Automated sortation systems and methods

Abstract

A sortation system for use in fulfilling orders of inventoried items is provided. The sortation system comprises a first load handling system comprising a plurality of first load handlers circularly arranged about a substantially vertical center axis and controllable to collectively rotate about the center axis, each of the first load handlers being selectively and individually controllable for vertical movement. The sortation system further comprises a plurality of sortation bays arranged in a first cylindrical wall extending substantially concentrically about the first load handler, the sortation bays configured to hold portable containers therein, wherein, during circular movement of the load handlers. Each load handler is controllable to: move for receiving items at one or more item intake locations; move for delivering the items to the containers within individual ones of the sortation bays; and selectively deliver the items to the containers within the individual ones of the sortation bays.

Description

AUTOMATED SORTATION SYSTEMS AND METHODSRELATED APPLICATION

[0001] The present application claims priority to United States Provisional Patent Application No 63 / 771,808, filed March 14, 2025, the entire contents of which are incorporated herein by reference.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to automated sortation systems. More particularly, the present disclosure relates to automated systems for sorting items into containers for order fulfillment.BACKGROUND

[0003] Automated systems may be employed for sorting goods for order fulfillment. For example, a warehouse may include one or more storage structures storing inventoried items that may be ordered. Items may be retrieved from the storage structure and sorted into containers for fulfilling orders or suborders. For example, robotic storage / retrieval vehicles (RSRVs) may be used to fetch storage units (e.g. storage bins) from storage locations within the storage structure and deliver the bins to stations where items are picked and fed into a sortation system (e.g. by conveyors).

[0004] In existing systems, the rate and efficiency at which items may be processed by the sortation system may limit the rate at which orders are fulfilled. For example, load handling equipment may sequentially receive one or more items and deliver the item(s) to a container for an order. Movement of the load handling equipment for this process may limit the speed and efficiency of the sorting process. There is a need for improved sortation systems.SUMMARY

[0005] According to an aspect, there is provided a sortation system for use in fulfilling orders of inventoried items, the sortation system comprising: a first load handling system comprising a plurality of first load handlers circularly arranged about a substantially vertical center axis and controllable to collectively rotate about the center axis, each of the first load handlers being selectively and individually controllable for vertical movement; a plurality of sortation bays arranged in a first cylindrical wall extending substantially concentrically about the first load handler, the sortation bays configured to hold portable containers therein, wherein, during circular movement of the load handlers, each of the plurality of first load handlers is controllable to: move to one or more elevations for receiving items at one or more item intake locations; move to one or more elevations for delivering the items to the containers within individual ones of the sortation bays; and selectively deliver the items to the containers within the individual ones of the sortation bays.

[0006] In some embodiments, the system further comprises: a plurality of buffer bays arranged in at least a second cylindrical wall extending concentrically about the first cylindrical wall of the sortation bays; and a second load handling system positioned between the plurality of sortation bays and the plurality of buffer bays, the second load handling system comprising one or more second load handlers controllable and movable to selectively and individually move the containers from the sortation bays to the buffer bays.

[0007] In some embodiments, the buffer bays are each configured to receive and hold at least one container from the sortation bays, and optionally the buffer bays are each configured to receive and hold up to two containers from the sortation bays.

[0008] In some embodiments, the system further comprises a controller operable to control the first load handling system to: receive the items at the one or more item intake locations; and sort the items into the individual ones of the sortation bays.

[0009] In some embodiments, the system further comprises a controller operable to: control the first load handling system to receive the items at the one or more item intake locations and sort the items into the individual ones of the sortation bays; and control the second load handling system to selectively and individually move the containers from the sortation bays to the buffer bays.

[0010] In some embodiments, the controller receives order data and acquires item identification information for the items, and the sorting the items into the individual ones of the sortation bays is performed as a function of the order data and the acquired item identification information.

[0011] In some embodiments, the first load handling system comprises a plurality of vertically aligned guiderails, each guiderail having a respective one of the first load handlers mounted thereon.

[0012] In some embodiments, the first load handing system comprises, for each guiderail of the plurality of vertically aligned guiderails, respective actuation mechanism for actuating the vertical movement of the respective load handler along the guiderail.

[0013] In some embodiments, each load handler of the first load handling system comprises a respective platform for receiving the items at the intake locations and for delivering the items to the containers.

[0014] In some embodiments, each load handler further comprises an axial drive mechanism operable to move the load handler axially along the respective guiderail.

[0015] In some embodiments, each load handler further comprises a tilt actuation mechanism operable to move the respective platform between an upward tilted position and a downward tilted position.

[0016] According to another aspect, there is provided a method for sorting items for order fulfillment using the system as described herein comprising: receiving order data comprising a plurality of orders for fulfillment; assigning each order to a respective one or more of the sortation bays, comprising generating astock list for each of the respective one or more sortation bays as a function of the order data; receiving items at the one or more intake locations; and sorting items into containers held within the sortation bays as a function of the stock lists.

[0017] In some embodiments, the method further comprises transferring completed containers from the sortation bays to the buffer bays, each completed container containing all items designated by the corresponding stock list.

[0018] According to another aspect, there is provided a controller comprising memory and one or more processors configured to perform one or more of the methods described herein.

[0019] Other aspects and features of the present disclosure will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific embodiments of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present disclosure will be better understood having regard to the drawings in which:

[0021] FIG. 1 is a perspective view of an automated sortation system for use in fulfilling orders of inventoried items according to some embodiments, with a portion of sortation and buffer bays of the system removed for illustrative purposes;

[0022] FIG. 2 is another perspective view of the automated sortation system of FIG. 1;

[0023] FIG. 3 is another perspective view of the automated sortation system of FIGs. 1 and 2;

[0024] FIG. 4 is a side perspective view of the automated sortation system of FIGs. 1 to 3;

[0025] FIG. 5A is upper perspective view of the automated sortation system of FIGs. 1 to 4;

[0026] FIG. 5B is an enlarged partial view the system of FIG. 5A;

[0027] FIGs. 6 and 7 are perspective views of a first load handling system and a cylindrical wall of sortation bays of the system of FIG.s 1 to 5B;

[0028] FIG. 8 is a top view of the cylindrical wall of sortation bays and the first load handling system of FIGs. 6 and 7;

[0029] FIG. 9A is a functional block diagram showing a system controller operatively connected to first load handling system controls and second load handling system controls;

[0030] FIG. 9B is a functional block diagram of an example system controller according to some embodiments;

[0031] FIGs. 10A and 10B are perspective views of an example load handler mounted to an example guiderail and in an upward tilted position according to some embodiments;

[0032] FIG. 11 is a perspective view of the example load handler of FIGs.10A and 10B in a downward tilted position.

