An auto sort and label (ASL) system (100,200) includes a conveyor, a controller (150), a sensor (121,122,220,222,224,226), and a label, print, and apply (LPA) system (106,208). The conveyor conveys articles through the ASL system. The sensor is positioned along the conveyor and identifies an article. The controller receives sensor data from the sensor. The LPA is positioned alongside the conveyor and prints labels in sequence with the corresponding article as it travels along the conveyor and applies the labels to the corresponding articles as the article passes the LPA. The controller controls the conveyor such that a gap and/or pitch between first and second articles is adjusted to an optimal distance to match the operation capability of the LPA. The controller verifies placement and contents of the label upon the article as defined by sensor data and accepts or rejects the labeled article for further handling based on the verification.
B41J 3/407 - Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
B65C 1/02 - Affixing labels to one flat surface of articles, e.g. of packages, of flat bands
B65C 9/18 - Label feeding from strips, e.g. from rolls
B07C 5/00 - Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
2.
AUTOMATIC SELF ALIGNING AND SELF SUSTAINING BELT TRACKING SYSTEM FOR BELTED CONVEYORS
A conveyor surface adjustment system (100) includes first and second belt tracking actuators(106a, 106b) positionable at opposite first and second sides (102a, 102b) of a conveyor belt (102). An adjustable roller (120) in movable contact with the belt (102) has a fixed end (120a) and an adjustable end (120b) coupled to an adjustment gear (118). When the belt (102) is improperly positioned or aligned towards the first (106a) or second belt tracking actuator (106b), the belt (102) physically contacts or engages the first (106a) or second belt tracking actuator (106b). The engaged belt tracking actuator (106a, 106b) causes the gear (118) to rotate in either a first direction or a second direction to move the adjustable end (120b) of the adjustable roller (120) to adjust the tension of the belt (102). This tension change causes the belt (102) to track towards a corrected position or alignment.
A conveyor system for transporting goods within a warehouse facility. The system includes an array of guide tracks and carriages moveable along the guide tracks for transporting goods within the warehouse facility. A drive system includes drivers spaced along the guide tracks. The drivers may utilize linear induction motors, propels the carriages along the guide tracks. The linear induction motors utilize stepper motors, and optionally microstepping motors. A warehouse management system controls the linear drive system to transport goods throughout warehouse facility for storage and order fulfilment. The linear driver conveyor system includes perpendicular transfers at which carriages can be transferred from one conveyor line to another, without the need for mechanical processes, such as lift or buffers, to move the carriage between conveyor lines.
B60L 13/04 - Magnetic suspension or levitation for vehicles
B60L 15/00 - Methods, circuits or devices for controlling the propulsion of electrically-propelled vehicles, e.g. their traction-motor speed, to achieve a desired performance; Adaptation of control equipment on electrically-propelled vehicles for remote actuation from a stationary place, from alternative parts of the vehicle or from alternative vehicles of the same vehicle train
An order fulfillment control system (300) for a warehouse (200) includes a controller (301), storage (103), and a training module (102). The controller (301) controls mobile autonomous devices, fixed autonomous devices, and issues picking orders to pickers (202, 204). The controller (301) controls fulfillment activities in the warehouse (301) using hierarchically tiered algorithms, and records operational data for the fulfillment activities. The training module (102) retrains the algorithm using reinforcement learning and performs the reinforcement learning on the operational data to retrain/update the algorithms. The training module (102) retrains a macro algorithm according to a first set of priorities for optimal operation of the warehouse and retrains a plurality of micro algorithms according to corresponding second sets of priorities for optimal operation of a particular location and/or activity within the warehouse (200). The controller (301) adaptively controls the fulfillment activities using the updated algorithms.
A motor driven roller transmission system for a conveyance assembly (20) includes a transmission assembly (30) connected between first and second rotatable members (28, 32) that are oriented at an angle from one another. The transmission assembly (30) is adapted to efficiently transfer rotational motion of the first rotatable member (28) to the second rotatable member (32). Rotation of the second rotatable member (32) causes a conveyance surface (26) to move in order to convey an object. The transmission assembly (30) decreases the power required to drive the first rotatable member (28) in order to move the conveyance surface (26) by increasing the torque output of the first rotatable member (28), while also reducing the rotational speed required of the first rotatable member (28) to drive the conveyance surface (26) at a desired speed, thus extending the operational life of the first rotatable member (28).
B65G 47/53 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices between conveyors which cross one another
A system (102, 202, 302, 402) and method (500) are provided for loading trays (106), with articles using a first tray conveyor (104, 204, 304, 404) on which empty trays are delivered and an article conveyor (110, 210, 310, 410) on which articles (112) are delivered to be transferred onto empty trays. The trays (106) include a frame (116) and a movable transport plate (124) for the articles. A lifting apparatus (226, 326, 426) is provided for the transport plate (124) of the tray (106) at a height that is about equal to the height of the article conveyor (110, 210, 310, 410), such as about 10 millimeters (10 mm) or less to reduce or eliminate drop forces as articles as transferred from the article conveyor (110, 210, 310, 410) onto the tray (106).
