplated that the first and second pusher elements 228 and 234, the first and second linear actuators 232 and 236, and the chute(s) 237 might also be stored with the wheeled components, i.e., with the first robotic operator 220, conveyor 222, and transfer belt 227. It isAty. Docket No. 1127P017425-WO (PCT)generally contemplated that components at the container processing station 210 itself would not be moved or altered. For example, as shown in FIG. 7, the third robotic operator 242 and mobile robots 240 transporting containers 224 are generally unaltered at the container processing station 210.

[0040] FIG. 8 shows the container processing station 210 available for manual use. In other words, when components of the item transfer and assembly system 212 are stored and not in use, it is contemplated that the container processing station 210 would still be available for manual use. In this example, an individual is shown at the container processing station 210 with a cart 250, although other transport vehicles may also be used. The individual may perform a manual decanting operation at the container processing station 210, such as, for example, by bringing one or more cases of items that may have been recently received at the facility 100 and depositing the items in one or more containers 224, or may perform other functions. In other forms, instead of a cart 250, mobile robots or autonomous vehicles might, in an automated manner, transport and deposit items from cases at the container processing station 210. Other workstation operations may also be performed when the components of the item transfer and assembly system 212 are stored and not in use. For instance, the operator 242 may pick eaches from one tote transported to the station 210 by a mobile robot 240 and place them in an adjacent order tote transported away from the station 210 by another mobile robot 240.

[0041] FIG. 9 shows the transfer and assembly system 212 in an operational condition. In other words, relative to FIG. 7, components have been moved from storage area or location to an operational position or location adjacent the container processing station 210. The first robotic operator 220, the conveyor 222, the transfer belt 227, the first and second pusher elements 228 and 234, the first and second linear actuators 232 and 236, and the chute(s) 237 have all been moved from the storage area or location to the operational position / location. The conveyor modules 248 have been assembled to form the conveyor 222. This arrangement corresponds generally to the arrangement of the first embodiment shown in FIGS. 3-6. FIG. 10 shows the transfer and assembly system 212 as it is being pulled away from the operational position / location next to the container processing station 210. It is disassembled from its operational condition and returned to the storage area or location.Aty. Docket No. 1127P017425-WO (PCT)

[0042] FIG. 11 shows a process 300 of transferring items from pallets to containers. It is generally contemplated that the transfer of items is made to container processing station at a facility. Further, it is generally contemplated that the process 30 may use some or all of the components described above, such as, for example components of the transfer and assembly systems 112 and 212.

[0043] Optionally, block 302 involves portable components that may be positioned next to a container processing station. Under this step, components are moved to the required container processing station. For example, a first robotic operator, a conveyor, a transfer belt, first and second pusher elements, first and second linear actuators, and chute (s) are moved from a storage area or location to an operational position or location next to the container processing station. Once at the operational position / location, the components may be assembled and arranged to perform the transfer function. The conveyor may be composed of individual conveyor modules that are assembled to collectively form the conveyor. In some forms, the components may be more permanently positioned next to the container processing station, and this step may not be required.

[0044] At block 304, pallets arrive at the pallet receiving area. For example, a delivery vehicle may have arrived at the facility, and pallets of cases from the delivery vehicle may have been unloaded from the vehicle. In one form, a pallet with cases may be transported from the unloading area to the pallet receiving area, such as, for example, by automated vehicle or forklift.

[0045] At block 306, a robotic operator transfers cases from the pallet to the conveyor. In other words, a robotic operator, such as, for example, first robotic operator 120 transfers cases containing eaches (or individual items) from the pallet receiving area. In one form, the robotic operator is a robotic arm disposed within reach of both the cases in the pallet receiving area and the conveyor.

[0046] At block 308, the cases may advance to the unpack / decase station along the conveyor. It is generally contemplated that the unpack / decase station is located along or adjacent the conveyor intermediate the pallet receiving area and the container processing station. At block 310, eaches are removed from each individual case at the unpack / decase station, and the eaches are advanced on the conveyor. The unpacking / decasing operation may be performed by a human or by another robotic operator. Further, in one form, a transfer belt may be located at the unpack / decase station to allow for removal of empty cases from that area.Aty. Docket No. 1127P017425-WO (PCT)

[0047] It is also contemplated that the conveyor may have dividers that separate eaches into groups for the pusher elements. These dividers may be part of the conveyor structure or may be added by an operator, such as, for example, at the unpack / decase station. Thus, in one form, the conveyor may have dividing elements, such as standing ribs, that separate the eaches into groupings that correspond with the width of the pusher elements.

[0048] At block 312, eaches arrive at a transfer station / area adjacent to the container processing station. It is then contemplated that the eaches are loaded or moved into containers at the container processing station. In one form, a pusher element mounted adjacent the container processing station moves a set of items from the conveyor to a container at the container processing station. In some forms, movement of the pusher element may be controlled by a linear actuator. Further, in some forms, there may be multiple pusher elements that push or move corresponding sets of items into multiple containers.

[0049] At block 314, mobile robots carrying empty containers arrive at the container processing station. At block 316, eaches / items are transferred from the conveyor to the container at the container processing station, such as by a pusher element and linear actuator. The pusher element may have walls that enclose the eaches / items to be pushed. Further, a chute (such as, in one form, a ramp with sidewalls) may be used to support the pusher element to guide the eaches / items from the conveyor into the container.