[0033] FIG. 12 is a top perspective view of the load handler and guiderail of FIGs. 10A to 11;

[0034] FIGs. 13 is a partial, upper perspective view of another example load handling system, according to some embodiments;

[0035] FIG. 14 is partial, upper side perspective view of the load handling system of FIG. 13 with sortation bays;

[0036] FIG. 15 is partial, lower side perspective view of the load handling system of FIG. 13 with the sortation bays;

[0037] FIG. 16 is a flowchart of example method for sorting items, according to some embodiments;

[0038] FIG. 17 is a a flowchart of example method for for inbound buffering and / or sequencing, according to some embodiments;

[0039] FIG. 18 is a a flowchart of another example alternate method for inbound buffering and / or sequencing, according to some embodiments;

[0040] FIG. 19 is a a flowchart of example outbound buffer method, according to some embodiments;

[0041] FIG. 20 is a a flowchart of example method for buffer operations, according to some embodiments;

[0042] FIG. 21 is a a flowchart of example method for inbound sortation, according to some embodiments; and

[0043] FIG. 22 is a top view diagram of an example layout of the system 100 of FIGs. 1 to 5B, according to some embodiments.DETAILED DESCRIPTION

[0044] It may be beneficial to increase or maximize the number of orders that can be concurrently processed and / or the number of items that can be sorted over a period of time. It may also be beneficial to reduce or minimize the number of bin presentations required to fulfill orders. A presentation may comprise retrieving a bin (or other container) of inventoried items from storage so that items can be picked from the bin and sorted into orders. For example, it may be a beneficial to retrieve each required bin only once per day, if possible, and to pick all items needed from the bin that day. However, existing sortation systems may be limited by the rate at which items may be sorted into “put spots” of a “put wall”.

[0045] FIG. 1 is a perspective view of an automated sortation system 100 for use in fulfilling orders of inventoried items according to some embodiments. The system 100 comprises a first load handling system 102 comprising a plurality of load handlers 104, and a plurality of sortation bays 106 arranged in a first cylindrical wall 108 extending substantially concentrically about the load handlers 104. The term “bay” as used herein may refer to any structure providing an accessible space configured to receive and hold a portable container and receiving items into the container as described herein. The sortation bays 106 may also be referred to as “put spots” and are configured to hold portable containers such astotes or bins (not shown) therein. More specifically, each bay 106 may hold a respective portable container therein. The cylindrical wall 108 of sortation bays 106 may essentially function as a cylindrical “put wall” for order fulfillment. The sortation system 100 further comprises a buffering system including buffer bays 114 and a second load handling system described below. The buffer bays 114 and a second load handling system may be omitted in other embodiments.

[0046] The bays 106 and 114 are functionally represented by rectangular prism shapes in the drawings for illustrative purposes. However, the bays 106 and 114 may comprise any structure suitable for use as put spots for items being sorted into orders or suborders. For example, each wall 108 and 116 may comprise a frame structure defining a void for each bay, with support structures configured to releasably hold totes, bins, or other containers within the bays 106 and 114. Each sortation bay 106 may have an open or partially open inward facing side (facing inward toward the first load handling system 102) to receive items from the load handlers 104.

[0047] The load handlers 104 of the first load handling system 102 may be referred to herein as “sortation load handlers 104”. The sortation load handlers 104 are arranged circularly about a vertically aligned center axis 105 and configured for circular movement about the center axis 105. In other words, the sortation load handlers 104 collectively rotate or move in a circular orbit about the center axis 105, similar to a carousel. Each of the sortation load handlers 104 is also selectively and individually controllable for vertical (axial) movement. The vertical movement of the sortation load handlers 104 may be substantially parallel to the center axis 105.

[0048] In FIG. 1 , several columns of the sortation bays 106 and buffer bays 114 are removed or not shown (generally in region 120) so that the first load handling system 102 is partially visible. However, the sortation bays 106 may fill some or all of the cylindrical shape about the first load handling system 102. In other embodiments, the cylindrical wall 108 may only extend partially about the center axis 105 or may have one or more gaps. The sortation bays 106 need not be fill all available space(s) in the cylindrical shape of the wall 108. For example,spaces or voids without bays may be provided, for example, to provide space for other equipment or to provide access or clearance.

[0049] The combination of circular rotation about the center axis 105 (similar to a carousel) and upward / downward vertical movement of the sortation load handlers 104 may allow the sortation load handlers 104 to move 360 degrees around the center axis 105 and to any elevation from a top 110 first cylindrical wall 108 of sortation bays 106 to the bottom 112 of the first cylindrical wall 108 of sortation bays 106.

[0050] FIG. 2 is another perspective view of the system 100 of FIG. 1. With reference to FIG. 2, one or more item intake locations 202 may be positioned adjacent to the periphery of the first load handling system 102. An item intake location 202 may, for example, be an end of a feed line conveyor device (not shown) such as a belt conveyor arranged to deliver items to the sortation system 100. Arrow 204 in FIG. 2 represents a path along which an input feedline (e.g. conveyor system) may bring items to the item intake location 202 in this example embodiment. An example input feedline 230 carrying items 232 to the sortation load handlers 104 is shown in FIG. 22. Alternatively, a worker or robotic vehicle may deliver items directly to the intake location(s) 202.

[0051] In this example, the intake location 202 is shown at an elevation corresponding to a bottom elevation position of the load handlers 104. However, the one or more item intake locations 202 may be positioned at any elevation within the range of movement of the sortation load handlers 104. For example, the item intake location(s) may be at or near the top 110 or bottom 112 of the system 100, or one or more positions intermediate the top 110 and bottom 112. Different intake locations may be at different elevations.