B65G 47/22 - Devices influencing the relative position or the attitude of articles during transit by conveyors
B65G 47/52 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices
B65G 47/84 - Star-shaped wheels or devices having endless travelling belts or chains, the wheels or devices being equipped with article-engaging elements
B65G 47/76 - Fixed or adjustable ploughs or transverse scrapers
B65G 47/82 - Rotary or reciprocating members for direct action on articles or materials, e.g. pushers, rakes, shovels
A multi-directional or omni-roller (100, 100b, 200) for a conveyor system (300, 500) includes a first transport surface (102, 202) formed by a cylindrical roller body (104, 204), and a second transport surface (110, 110b, 210) formed by multi-directional wheels (112, 212). The wheels have a main body (112, 212) that rotate about a longitudinal axis of the roller, and secondary wheels (116, 216) disposed at an outer circumference that rotate perpendicular to the roller (100, 100b, 200), and permit articles or drive belts (504) to travel over the roller (100, 100b, 200) in a conveyance direction in a driven manner and permit articles to move laterally across the second transport surface portion (110, 110b, 210) without transferring lateral forces to a conveyor frame (502). For skew roller beds, a drive belt (504) may drive the roller (100, 100b, 200) about the secondary wheels (116, 216).
B65G 39/04 - Adaptations of individual rollers and supports therefor the rollers comprising a number of roller- forming elements mounted on a single axle
B65G 39/12 - Arrangements of rollers mounted on framework
B60B 19/00 - Wheels not otherwise provided for or having characteristics specified in one of the subgroups of this group
B65G 47/24 - Devices influencing the relative position or the attitude of articles during transit by conveyors orientating the articles
B65G 47/54 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices between conveyors which cross one another at least one of which is a roller-way
8.
METHOD AND SYSTEM FOR DECANTING TO PARTIALLY FILLED RECEPTACLES
A system and method for decanting inbound goods into compartments of totes (14a, 14b, 14c) for storage in an ASRS storage system (12) includes decant workstations (18) with multiple tote decant positions (20a, 20b, 20c) each dedicated to receive totes (14a, 14b, 14c) having differing compartment configurations at the decant positions (20a, 20b, 20c). A decant operator (22) is provided multiple (14a, 14b, 14c) totes such that the operator (22) may have an empty or partially filled compartment of each available compartment size in which to place inbound items. A warehouse control system (11) guides the operator to which tote (14a, 14b, 14c) and which compartment within that tote to place the item. When the compartments of a given tote (14a, 14b, 14c) are all filled, that tote is returned to the storage system (12) and replaced with another tote having an identical compartment configuration.
A real-time belt tension sensing system (20) includes an engagement assembly (26) that is adapted to remain in substantially continuous contact with a belt (22) that is being driven in a conveyance or drive direction. As the belt (22) is driven in the drive direction, it simultaneously causes the position of the engagement assembly (26) to move in a slack direction that is substantially perpendicular to the drive direction. A tension sensor (32) produces a slack position signal based on the current position of a portion of the engagement assembly (26). The slack position signal is transmitted to a controller or control circuit (36) in electronic communication with the tension sensor (32). The control circuit (36) interprets the slack position signal to produce a tension measurement.
G01L 5/107 - Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring tension in flexible members, e.g. ropes, cables, wires, threads, belts or bands using electrical means for measuring a reaction force applied on an element disposed between two supports, e.g. on a plurality of rollers or gliders
B65G 23/44 - Belt- or chain-tensioning arrangements
F16H 3/12 - Toothed gearings for conveying rotary motion with variable gear ratio or for reversing rotary motion without gears having orbital motion exclusively or essentially with continuously- meshing gears, that can be disengaged from their shafts with means for synchronisation not incorporated in the clutches
G01L 5/105 - Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes for measuring tension in flexible members, e.g. ropes, cables, wires, threads, belts or bands using electrical means using electro-optical means
An omnichannel order fulfilment and sortation system (100) and method (200) are provided for optimizing order fulfilment processes within an order fulfilment facility. System (100) includes multiple automated storage and retrieval systems or units (106), including aisle-based, grid-based, and full case handling systems. A centrally positioned continuous loop sorter (102) receives a multitude of items for many different work in progress orders. Order consolidators (104) are provided adjacent the sorter (102) to receive items for individual orders from the sorter (102). The quantity of consolidators (104) is higher than the quantity of storage units (106) and inducts (108) of the storage units (106), providing for many order consolidation locations such that the storage units (106) need not wait for consolidation locations to become available before retrieving items for other orders. The consolidator (104) selected to receive a particular order is optimized to reduce strain on resources within the system.