[0050] At block 318, a third robotic operator may assist in positioning the eaches in each container. It is generally contemplated that the eaches will initially arrive in each container in a haphazard manner, and the third robotic operator rearranges them in an orderly fashion in each container. At block 320, after each container is filled, mobile robots with filled containers exit the container processing station.

[0051] Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can also be made with respect to the above described embodiments without departing from the scope of the disclosure, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

[0052] What is claimed is:

Claims

Aty. Docket No. 1127P017425-WO (PCT)CLAIMS1. An item transfer and assembly system comprising:a pallet receiving area;a first robotic operator configured to transfer cases from the pallet receiving area, the cases containing individual items;a conveyor configured to receive cases from the first robotic operator and to transfer items in the cases to a container processing station where items are deposited in containers; anda first pusher element mounted adjacent the container processing station, the first pusher element configured to move a first set of items from the conveyor to a first container at the container processing station.

2. The item transfer and assembly system of claim 1, wherein the conveyor further comprises:a plurality of conveyor modules that may be assembled to form the conveyor, each conveyor module including a locomotion element configured to allow the conveyor module to move from a storage area to an operational location.

3. The item transfer and assembly system of claim 1, wherein the first robotic operator comprises a robotic arm disposed adjacent the pallet receiving area and adjacent the conveyor.

4. The item transfer and assembly system of claim 1, further comprising:a decasing station adjacent the conveyor intermediate the pallet receiving area and the container processing station;wherein, at the decasing station, items are removed from an individual case on the conveyor and the removed items are placed on the conveyor.

5. The item transfer and assembly system of claim 4, further comprising a second robotic operator at the decasing station configured to remove items from the individual case and place the removed items on the conveyor.Aty. Docket No. 1127P017425-WO (PCT)6. The item transfer and assembly system of claim 1, wherein the first pusher element comprises a plurality of walls defining an open side facing the container processing station, the plurality of walls configured to surround the first set of items other than on the open side.

7. The item transfer and assembly system of claim 1, further comprising:a first linear actuator disposed above the conveyor adjacent the container processing station, the first pusher element being mounted to the first linear actuator.

8. The item transfer and assembly system of claim 7, wherein the first linear actuator is configured to move the first pusher element in a direction substantially perpendicular to a direction of travel of items on the conveyor.

9. The item transfer and assembly system of claim 8, further comprising:a second pusher element mounted adjacent the container processing station, the second pusher element configured to move a second set of items from the conveyor to a second container at the container processing station.

10. The item transfer and assembly system of claim 9, further comprising:a second linear actuator disposed above the conveyor adjacent the container processing station, the second pusher element being mounted to the second linear actuator;wherein the second linear actuator is configured to move the second pusher element in the direction substantially perpendicular to the direction of travel of items on the conveyor.

11. The item transfer and assembly system of claim 10, wherein:the first pusher element is disposed upstream of the second pusher element in the direction of travel of the conveyor; andthe first pusher element is coordinated with the conveyor to avoid blocking the second set of items moving on the conveyor.

12. The item transfer and assembly system of claim 1, further comprising:Aty. Docket No. 1127P017425-WO (PCT)a third robotic operator at the container processing station configured to arrange the first set of items moved from the conveyor to the first container.

13. A method of transferring items from pallets to containers, the method comprising:by a first robotic operator, transferring cases from a pallet receiving area, the cases containing individual items;by a conveyor, receiving cases from the first robotic operator and transferring items in the cases to a container processing station where items are deposited in containers; andby a first pusher element mounted adjacent the container processing station, moving a first set of items from the conveyor to a first container at the container processing station.

14. The method of claim 13, further comprising:at a decasing station adjacent the conveyor intermediate the pallet receiving area and the container processing station, removing items from an individual case on the conveyor and placing the removed items on the conveyor.

15. The method of claim 14, wherein a second robotic operator at the decasing station removes items from the individual case and places the removed items on the conveyor.

16. The method of claim 13, further comprising:by a first linear actuator disposed above the conveyor adjacent the container processing station, the first pusher element being mounted to the first linear actuator moving the first pusher element in a direction substantially perpendicular to a direction of travel of items on the conveyor.

17. The method of claim 16, further comprising:a second pusher element mounted adjacent the container processing station, the second pusher element configured to move a second set of items from the conveyor to a second container at the container processing station.

18. The method of claim 17, further comprising:Aty. Docket No. 1127P017425-WO (PCT)by a second linear actuator disposed above the conveyor adjacent the container processing station, the second pusher element being mounted to the second linear actuator, moving the second pusher element in the direction substantially perpendicular to the direction of travel of items on the conveyor.

19. The method of claim 18, wherein the first pusher element is disposed upstream of the second pusher element in the direction of travel of the conveyor, the method further comprising:coordinating the first pusher element with the conveyor to avoid blocking the second set of items moving on the conveyor.

20. The method of claim 13, further comprising:by a third robotic operator at the container processing station, arranging the first set of items moved from the conveyor to the first container.

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