[0052] The sortation load handlers 104 may continuously or semi-continuously rotate about the center axis 105, and the load handlers 104 may move vertically for sorting items. By this combination of rotation and vertical movement, the sortation load handlers 104 are controllable to move to: receive items at the one or more intake locations (such as intake location 202 in FIG. 2); move one or more elevations for delivering the items to the containers withinindividual ones of the sortation bays 106; and selectively deliver the items to the containers (e.g. bins or totes) within the individual ones of the sortation bays 106.

[0053] As also shown in FIGs. 1 and 2, the first load handling system 102 in this example includes a plurality of vertical guiderails 122 that are positioned and spaced apart in a circular arrangement about the center axis 105. Each sortation load handler 104 is mounted to and vertically movable along a respective one of the guiderails 122. Any suitable actuation means to move the sortation load handlers 104 along the guiderails 122 may be used. For example, a sprocket and rack system may be used to drive the vertical movement of the sortation load handlers 104 along the guiderails 122. An example actuation mechanism in the form of a sprocket and rack system is shown in FIGs. 10A and 10B and described below.

[0054] The guiderails 122 may be mounted to a rotating platform (not shown) to drive the circular rotation of the guiderails 122 about the center axis 105. Alternatively, the guiderails 122 may be connected (at their top and / or bottom) to a circular track that drives the circular movement about the center axis 105. Any other suitable mechanism for moving the guiderails in the circular, rotational path about the center axis 105 may be used in other embodiments.

[0055] The first load handling system 102 may further include frame structure or other support structure supporting the guiderails 122. For example, with reference to FIG. 1 , ring-shaped supports 123 may be provided.

[0056] As an example, to pick up an item at an intake location 202 at the bottom 112 of the system 100, a given load handler 104a moves to a bottom elevation position (as shown in FIG. 2) while the sortation load handlers 104 rotate about the center axis 105 similar to a carousel. When the given load handler 104a circles around to a position adjacent the item intake location 202, a conveyor device or other feedline mechanism (not shown) may dump the item into the given load handler 104a. While the sortation load handlers 104 continue to collectively rotate (i.e. circle around the center axis 105), the load handler 104a may then move to the elevation of the corresponding sortation bay 106 to which an order including the item has been assigned. At the elevation of the designated sortation bay 106,the load handler 104a will eventually rotate to a position adjacent the sortation bay 106. The load handler 104a may then deposit the item into the designated sortation bay 106. The system may further include a computerized system controller, such as the system controller 900 shown in FIGs. 9A and 9B and discussed below. The the first load handling system 102 may be controlled by a system controller 900 shown in FIGs. 9A and 9B, for example.

[0057] With reference to FIGs. 1 and 2, the axial (vertical) movement of the sortation load handlers 104 may be sufficient to allow each sortation load handler 104 to receive an item (at an intake location), move to any elevation to deliver the item to a sortation bay 106, and return to the elevation for item intake within two full rotations (720 degrees of rotation) of the sortation load handlers 104 about the center axis 105. In some embodiments, it a single full orbit around the center axis may take approximately 5 seconds, although the speed and rotation (orbit) time for the load handlers may be faster or slower. The sortation load handlers 104 may move very fast vertically without losing items. The carousel format of the first load handling system 102 may allow for continuous rotation of the sortation load handlers 104 about the center axis 105 for efficient sorting of items into the sortation bays 106.

[0058] The system 100 in FIGs. 1 and 2 further includes the plurality of buffer bays 114 arranged in a second cylindrical wall 116 extending concentrically about the first cylindrical wall 108 formed by the sortation bays 106. In this example, buffer bays 114 are double-deep bays meaning they are deep enough to receive and hold two containers from the sortation bays 106. Similar to the cylindrical wall 108 of sortation bays 106, several columns of the buffer bays 114 are removed in FIGs. 1 and 2 to provide better visibility of the sortation bays 106 and the first load handling system 102.

[0059] The first load handling system 102 in this example does not use a conveyor belt to eject items from the sortation load handlers 104 into the sortation bays 106. Rather, the angle of the platform 1006 and / or centrifugal force may be sufficient to eject items. Centrifugal force act may act on all items equally, including stacked items. By contrast, if items are stacked on a conveyor belt, friction onlyacts on lowest item. Thus, the first load handling system 102 may utilize centrifugal force to more efficiently move items into the sortation bays 106.

[0060] The first load handling system 102 in this example includes 12 sortation load handlers 104 on 12 corresponding guiderails 122. However, the number of load handlers and guiderails may vary in other embodiments (more or fewer).

[0061] The system 100 may further include a second load handling system (see shuttle 502 of the second load handling system 117 visible in FIGs. 5B and 22) positioned between the plurality of sortation bays 106 and the plurality of buffer wall bays 114. The second load handling system 117 (FIG. 5B) may be controlled by the system controller 900 (FIGs. 9A and 9B). The second load handling system may comprise one or more second load handlers controllable and movable to selectively and individually move the containers from the sortation bays 106 to the buffer bays 114.

[0062] The load handlers of the second load handling system 117 may, for example, include a plurality of shuttles. In one embodiment, the system 100 may include one shuttle, such as shuttle 502 in FIG. 5, for each row (level) of the sortation bays 106 and buffer bays 114. Each shuttle may be mounted on a track that extends fully or partially about the respective row of bays 106 and 114 for horizontal movement in the annulus between the buffer bays 114 and sortation bays 106. The second load handling system may also include one or more vertical elevators (not shown) for vertical movement of containers between rows of the buffer bays 114 and / or moving items to an outtake location for removal from the system. Alternatively, the shuttles 502 may be capable of horizontal and vertical movement. Various shuttle systems for moving containers horizontally and vertically, such as into double deep buffer locations or bays, are known and may be adapted for use as the second load handling system. The second load handling system 117 may perform one or more of the following functions: moving empty containers into the sortation bays 106; moving full containers from the sortation bays 106 into the buffer bays 114; remove completed containers from the buffer bays 114 out of the system (e.g. bringing those containers to an outbound line tobe removed from the system 100); inject containers that may have been filled in other areas of the warehouse to be stored for later.