An automated warehouse system (10) and method (100) are provided for controlling internal microclimates of totes (12) within a warehouse or order fulfilment facility. The system (10) provides independent environmental condition monitoring and regulation for each tote (12) independent of its position within a storage system (14) or the environmental conditions of adjacent totes (12). The storage system (14) includes environmental control inputs at individual storage locations to adjust or maintain environmental conditions within a tote (12) at a particular storage location via covers (21) that are selectively engageable with the totes (12). The covers (21) engage the totes (12), which may be standard or commercially available totes (12), when they are stored at a storage location. The system (10) is operable to monitor and control the microclimate of a tote (12) via its cover (21) while it is stored at a storage location.
B65D 81/18 - Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents providing specific environment for contents, e.g. temperature above or below ambient
B65D 81/38 - Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
B65B 63/08 - Auxiliary devices, not otherwise provided for, for operating on articles or materials to be packaged for heating or cooling articles or materials to facilitate packaging
G06Q 10/0832 - Special goods or special handling procedures, e.g. handling of hazardous or fragile goods
A right angle transfer device (20, 120) has a conveying surface (25, 125) defined by a plurality of driven conveying members (26, 126) for conveying objects in a conveyance direction. A diverting conveying member (24, 124) is mounted to a frame (36, 136) and is driven to divert objects in a direction angled away from the conveyance direction. A lift drive (28, 128) rotates a cam (30, 130) to move a bar (32, 132) in a substantially horizontal direction. The movement of the bar (32, 132) causes a frame link (34, 134) connected to the bar (32, 132) and the frame (36, 136) to raise and lower the frame (36, 136). Once the frame (36, 136) has been moved upward to a sufficient extent, the diverting conveying member (24, 124) is raised above the conveying members (26, 126) to move and divert an object away from the conveyance direction.
B65G 47/54 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices between conveyors which cross one another at least one of which is a roller-way
Methods are provided for optimizing retail inventory receiving and putaway processes within a retail store. The methods include segregating items from inbound inventory loads by unloading and identifying each of the items in the load. Based on the identity of an item, a computer directs the operator to segregate each item to a putwall, such as to a container on a mobile inventory cart. A pick to light (PTE) system is utilized to direct the operator's segregation processes. Each item is segregated into a family or sub-family grouping of inventory items that correspond to a particular department or sub-department of the retail floor of the store. Segregated family or sub-family groupings are distributed to respective departments to be putaway by an associate on the retail floor. The methods may be adapted to process e-commerce orders for shipment out of the store or for in-store customer pickup.
An assessment system and method are provided for determining whether an item handled in a material handling system is stable and conveyable or unstable and non-conveyable. If an item is deemed non-conveyable, it is diverted or otherwise removed from the material handling system before it is transported downstream where it may affect the operation of the system or cause damage to the system and/or item. The system utilizes a dimension sensor system, such as including photo arrays, to measure contact region dimensions between an item being conveyed and the conveyor surface. The contact region is observed under constant conveyance rates, accelerating conveyance rates, and decelerating conveyance rates to determine whether the item orientation changes due to shifts in momentum. Any measured contact region changes are compared to a maximum allowed value, and if the measured change is greater than the maximum, the item is deemed non-conveyable.
A network module configured to provide switched auxiliary (AUX) power for E-stop system functionality in a network system. The network module includes a switching module and a controller. The switching module is configured to control the passage of power through a switched AUX cable for E-stop functionality. The switching module is configured to receive an unswitched AUX cable and the switched AUX cable. The controller is communicatively coupled to a communications cable. The controller is configured to control the switching actions of the switching module as defined by switching instructions received via the communications cable.
G05B 19/042 - Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
H01H 3/02 - Operating parts, i.e. for operating driving mechanism by a mechanical force external to the switch
H01H 13/50 - Switches having rectilinearly-movable operating part or parts adapted for pushing or pulling in one direction only, e.g. push-button switch having a single operating member
H02J 9/04 - Circuit arrangements for emergency or stand-by power supply, e.g. for emergency lighting in which the distribution system is disconnected from the normal source and connected to a standby source
A system and method are provided for auditing the inventory within an automated warehouse utilizing RFID technology. The system and method enable real-time tracking and monitoring of inventory and load units as they travel through and are stored in the warehouse. The system may require only a single RFID reader coupled with an automated shuttle for traversing a majority of the warehouse storage system to read, recognize, and audit the inventory as stored in load units stored in the system. The system may utilize multiple RFID readers throughout the warehouse to provide ample coverage, enabling real-time, whole warehouse inventory tracking. The system and method of the present invention contemplate both readily available RFID technologies, as well as advanced or improved RFID technologies having greater detection range, larger information storage capabilities, and the ability to determine precise spatial location of tags relative a reader.
B65G 65/08 - Loading or unloading machines comprising essentially a conveyor for moving the loads associated with a device for picking-up the loads with reciprocating pick-up conveyors
G05B 15/02 - Systems controlled by a computer electric
An RFID enabled system and method for tracking, directing, verifying, and validating item level order picking functions within order fulfilment and warehouse facilities having different SKUs sharing an inventory tote. RFID tags are coupled to each inventory item to be read by one or more RFID reader(s) in the facility. The system and method verify that a required item is picked and transferred correctly by the picker. The system provides feedback to the picker without requiring additional verification steps and preferably without any visual inspection by the picker. The picker may be guided to the required item and later directed to a location to place the retrieved item. The verification system may be adapted for use in a material handling system to monitor and direct material handling functions based on relative positions of RFID tags on individual items relative to RFID readers positioned throughout the facility.
A time tracking and indicator system and method are provided for tracking and indicating initialization-to-completion times for order fulfilment operations, such as order packaging and shipping operations. The system includes a put-wall with multiple order storage locations and indicators at each of the storage locations. The indicators are independently addressable by a computer and may include color changeable lights and/or alphanumeric displays. The method and system provide visual prompts to an operator of the put-wall to indicate multiple statuses for an order at a particular storage location. Prompts include indications that (i) an order is ready to be attended to, (ii) an operation time limit has been exceeded, and (iii) that an operation for that location is exceedingly overdue. Time limits and prompts may be preset by a user or may be automatically set and adjusted by the computer based on historic operation completion times.
A tolerance adjuster and wear device, e.g. spring clip, is provided for automatically adjusting the tolerance or clearance between a pusher shoe surface and an adjacent surface of a linear slat of a positive displacement sorter. The spring clip includes an engagement portion to couple the clip to a pusher shoe and a wear portion to automatically bias or adjust a tolerance between the pusher shoe and a corresponding slat. The engagement portion includes a retainer, in the form of a pair of opposing elastic grips or teeth that are insertable through a receiver in a surface of the shoe. The wear portion includes a wear surface and spring element, such as a spring arm or convex dome. The spring element is elastic to provide a consistent and automatic bias against the slat surface. Preferably, the spring clip is extruded from a resilient, wear-resistant self-lubricating polymer.
B65G 47/84 - Star-shaped wheels or devices having endless travelling belts or chains, the wheels or devices being equipped with article-engaging elements
B07C 3/06 - Linear sorting machines in which articles are removed from a stream at selected points
B07C 5/36 - Sorting apparatus characterised by the means used for distribution
B65G 47/46 - Devices for discharging articles or materials from conveyors with distribution, e.g. automatically, to desired points
20.
MULTI-FUNCTION ORDER FULFILLMENT SYSTEM WITH GRID STORAGE
A system and methods for utilizing a grid storage array for high rate picking in a micro-fulfilment facility. The system includes a grid storage array and multiple transfer ports that are dedicated to a particular directional function, i.e. discharge ports and intake ports. The system includes a multi-function workstation that can operate as either a picking station or a decant station. A conveyor loop is provided and includes right-angle-transfers (RATs) and accumulators to transport and sequence the flow of storage bins and order totes. The combination and configuration of the grid storage array, conveyor loop, and multi-function workstation optimizes space utilization which is particularly beneficial in micro-fulfilment facilities where space is at a premium.
An automated warehouse material movement system and method of moving material in a warehouse. A computer based vehicle tasking subsystem (VTS) is programed with computer code to respond to mission commands from a computer based warehouse executive subsystem (WEX) to issue commands to a computer based mobile robot automation subsystem (MAS) to reserve and schedule mobile robots including movement of inventory between a source and a destination within the warehouse and to report status information from the MAS to the VTS regarding status of missions. At least one microservice component is configured to be tightly designed, stateless and loosely coupled with said WEX and MAS. The VTS is the at least one microservice component.
A method and system for opportunistically picking order items during decant processes. An order management system determines which items required for a pending order are depleted within a decant function or storage system and orders replenishment, such as inbound vendor cases containing the depleted required items, to the decant function. Operators at decant workstations pick the required items from the inbound vendor cases into order containers while simultaneously decanting any remaining, non-required vendor items into inventory containers. The order containers and the inventory items are stored in a storage system until all required items for an order are present therein. Once all required items are present, the items are released to a downstream picking workstation, sorter, and/or packing station. The method with opportunistic decant may enable minimized facility space requirements, labor reductions, and resource reductions while improving facility throughput.
A system and method for consolidating order items into individual or batch orders within an order fulfilment workstation and discharging the order items to a takeaway device, such as a trackable segmented conveyor. The system includes a temporary holding container at the workstation and a discharge mechanism to release or transfer the contents of the temporary container to the takeaway device. The system and method reduce or eliminate the process of an operator replenishing order transport containers to the workstation once a completed order container has dispatched from the workstation. Empty order containers are supplied the workstation via the takeaway device. The empty order container is positioned adjacent the temporary container such that the discharge mechanism may transfer the order items from the temporary container into the empty order container. The discharge mechanism may transfer the order items directly to the surface of the takeaway device.