[0063] For example, as orders (or suborders) are completed within the sortation bays 106, the containers within those sortation bays 106 may be moved to the buffer bays 114 and empty containers (e.g. totes orbins) may be moved into those now-vacant sortation bays 106. Empty containers may be moved into the vacant sortation bays 106 by shuttles of the second load handling system 117, for example. One or more other devices may also move empty containers into vacant sortation bays 106. In some embodiments, the second load handling system 117 may remove a completed container from a sortation bay 106 and in the same cycle move an empty container into the sortation bay as part of the same cycle (e.g., performed substantially simultaneously). New orders or suborders may then be assigned (e.g. by the system controller 900 shown in FIG 9) to those sortation bays 106. The load handlers of the second load handling system may comprise shuttles, for example.

[0064] Any suitable load handing system for transferring containers from the sortation bays 106 to the buffer bays 114 may be used. For example,

[0065] The containers filled in the sortation bays and moved to the buffer bays 114may later be moved for final collation or other outbound process steps such as finishing pallets at palletizer for shipping. Each buffer bay 114may hold multiple totes or other containers filled in the sortation bays. For example, suborders (i.e. partial orders) may be filled in different individual sortation bays 106 and then consolidated into a completed order in a buffer bay 114.

[0066] FIG. 3 is a perspective view of the system 100 of FIGs 1 and 2, showing the full cylindrical walls 108, 116 of sortation bays 106 and buffer bays 114.

[0067] The system 100 may have capacity for hundreds of sortation bays 106 or more than 1000 sortation bays. The example in FIGs. 1 to 3 includes 240 sortation bays 106, but other embodiments may have more or fewer, including more or fewer rows and / or columns of bays 106. In some embodiments, thesystem may include 2400 sortation bays or more, for example, and may be capable of sorting 2000, 3000, 4000, 5000, 6000, 7000, or 8000 or more items per hour. The number of sortation bays 106 may be customized by increasing or decreasing the number of rows of the cylindrical wall 108 and increasing or decreasing the height of the first load handling system 102 accordingly. In some embodiments, the system 100 shown in FIGs. 1 and 2 may have a height of approximately 8 meters or more (or less).

[0068] FIGs. 4 and 5A are additional perspective views of the system 100 of FIGs. 1 to 3, with some columns of the bays 106 and 114 removed for illustrative purposes.

[0069] FIG 5B is an enlarged partial view of the system 100 shown in FIG.5A. In FIG. 5B, a shuttle 502 of the second load handling system 117 is visible.

[0070] FIGs. 6 and 7 are perspective views of the first load handling system 102 and the cylindrical wall 108 of sortation bays 106 of the system 100 of FIG.s 1 to 5B.

[0071] FIG. 8 is a top view of the cylindrical wall 108 of sortation bays 106.

[0072] FIG. 9A is a functional block diagram showing a system controller 900 operatively connected to the first load handling system 102 and the second load handling system 117. The first load handling system 102 may include one or more control(s) for motor(s), actuators, or other controllable components of the first load handling system 102. The second load handling system 117 may include one or more control(s) for motor(s), actuators, or other controllable components of the second load handling system 117. The system controller 900 may be operable to operate the first load handling system control(s) 901 and the second load handling system control(s) 903. The system controller 900 may be operatively coupled to the first load handling system 102 and / or the second load handling system 117 by any suitable means for electronic communication and / or control, such as a wired or wireless network. In some embodiments, the control(s) 901 and / or 903 may comprise computer hardware and / or software.

[0073] FIG. 9B is a functional block diagram of the system controller 900 according to some embodiments.The controller 900 in FIG. 9B comprises one or more processors 902 and memory 904 operatively coupled to the one or more processors 902. The memory 904 may have processor executable instructions stored thereon that, when executed by the one or more processors 902, cause the one or more processors 902 to implement one or more methods described herein, including (but not limited to) the method of FIGs. 16 to 21. For example, the system controller 900 may operable to control the first load handling system 102 (FIGs. 1 and 2) to: receive items at the one or more item intake locations 202; and sort the items into the individual ones of the sortation bays 106. The system controller 900 in this example may be further operable to control the second load handling system 117 (FIG. 5B) to selectively and individually move containers from the sortation bays 106 to the buffer wall bays 114. The system controller 900 may also include controls for scanners, sensors, and / or other hardware of the system 100, such as equipment for acquiring items received into the system for sorting.

[0074] The system controller 900 may also control one or more feedlines, conveyors, or other equipment, such as the input feedline 220, the container input feedline 226 or outbound feedline 228 shown in FIG. 22.

[0075] Embodiments are not limited to the specific configuration shown in FIGs. 9A and 9B and may comprise any combination of hardware and / or software to enable the control functionality described herein.

[0076] The controller 900 also optionally includes a user interface 906 that may include any suitable input and / or output hardware for receiving input from a user and / or providing output to the user. The controller 900 may further include one or more communication components 908, such as a transceiver, to enable communication with other elements of the system 100 over a wired or wireless network. For example, the controller 900 may communicate with the first load handling system 102 to control movement of the sortation load handlers 104. In some embodiments, the first load handling system 102 may comprise control circuitry (such as a separate controller system) in communication with the system controller 900. The control circuity of the first load handling system 102 may control the motors and / or other drive components to actuate the rotational (circular)movement of the guiderails 122 and the vertical movement of the sortation load handlers 104, in accordance with control signalling or instructions received from the system controller 900. The controller 900 may also control the second load handling system for transferring containers from the sortation bays 106 to the buffer bays 114.

[0077] The memory 904 may store order data 910. The order data 910 contains information relating to one or more orders, including at least the identity of ordered items in each of the one or more orders. The order data may also include 910 customer information (e.g., customer ID), the destination of each order (e.g., mailing address), whether the order must be fulfilled by a certain date and / or time, and any other information in relation to the one or more orders. The order data 910 may be received from an order system (not shown) over a network such as the Internet. The term “order” as used herein may refer to information (e.g. list) indicating ordered items, quantities of items ordered, etc. as defined by the order data. The terms “completed order” or “fulfilled order” may refer to the physical items as retrieved and gathered together for shipping.