A contactless order dispensing system is provided for dispensing e-commerce orders to customers at a store without a person-to-person interaction. The dispensing system includes a customer access portal for presenting orders to the customer, preferably at an exterior location. A transportation system (e.g. conveyer system) transports orders from a storage buffer system to the customer access portal. The storage buffer holds customer orders until the customer arrives to retrieve them and may store portions of orders at different temperatures. The dispensing system includes a confirmation sensor system to verify whether a customer has retrieved their entire order or whether the customer has rejected one or more of the order items. The dispensing system provides the order to the customer within about two minutes of the customer indicating that they are at the access portal and ready for their order.
Methods and systems are provided for verifying a pick/put operation within an order fulfilment workstation or a storage rack. An optical device observes an operator performing a pick/put operation at the workstation. An indicia is located on the operator such that it is visible to the optical device. Image data of the indicia captured by the optical device is transmitted to a control system of the workstation. The control system determines a relative location of the indicia and then determines the location at which an item was picked from or put to relative to the workstation within a high degree of positional accuracy. The method verifies that the operator has completed the assigned pick/put operation at the required location. The methods and systems may be adapted to track or monitor relative positions of mobile and stationary equipment in an automated warehouse.
G06Q 50/28 - Logistics, e.g. warehousing, loading, distribution or shipping
B66F 9/06 - Devices for lifting or lowering bulky or heavy goods for loading or unloading purposes movable, with their loads, on wheels or the like, e.g. fork-lift trucks
G06K 7/14 - Methods or arrangements for sensing record carriers by corpuscular radiation using light without selection of wavelength, e.g. sensing reflected white light
26.
SYSTEM AND METHOD FOR ORDER FULFILLMENT SEQUENCING AND FACILITY MANAGEMENT
A system and method is provided for controlling an automated warehouse or order fulfillment facility. The system includes a sequencing tower, which functions as a buffer for inbound items and shipping containers, and various pick/decant workstations which are connected between the sequencing tower and an automated storage and retrieval system (ASRS). The sequencing tower is adapted for receiving, storing, and releasing newly erected shipping containers and inbound vendor cases. The pick/decant workstations function as a hub between the sequencing tower and the ASRS, where operators at the pick/decant workstations pick order items to shipping containers to fulfil orders or pick inbound/vendor items to inventory containers to be stored in the ASRS. The system and methods synchronize the sequencing tower and ASRS to release items to arrive at the workstations simultaneously to optimize efficiency and throughput of the facility.
A de-traying method and apparatus for removing articles from trays, is useful with a plurality of trays. The article is detrayed at the detraying assembly by elevating the moveable bottom of the tray at least to the level of the tray rim with an article lifter from below the tray. The article lifter includes a lifting base and a plurality of lifting blocks fixed to the lifting base. The lifting blocks are sized and arranged to engage the tray bottom through the opening in response to the lifting base being elevated. The lifting blocks are sized and arranged to maintain orientation of the tray with at least one of said blocks positioned outside of the tray adjacent the rim. The article is displaced off of the elevated tray bottom.
An automated storage and retrieval system and method of storing articles to and retrieving articles from at least one stacked storage rack that is configured to store articles double deep in each storage location with one article at a front position and another article at a back position behind the one article includes a robot having an end of arm tool (EOAT). The EOAT has a platform and an extendable article manipulator. The platform is sized to support at least two articles. The robotic arm selectively positions the end of arm tool to retrieve articles from front and back storage positions of said at least one stacked storage rack and storing at least one of the articles from the platform to a front or back storage position after the robot rotates the EOAT about a generally vertical axis.
A method, a palletizing sleeve, and a hand truck are provided for preparing a plurality of shipments of goods and transporting each shipment to one of a plurality of delivery destinations. The method includes determining the goods for the shipment, virtually building an optimized stacking configuration of those goods, physically building the stack based on the optimized configuration, transporting the shipment to a pre-determined delivery destination, and unloading the shipment at the delivery destination. The palletizing sleeve includes a base and a vertical wall that cooperate to support and stabilize a stack of goods that make up a portion of the shipment. Standoffs on the sleeve base provide openings to accept forks from the hand truck so that the hand truck can engage the sleeve from underneath the base. A fork height adjustment system selectively adjusts the fork height relative to the bottom of the hand truck.
A confirmation system including a touchless sensor and method for confirming that an order fulfilment operation has been performed. The system includes at least one touchless sensor to sense or recognize a gesture given by an operator, wherein the gesture confirms that a desired operation has been performed. The touchless sensor is connected to a workflow control system configured to transmit order fulfilment information to and from the touchless sensor. The touchless sensor is configurable to recognize a plurality of gestures, and may be configured to recognize those gestures at a plurality of distances away from the touchless sensor. The touchless system is configurable to provide alerts to operators to indicate locations requiring action. The confirmation system may be provided with a cubby or bin order fulfilment system. Additional features include placement or retrieval sensors, cubby illumination lights, pick-to and put-to lights, and information scanners.