[0078] The controller may receive the order data 910, and sorting the items into the individual ones of the sortation bays may be performed as a function of the order data 910. As one example, the memory 904 may further include sortation data 912 that is generated at least in part as a function of the order data 910. The sortation data 912 may include a database indicating current assignments of orders (or suborders) to sortation bays 106, stock data including items currently within each sortation bay 106, items still required for each sortation bay 106 (e.g. a stock list (e.g. waitlist) for each bay with an assigned order), and / or items currently on route to the first load handling system 102 via one or more conveyor devices, etc.

[0079] The controller 900 may acquire each item being fed into the system 100. The term “acquire” in this context may comprise the controller 900 obtaining item identification information and order information / identification corresponding to the item (i.e. becoming aware of the item within the system 100 and the order to which it belongs) so that the system 100 can direct the item to the correct sortation bay 106. In some embodiments, item acquisition may be performed by scanningthe item when the item is picked from a storage bin. For example, a worker or robot may scan items as they are picked from bins (at a picking station) and placed on a conveyor system. Once an item is acquired, the controller 900 may track the position of the item by monitoring movement of the conveyor systems, and the item may only need to be acquired once. In another embodiment, item acquisition could be accomplished by a scanner mounted to or proximate to a conveyer device (e.g. conveyor belt) at some position downstream of the picking station. In yet another embodiment, item acquisition may be performed using one or more scanners at the one or more item intake locations 202 of the sortation system 100. Scanning to acquire items may, for example, be performed an RFID scanner that scans RFID tags on the items.

[0080] The memory 904 may further include storage data (not shown) indicating items in storage and locations of the items in storage. The controller 900 may issue commands to retrieve items from storage for sortation. Alternatively, a warehouse control system (not shown) may manage item storage and retrieval from storage, and the warehouse control system may generate and transmit sortation data 912 to the controller 900 for controlling the sortation process. Other variations and distributions of control functionality are also possible.

[0081] The first load handling system 102 may include a sortation load handling controller (not shown) including one or more processors and memory configured to control the sortation load handlers 104. For example, the system control 900 may send signalling to the sortation load handling controller indicating determined locations for items accepted by the first load handling system 102. The sortation load handling controller may then control the elevation of the load handers 104 accordingly to deliver the items to the designated sortation bays.

[0082] Similarly, the second load handling system 117 (shown in FIG. 5B) may include a buffer load handling controller including one or more processors and memory configured to control the second load handling system. For example, the system control 900 may send signalling to the buffer load handling controller indicating determined buffer bay locations for containers to be transferred from the sortation bays 106 to the buffer bays 114. The buffer load handling controller maythen control the second load handling system 117 accordingly to deliver the containers to the designated buffer bays 114.

[0083] The sortation load handling controller and / or the buffer load handling controller may be separate from the system controller 900 and may be in communication with the system controller 900 via wired or wireless communication. In other embodiments, sortation load handling controller and / or the buffer load handling controller may be integrated into the system controller 900.

[0084] The sortation load handlers 104 of the first load handling system 102 shown in FIGs. 1 to 8 may have a variety of implementations. FIGs. 10A to 11 are perspective views of an example load handler 1004 and mounted to an example guiderail 1022 (the guiderail 1022 is partially shown). FIG. 12 is a top perspective view of the handler 1004 and guiderail 1022. The sortation load handlers 104 and guiderails 122 shown in FIGs. 1 and 2 may each be in the form of the example load handler 1004 and guiderail 1022 in FIGs. 10A to 12.

[0085] As shown in FIGs. 10A and 10B, the load hander 1004 in this embodiment generally comprises a movable platform 1006 configured to convey items as described below, an axial drive mechanism 1008, and a tilt actuation mechanism 1010. The axial drive mechanism 1008 is coupled to the guiderail 1022. The platform 1006 is coupled to the axial drive mechanism 1008 and the tilt actuation mechanism 1010. The term “platform” is used herein to refer to any support surface configured to support one or more items thereon, such as a shelf, tray, etc.

[0086] The platform 1006 has a raised or upward tilted position shown in FIGs. 10A and 10B in which a floor 1012 of the platform 1006 is angled upward (extending from the guiderail 1022 to a distal end 1014 of the platform 1006). The platform 1006 also has a lowered or downward tilted position (shown in Fig. 11), in which the floor 1012 is angled downward. The tilt actuation mechanism 1010 is controllable to actuate the platform 1006 between the upward and downward tilted positions. The upward tilted position may be used for catching items from a conveyor at the intake location(s) and for carrying items. The downward tilted position may be used for releasing items into the sortation bays 106.

[0087] The axial drive mechanism 1008 is a motor 1009 that is controllable to move the load handler 1004 axially along the guiderail 1022. The axial drive mechanism 1008 in this example comprises a sprocket gear 1016. The guiderail 1022 comprises a vertically aligned rack 1018, and the sprocket gear 1016 is engaged with the rack 1018, such that rotation of the sprocket gear 1016 drives vertical movement of the load handler 1004 along the guiderail 1022. The axial drive mechanism 1008 further comprises a frame 1020 to which the sprocket gear 1016 and platform 1006 are mounted. In this example, the load handler 1004 further comprises two pairs of guide wheels 1024 coupled to the frame 1020. The pairs of guide wheels 1024 are engaged with opposite corner edges of the guiderail 1022.

[0088] The tilt actuation mechanism 1010 in this embodiment comprises a pivot hinge 1026, on which the platform 1006 is mounted, and a release mechanism 1025 (visible in FIG. 12) that releases the platform 1006 to move via gravity about the pivot hinge 1026 to the downward tilted position of FIG. 11. A motor, or other mechanical means may move the platform 1006 back to the upward tiled position of FIGs. 10A and 10b. For example, an additional motor may be included to raise the tilt of the platform 1006. Alternatively, a cam member or other mechanical device may be mounted in a position to engage and raise (tilt upward) the platform 1006 as the platform returns to an intake location 202. However, any other suitable method to actuate the platform 1006 may be used in other embodiments.

[0089] When holding one or more items, the platform 1006 may be maintained in the upward tilted position shown in FIGs. 10A and 10B. To deposit an item in a sortation bay 106, the platform 1006 may be actuated to the downward tilted position, which is shown in FIG 11. The downward angle of the floor and / or centrifugal force may move the item(s) from the platform 1006 into a container in the sortation bay 106.

[0090] Other means for selectively releasing the item(s) from the load handlers 1004 may be used in other embodiments. For example, the platform 1006 may include a tailgate in other embodiments, and the tailgate may open to release the item(s) held in the platform 1006. In some embodiments, centrifugal force maybe sufficient to urge item(s) out of the platform 1006 when the tailgate opens. In yet another embodiment, each load handler may include a conveyor belt that pushes item(s) out of the load handlerand into a sortation bay 106.

[0091] FIGs. 13 to 15 are partial views of an example load handling system 1302, similar to the load handling system 102 in FIGs. 1 to 8. The load handling system 1302 includes a plurality of load handlers mounted on guiderails 1322. The load handlers 1304 are movable to load items into sortation bays 1306 (which are similar to the bays 106 shown in FIGs. 1 to 8).

[0092] The sortation systems and methods described herein may allow items to be sorted into totes or bins to fulfill orders without requiring a worker to physically take picked items to a put wall. Rather, items may be picked from storage bins and placed into a conveyor system (e.g. in another bin or tote, or individually) that delivers the items to the sortation system. Items may be singularized and placed in a handler (e.g. shuttle) for delivery to the sortation system. There may, for example, be several intake locations, such as 12 intake locations.

[0093] FIG. 16 is a flowchart of an example method 1600 of using a sortation system as described herein. The method 1600 is described below with reference to the system 100 of FIGs. 1 to 5B for illustrative purposes. For example, the method 1600 may be implemented by the system controller 900 of FIGs. 9A and 9B, by another computer system, or a combination thereof. Separate control circuitry of the first load handling system 102 and / or second load handling system 117 described above may also be used to implement one or more of methods or method steps described herein.

[0094] At block 1602, order data is received. The order data comprises a plurality of orders for fulfillment. As noted above, the order data may be received over a network (e.g. Internet), from another database or system, or by any other suitable means.

[0095] At block 1604, each order is assigned to a respective one or more of the sortation bays 106. This step may comprise generating a stock list for each ofthe respective one or more sortation bays 106 as a function of the order data. One or more orders may be split into suborders with each suborder assigned to a respective sortation bay 106. The stock list for each order (or suborder) may indicate each of the items corresponding to the order (or suborder) assigned to the corresponding sortation bay 106.

[0096] The items may be picked from bins retrieved from storage and placed into a conveyor system that delivers the items to the intake location(s). The items may scanned or otherwise identified and tracked so that the system controller (e.g. controller 900 of FIGs. 9A and 9B) can assign items received at the intake location(s) to the corresponding sortation bays 106. The scanning may occur when the items are picked from the bins and placed in the conveyor system that delivers the items to the intake location(s).

[0097] At block 1606, items are received at the one or more intake locations. Receiving the items may comprise picking up the items by the load handlers (104, 1004, or 1304) of the first load handling system 102, as described above. Prior to receiving the items, or at the time the items are received, the items may be acquired by scanning the items, for example. This scanning may include obtaining item identification information.

[0098] At block 1608, the items are sorted into containers held within the sortation bays 106 as a function of the stock lists. For example, the load handlers (104, 1004, or 1304) of the first load handling system 102 may deliver each item to the container held in the corresponding sortation bay 106 to which an order (or suborder) has been assigned.

[0099] Optionally, at block 1610, the method may comprise transferring completed containers from the sortation bays 106 to the buffer bays 114 as described herein. The term “completed container” may refer to a container that includes all items designated by the stock list for the order (or suborder) assigned to the corresponding sortation bay 106. A completed container may contain a suborder (e.g., portion of an order). One or more steps of the method of FIG. 16 may be omitted, and / or additional step(s) may be included. The order of the stepsmay also vary. Alternatively, containers may be moved directly from the sortation bays 106 to an outbound line or outbound area, bypassing the buffer system.

[0100] Additional example methods are will now be described with reference to FIGs. 17 to 21. One or more of these methods (1700, 1800, 1900, 2000, 2100) may be implemented by the system controller 900 of FIGs. 9A and 9B for example. Additional control hardware and / or software (e.g., circuitry) of the first load handling system 102 and / or second load handler described above may also be used to implement one or more of these methods (1700, 1800, 1900, 2000, 2100). One or more steps of these methods (1700, 1800, 1900, 2000, 2100) may be omitted, and / or additional step(s) may be included. The order of the steps may also vary.

[0101] FIG. 17 is a flow diagram of an example method 1700 for inbound buffering and / or sequencing of items in the system 100 of FIGs. 1 to 8. In the following description, the buffer bays 114(cylindrically arranged) and the second load handling system 117 may collectively be referred to as the buffer system (or alternatively to a “sequencer system”), and the sortation bays 106 and first load handling system 102 may collectively be referred to as the sortation system.

[0102] At block 1702 a notification may be sent when order / suborder is complete in sortation bay(s). The notification may, for example, be sent by the first load handling system 102 to the system controller 900 of FIGs. 9A and 9B. Alternatively, the system controller 900 may monitor the stock within the sortation bays 106 and may determine that an order / suborder is complete.

[0103] At block 1704, the system controller 900 provides the second load handling system 117 (between the sortation bays 106 and buffer bays 114) a destination location corresponding to the sortation bay(s) 106 that hold the completed container(s). The containers may be totes, bins, boxes, cases or any other suitable container.

[0104] At block 1706 a location of one or more buffer bays 114within the buffer system is identified, for placing the completed container(s). This step may be performed by the system controller 900 or (if separate from the systemcontroller 900) a controller of the second load handling system. The location(s) within buffer system (i.e. locations of buffer bays 114) may be identified based on various factors, such as optimized unloading sequence in the future.

[0105] At block 1708, the completed container(s) are delivered to the identified location(s) in the buffer system by the load handler(s) of second load handling system. Optionally, the container(s) are stored in the buffer bays 114until they are required to be ejected (e.g. for moving the containers to another location for packing, or another stage). Containers making up an order may be stored in the buffer bays 114 until that entire order is ready to be prepared. For example, an order may include 10 containers that need to be put on a pallet to be shipped to a customer. The buffer system allows removal containers in a specific order, which may align with a store plan-o-gram, for example. This may allow for efficient unloading of the containers in a store to which an order is delivered. For example, the container expected to be unloaded first may be added to a pallet last.