A multiple temperature automated storage system includes a rack with multiple levels of shelves defining item storage positons, an aisle at each level, and a plurality of shuttles to operate in the aisles for storing items to and retrieving items from the storage positons. A thermally insulated enclosure encloses some levels of the rack to define a low temperature zone with the remaining levels of the rack defining a higher temperature zone. A method of storing items at two different temperatures in a common automated storage system includes having a first portion of the automated storage system enclosed in a thermally insulated enclosure and a second portion of the automated storage system outside of the thermally insulated enclosure. A lift is provided in the second portion for supplying items to and retrieving items from both of the first and second portions, without entering the first portion.
B65G 1/137 - Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
F25D 13/02 - Stationary devices associated with refrigerating machinery, e.g. cold rooms with several cooling compartments, e.g. refrigerated locker systems
F25D 13/04 - Stationary devices associated with refrigerating machinery, e.g. cold rooms with several cooling compartments, e.g. refrigerated locker systems the compartments being at different temperatures
F25D 13/06 - Stationary devices associated with refrigerating machinery, e.g. cold rooms with conveyors carrying articles to be cooled through the cooling space
F25D 25/02 - Charging, supporting, or discharging the articles to be cooled by shelves
F25D 25/04 - Charging, supporting, or discharging the articles to be cooled by conveyors
32.
POSITIVE DISPLACEMENT SORTER WITH PARALLEL DIVERT AND DIAGONAL DISCHARGE
A positive displacement sorter and method of diverting articles includes a conveying surface to convey articles in a longitudinal direction and at least one diagonal takeaway lane extending diagonally from the conveying surface to receive articles being diverted from the conveying surface. The sorter includes plurality of pushers to move together in a lateral direction to displace an item on the conveying surface to the diagonal takeaway lane and a rotational system to rotate a leading portion of a diverted article in the direction of the takeaway lane. The rotational system may be a portion of the takeaway lane including a conveying surface having a first portion of rollers and a second portion of rollers. The first portion of rollers direct a diverted article toward the second portion of rollers and the second portion of rollers convey the diverted article in the direction of the takeaway lane.
B65G 47/71 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor and to transfer them in individual layers to more than one conveyor, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor the articles being discharged to several conveyors
B65G 47/244 - Devices influencing the relative position or the attitude of articles during transit by conveyors orientating the articles by turning them about an axis substantially perpendicular to the conveying plane
B65G 47/68 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor and to transfer them in individual layers to more than one conveyor, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor
33.
METHOD AND APPARATUS FOR CONTROLLING FLOW OF OBJECTS IN A MATERIAL HANDLING SYSTEM
A material handling system having object handling and transportation devices and method of receiving objects into a warehouse having a material handling system includes scanning a machine readable code of an incoming load forming at least a portion of an order and comparing the machine readable code with an order file listing objects on the incoming load. For each object on the load, object data including a 3D image and product code of the object removed from the incoming load is received with an image capture station and reconciled with the order file. Each object is identified by comparing the 3D image of the object captured with the image capture station with the 3D images in the database. The material handling system is controlled as a function of the identity of the objects being handled and transported by the material handling system.
G06K 7/00 - Methods or arrangements for sensing record carriers
G06K 7/14 - Methods or arrangements for sensing record carriers by corpuscular radiation using light without selection of wavelength, e.g. sensing reflected white light
A method of order fulfillment, and system for carrying out the method, includes presenting individual items for multiple orders to an automated put wall and segregating the individual items for each order at a location on the put wall that is assigned to that order. Individual items for an order are removed together from the automated put wall and transported together to a packing function. Preferably individual items are stored as inventory items in an automated storage and retrieval system and retrieved from the automated storage and retrieval system in response to an order for those inventory items. The retrieved inventory items are sorted into order batches and automatically inducted to the automated put wall.
A method of order fulfillment, and system for carrying out the method, includes storing individual items as inventory items in an automated storage and retrieval system and retrieving inventory items from the automated storage and retrieval system in response to an order for those inventory items. The retrieved inventory items are sorted into order batches and transported to an automatic induct for an automated put wall. The order batches are automatically inducted to the automated put wall as individual items. The individual items are segregated for each order at a location on the put wall that is assigned to that order. Individual items for an order are removed together from the automated put wall and transported together to a packing function.
A method of training a robot to pick a plurality of articles includes determining an identity of an article and determining if the article has a uniform distribution of weight. If the article has a uniform distribution of weight, a three-dimensional (3D) model of the article is created and stored in a database record associated with the identity. If the article does not have a uniform distribution of weight, a 3D model is created, two-dimensional (2D) images of each side of the article are created, and a 3D center of gravity of the article is determined. The 3D model, the 2D images, and the 3D center of gravity of the article are stored in a database record associated with the identity of the article.
G05B 19/18 - Numerical control (NC), i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
A continuous flow material handling system and method for consolidating articles into article groups. A plurality of article merges and at least one sorter are between the article sources and destinations. A control system receives data from a warehouse management system (WMS). The control system activates each group at a merge in a same sequence as the group is released to the material handling system. The control activates a new group at a merge when all of the articles of the group that is already activated at that merge have cleared that merge.