[0106] FIG. 18 is a flowchart of another example method 1800 for inbound buffering and / or sequencing of items in the system 100 of FIGs. 1 to 8.

[0107] At block 1802, one or more containers containing items for an order or suborder are presented directly to the second load handling system (between the sortation bays 106 and buffer bays 114). More specifically, containers completed outside of the sortation system may be inducted directly into the buffer system. The containers may be provided to the second load hander via one or more feedlines (e.g. conveyor lines).

[0108] At block 1804, the container(s) are accepted by the second load handling system.

[0109] At block 1806, one or more locations of buffer bays 114are identified, similar to block 1706 in FIG. 17.

[0110] At block 1808, the container(s) are moved / delivered to the identified location(s), similar to block 1708 in FIG. 17.

[0111] FIG. 19 is a flowchart of an example outbound buffer method 1900 according to some embodiments.

[0112] At block 1902, containers in the buffer system required for the outbound process, and their locations (buffer bays 114), are identified.

[0113] At block 1904, the identified container(s) are removed from the buffer bays 114by the second load handling system 117 (or other equipment). The second load handling system 117 may be configured for removing containers from the buffer bays 114 and moving the containers to an outtake location (in addition to moving containers from the sortation bays 106 into the buffer bays 114).

[0114] At block 1906, the containers are brought to another location for an outbound process, which may be any area outside of the sortation system 100 such as a packing or collating / assembling area. The prescribed order may be based on customer specific criteria for outbound workflow, for example. The completed containers may be taken to an outbound line at the bottom of the buffer system, for example, where they may be ejected from the system 100 and prepared to be built onto a pallet or prepared in other ways for shipping.

[0115] At block 1908, the container(s) are presented to outbound feedline(s) connected to the buffer system in accordance with the prescribed order.

[0116] At block 1910, the containers are removed from the buffer system by the outbound feedlines for final collation activity. The final collation activity may include collating and packing the completed orders for shipping.

[0117] FIG. 20 is a flowchart of an example method 2000 for buffer operations according to some embodiments. The buffer operations (using the buffer bays 114 as described below) may also be referred to as sequencer operations.

[0118] At block 2002, containers are moved rom sortation bays into buffer system once container(s) contain all items required for the order / suborder (as described above with reference to FIG. 17). Alternatively, or in addition to block 2002, container(s) may be moved directly to buffer system directly, skipping thesortation system (as described above with reference to FIG. 18). As noted above, locations of the containers in the buffer bays 114 may be selected based on based on optimized outbound flow.

[0119] At block 2006, the outflow process defined by blocks 2008 to 2014 may be triggered when locations within the buffer are required to be ejected. By way of example, containers may be requested for an outbound process such as collation and / or to preparation for shipping. This may include preparing a single order, preparing an outbound pallet, or another collation event. All required containers may then be ejected in a prescribed order for the outbound process.

[0120] At block 2008, the identified container(s) for ejection for outbound workflow are removed from the buffer bays 114by the second load handling system 117 (or other equipment), comprising retrieving container(s) from location within the buffer system by load handler.

[0121] At block 2010, the retrieved container(s) are brought to an outtake location, such as an outbound level to be placed on feedline(s) and taken out of the sortation system 100 for outbound collation. The collation may include grouping the containers in a pallet or otherwise assembling multiple containers for shipping. The containers may be removed from the buffer bays (block 2008) and / or brought to an outtake location or other location manually (rather than by the second load handling system 117).

[0122] At block 2012, once the container(s) are at the outbound feedline(s), remove container(s) from the buffer system. Removing the container(s) from the system may comprise both physically removing the container(s) as well as updating the controller 900 that the container has been removed. The controller 900 may digitally ‘hand off’ the container to a control system handling packing and shipping.

[0123] FIG. 21 is a flowchart of an example method 2100 for inbound sortation according to some embodiments.

[0124] At block 2102, items are presented to the sortation system via one or more feedlines. For example, items may be presented (e.g. sent to) one or moreintake locations by one or more conveyor belts or other feedlines. Prior to block 2102, items in the containers may be acquired by the controller 900 as described above.

[0125] At block 2104, the items are moved onto the first load handling system 102. This step comprises loading one or more items onto sortation load handlers 104 of the first load handling system 102. As the item(s) are moved onto the sortation load handlers 104, the rotation / cycling may continue. The sortation load handlers 104 may continuously rotate throughout this process or may follow a predictable pattern such as including slowing or stopping intermittently or periodically.

[0126] Optionally, at block 2106, pre-determined sortation bay location(s) for items are provided to first load handling system 102. For example, if the first load handling system 102 includes a separate controller (as described above), that controller may receive the location(s) of the selected sortation bays 106 from the system controller 900. The location(s) of the selected sortation bays 106 may be determined by software running on the system controller 900, for example.

[0127] At block 2108, for each load handler holding one or more items, the load handler 104 is moved to the elevation of the corresponding sortation bay 106 for the item.

[0128] At block 2110, the load hander 104 remains at that elevation and waits to for the rotation to bring the load handler 104 to the location of the designated sortation bay 106.

[0129] At block 2112, once at the location of the designated sortation bay 106, the load handler 104 is controlled to transfer the item(s) from load handler 104 to designated sortation bay 106. This step may be performed via motion of the load handler 104 (e.g. tilting), driven by system velocity (e.g. centrifugal force) and / or via a separate mechanism within the load handler 104 to release the item(s).

[0130] These steps may be repeated to complete the orders / suborders assigned to the sortation bays 106, at which time the containers of completedorders / suborders may be moved (e.g. to the buffer system as described above). The first load handling system 102 within the sortation bays 106 may rotate on a single center axis 105, passing all sortation locations within two full rotation cycles.

[0131] In some embodiments, container(s) for the completed orders are moved directly from the sortation bays to outbound flow and skip the buffer system (for example, if no buffering is required and the order is ready for the outbound process). The buffer system may also be omitted in some embodiments.

[0132] The sortation bays 106 may be fed with empty containers, as needed, by the buffer system.

[0133] Optionally, one or more incomplete containers (i.e. containers without the completed items for the order / suborder) may be moved from the sortation system temporarily into the buffer system if space is required in the sortation system. The incomplete container(s) may be moved back to the sortation bays 106 at a later time.

[0134] FIG. 22 is a top view diagram of an example layout of the system 100. FIG. 22 shows two circular zones representing the cylindrical (sortation bay) wall 108 and the cylindrical (buffer bay) wall 116. The first load handling system 102 and an example implementation of the second load handling system 117 are also shown. FIG. 22 further shows example input feedline 220, container input feedline 226, and outbound feedline 228. Each of these feedlines 220, 226 and / or 228 may comprise a conveyor belt or other conveyance means. The item input feedline is for feeding items 222 to the first load handling system 102. The container input feedline 226 may feed empty containers 227 to the second load handling system 117. The second load handling system 117 may place empty containers 227 into empty sortation bays 106 (FIG. 1). The second load handling system 117 may also convey completed containers 229 on the outbound feedline 228. The locations and elevations of the feedlines 220, 226 and / or 228 may vary. The number of feedlines 220, 226 and / or 228 may also vary. The feedlines 220, 226 and / or 228 are shown in FIG. 22 by way of non-limiting example.

[0135] FIG. 22 shows an example shuttle 502 that may be operable for horizontal movement in the annular space between the cylindrical wall 108 and buffer wall 116. The shuttle 502 may also be operable for vertical (elevator) movement to access bays in multiple rows / floors of bays in the system 100. Other load handling system configurations may be used for moving containers into and out of sortation bays 106 and / or buffer bays 114 in other embodiments.

[0136] In yet another embodiment, the system 100 may include a third load handling system (not shown) outside of the buffer bay wall 116 for moving completed containers to the outbound feedline 228. Other variations may also be implemented.

[0137] It is to be understood that a combination of more than one of the approaches described above may be implemented. Embodiments are not limited to any particular one or more of the approaches, methods or apparatuses disclosed herein. One skilled in the art will appreciate that variations, alterations of the embodiments described herein may be made in various implementations without departing from the scope of the claims.

Claims

CLAIMSWhat is claimed is:

1. A sortation system for use in fulfilling orders of inventoried items, the sortation system comprising:a first load handling system comprising a plurality of first load handlers circularly arranged about a substantially vertical center axis and controllable to collectively rotate about the center axis, each of the first load handlers being selectively and individually controllable for vertical movement;a plurality of sortation bays arranged in a first cylindrical wall extending substantially concentrically about the first load handler, the sortation bays configured to hold portable containers therein, wherein, during circular movement of the load handlers, each of the plurality of first load handlers is controllable to:move to one or more elevations for receiving items at one or more item intake locations;move to one or more elevations for delivering the items to the containers within individual ones of the sortation bays; andselectively deliver the items to the containers within the individual ones of the sortation bays.

2. The system of claim 1 , further comprising:a plurality of buffer bays arranged in at least a second cylindrical wall extending concentrically about the first cylindrical wall of the sortation bays; and a second load handling system positioned between the plurality of sortation bays and the plurality of buffer bays, the second load handling system comprising one or more second load handlers controllable and movable to selectively and individually move the containers from the sortation bays to the buffer bays.

3. The system of claim 2, wherein the buffer bays are each configured to receive and hold at least one container from the sortation bays, and optionally the buffer bays are each configured to receive and hold up to two containers from the sortation bays.

4. The system of claim 1, further comprising a controller operable to control the first load handling system to:receive the items at the one or more item intake locations; andsort the items into the individual ones of the sortation bays.

5. The system of claim 2 or 3, further comprising a controller operable to: control the first load handling system to receive the items at the one or more item intake locations and sort the items into the individual ones of the sortation bays; andcontrol the second load handling system to selectively and individually move the containers from the sortation bays to the buffer bays.

6. The system of claim 4 or 5, wherein the controller receives order data and acquires item identification information for the items, and wherein the sorting the items into the individual ones of the sortation bays is performed as a function of the order data and the acquired item identification information.

7. The system of claim 6, wherein the order data comprises a plurality of orders for fulfillment, and the controller is further operable to assign each order to a respective one or more of the sortation bays.

8. The system of claim 7, wherein assigning each order to the respective one or more of the sortation bays comprises generating a stock list for each of the respective one or more sortation bays as a function of the order data.

9. The system of any one of claims 1 to 8, wherein the first load handling system comprises a plurality of vertically aligned guiderails, each guiderail having a respective one of the first load handlers mounted thereon.

10. The system of claim 9, wherein the first load handing system comprises, for each guiderail of the plurality of vertically aligned guiderails, respective actuation mechanism for actuating the vertical movement of the respective load handler along the guiderail.

11. The system of claim 9 or 10, wherein each load handler of the first load handling system comprises a respective platform for receiving the items at the intake locations and for delivering the items to the containers.

12. The system of claim 11, wherein each load handler further comprises an axial drive mechanism operable to move the load handler axially along the respective guiderail.

13. The system of claim 11 or 12, wherein each load handler further comprises a tilt actuation mechanism operable to move the respective platform between an upward tilted position and a downward tilted position.

14. The system of any one of claims 1 to 13, further comprising one or more input feedline that conveys the items to the one or more intake locations.

15. A method for sorting items using the system of any one of claims 1 to 11 comprising:receiving items at the one or more intake locations by the first load handling system; andsorting the items into one or more containers held within one or more of the sortation bays using the first load handling system.

16. The method of claim 15, further comprising:receiving order data comprising a plurality of orders for fulfillment, the ; and assigning each order to a respective at least one of the sortation bays, including assigning , wherein the sorting the items comprises sorting the items into the one or more containers held within the one or more sortation bays as a function of the assigning.

17. The method of claim 16, wherein the assigning each order to the respective one or more of the sortation bays comprises generating a stock list for each of the respective one or more sortation bays as a function of the order data, wherein thesorting the items comprises sorting the items into the containers held within the sortation bays as a function of the stock lists.

18. The method of claim 16 or 17, further comprising, transferring completed containers from the sortation bays to the buffer bays, each completed container containing all items designated by the corresponding stock list.

19. A controller comprising memory and one or more processors configured to perform the method of any one of claims 15 to 18.

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