A system for replenishing a pick face includes a storage and retrieval machine (SRM) that traverses an aisle of a warehouse and monitors a replenishment position of each pick location of a pick face. The SRM transmits a message to the system indicating which ones of the replenishment positions are empty. The SRM delivers a replenishment load to a pick location that is indicated as empty in the message. Each pick location includes a flow lane configured to direct the motion of package loads sliding down to a picking position of the pick face. The flow lane includes a lever arm assembly that constrains and brakes the motion of package loads sliding down the flow lane. A bar stop of the lever arm assembly constrains a replenishment load, while a retainer bar of the lever arm assembly constrains a forward load. The replenishment load is behind the forward load.
A load handling system and method of handling a load includes a load handling device with a load support that is configured for engaging a load and a first drive is adapted to drive said load support with respect to a load. A conveyor is moveable along the load support and a second drive is adapted to propel the conveyor with respect to the load support. The first and second drives are operated to handle a load. The load support may be a pair of forks or a platen or the like.
B65G 1/00 - Storing articles, individually or in orderly arrangement, in warehouses or magazines
B65G 21/14 - Supporting or protective framework or housings for endless load-carriers or traction elements of belt or chain conveyors movable, or having interchangeable or relatively- movable parts; Devices for moving framework or parts thereof to allow adjustment of length or configuration of load-carrier or traction element
B65G 17/34 - Individual load-carriers having flat surfaces, e.g. platforms, grids, forks
B65G 60/00 - Simultaneously or alternatively stacking and de-stacking of articles
An article sortation system and method of sorting articles includes an article sorter having an article support surface moving in a longitudinal direction and a plurality of discharge conveyors extending from the article support surface. The sorter is adapted to discharge articles from the article support surface to said discharge conveyors. One or more of the discharge conveyors includes an active aligner having a driven surface that is adapted to reorient at least some of the diverted articles.
B65G 47/244 - Devices influencing the relative position or the attitude of articles during transit by conveyors orientating the articles by turning them about an axis substantially perpendicular to the conveying plane
A method of sorting articles with a sorter apparatus and a sorter apparatus having a distributed drive system including at least one drive that is adapted to produce and provide force with at least one body to propel an endless web. A diagnostic device traveling with the web and positioned at one of the bodies of the endless web. The diagnostic device is adapted to monitor operation of the sorter apparatus and includes at least one sensor that is adapted to detect at least one parameter of a proximate drive that is proximate to the at least one sensor. A controller adapted to receive the at least one parameter from the at least one sensor. A stationary thermal sensor may also monitor the endless loop via another controller that receives thermal data from the stationary thermal sensor and correlates the thermal images with a portion of the endless loop.
A mobile lighted pick or put cart includes a frame and transport members on the frame that facilitate movement of the frame. The frame defines a plurality of vertically spaced shelves. An electronic system supported with the frame includes a portable computing device and a plurality of lamp strips, one mounted to each of the shelves. An application program that is operated by the portable computing device is adapted to determine a quantity of items to be picked from or put to a physical location and illuminate a number of individual lamps on one of the strips at a particular location on one of said shelves. The number of individual lamps illuminated is equal to the quantity of items to be picked from or put to the physical location.
A belt conveyor (520, 620, 720) having a pair of side frames (540, 542, 640, 642, 740, 742) between which a belt (530, 630, 730) is moved for conveying items includes a pair of idler rollers (534, 536, 634, 636, 734, 736) about which the belt (530, 630, 730) is disposed for conveying items there between, a tension roller (532, 632, 732) that is biased into engagement with the belt (530, 630, 730), and a driven roller (524, 624, 724) operative to drive the belt about the idler and tension rollers. The tension and driven rollers are mounted between the side frames and are disposed lower than the idler rollers, with the tension roller (532, 632, 732) mounted by a tensioner mount (526, 528, 626, 628, 726, 728) configured to impart a biasing force to the tension roller (532, 632, 732) against the belt (530, 630, 730).
A method and system for picking articles from a collection of articles and arranging articles into placement locations, includes capturing an image with a first vision system from a collection of articles at a first pick location and determining coordinate data for at least some of the articles in the collection of articles. The coordinate data for an article in the collection of articles is provided to a first robotic manipulator. That article is picked from the collection of articles with the first robotic manipulator according to the coordinate data for that article and that article placed at a first place location. The position and orientation data of that article are obtained at a second pick location and provided along with a desired position and orientation of that article at a second place location to a second robotic manipulator. That article is picked with the second robotic manipulator using the position and orientation data of that article at the second pick location and that article is placed at the second place location at the desired position and orientation.
B65G 1/137 - Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
B65B 5/08 - Packaging groups of articles, the articles being individually gripped or guided for transfer to the containers or receptacles
B65G 47/30 - Devices influencing the relative position or the attitude of articles during transit by conveyors arranging the articles, e.g. varying spacing between individual articles during transit by a series of conveyors
G05B 15/02 - Systems controlled by a computer electric
G06F 7/00 - Methods or arrangements for processing data by operating upon the order or content of the data handled
G06Q 10/08 - Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
A job fulfillment system and method includes a storage module having article storage and access to the article storage for retrieval of articles and a unit sortation module that is adapted to receive articles retrieved from the storage module and sorting those articles into jobs. A control system includes a storage module controller that is adapted to control operation of the storage module and a unit sortation module controller that is adapted to control operation of the unit sortation module. Both the storage module controller and the unit sortation module controller have a pending job queue and a priority policy that opens jobs in the respective pending job queue according to a policy. The unit sortation controller has a work-in-progress (WIP) controller that limits orders active in the unit sortation module to not exceed a configured capability of that module. Incoming jobs to the system are received with the unit sortation module pending job queue and jobs are activated with the sortation module controller from the sortation module pending job queue according to the policy of the sortation module control. Jobs that are active in the sortation module WIP controller are received with the storage module pending job queue and are activated with the storage module controller from the storage module pending job queue according to the policy of the storage module controller.
An automated guided vehicle (AGV) that is configured to operate with a navigation and guidance system includes a base frame structure that supports a material handling apparatus. Casters may be attached at peripheral portions of the base frame structure to movably support the base frame structure away from a ground surface. Drive wheel assemblies may be disposed between two of the casters and configured to propel and steer the AGV. A suspension system may have intersecting swing arms that are pivotally mounted at the base frame structure and independently attach at each of the drive wheel assemblies. The suspension system biases the drive wheel assemblies against the ground surface to maintain friction of the drive wheel assemblies against the ground surface, such as for traversing sloped or uneven surfaces.
G01C 22/00 - Measuring distance traversed on the ground by vehicles, persons, animals or other moving solid bodies, e.g. using odometers or using pedometers
G05D 1/00 - Control of position, course, altitude, or attitude of land, water, air, or space vehicles, e.g. automatic pilot
G01S 15/88 - Sonar systems specially adapted for specific applications
B60W 30/09 - Taking automatic action to avoid collision, e.g. braking and steering
B62D 6/04 - Arrangements for automatically controlling steering depending on driving conditions sensed and responded to, e.g. control circuits responsive only to forces disturbing the intended course of the vehicle, e.g. forces acting transversely to the direction of vehicle travel
B60G 7/02 - Attaching arms to sprung part of vehicle
47.
COMMUNICATION SYSTEM FOR OPERATION AND MANAGEMENT OF WORKFLOWS AND INTEGRATION OF MULTIPLE DEVICES UTILIZING DIFFERENT OPERATING PLATFORMS
A communication and control system for enabling and controlling communications for execution of one or more tasks, functions, and/or operations within a facility can include devices that utilize disparate operating systems and/or software programs, and engines resident on or accessed by the devices. The engines be can operable to access one or more device-neutral workflows that have a set of instructions for directing performance of a selected one or more of the tasks, functions, and/or operations to be performed at the facility. The engines further can translate and communicate the set of instructions to initiate and cause the devices to carry out the set of instructions thereon and enable the devices to perform or execute the selected tasks, functions, and/or operations at the facility.
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
A bulk bin forming system configured as a container forming cell includes a multi-axis robot (22) to which is attached a multifunction tool (24). One or more collapsed card board boxes (28) are located at a first station (21a) of the container forming cell adjacent the robot (22). The robot (22) and multifunction tool (24) are configured to operate to grasp and move an individual box (28), orient and pre-form the box (28) by folding flaps (40) at a second station (21b) of the cell, and then move the box (28) to a third station (21c) of the cell to mount the box (28) to a support configured as a pallet (30) to thereby form a bulk bin or bulk box container referred to as a gaylord container. The tool (24) may include vacuum grippers (34) for grasping the boxes (28) and staplers (39) for securing the formed box (28) to the pallet (30), and may also be used to fold the bottom flaps (40) prior to mounting the box (28) to the pallet (30).
B65B 43/18 - Feeding individual bags or carton blanks from piles or magazines by grippers by suction-operated grippers
B65B 43/26 - Opening or distending bags; Opening, erecting, or setting-up boxes, cartons, or carton blanks
B65B 43/30 - Opening or distending bags; Opening, erecting, or setting-up boxes, cartons, or carton blanks by grippers engaging opposed walls, e.g. suction-operated
B31B 50/78 - Opening and distending flattened articles mechanically
A plurality of diverters each selectively divert at least one article moving member having a diverting member from a non-diverting path extending longitudinally along said sorter to a diverting rails in a diverting state. At least one of the diverters has a gate having a diverting surface. The gate is selectively rotatable between the diverting state and a non-diverting state about a generally horizontal axis. An actuator moves the gate between the non-diverting state and the diverting state. The actuator is an electrically operated rotary actuator that is rotatable about another generally horizontal axis of rotation.
B65G 47/46 - Devices for discharging articles or materials from conveyors with distribution, e.g. automatically, to desired points
B07C 5/36 - Sorting apparatus characterised by the means used for distribution
B65G 23/23 - Arrangements or mountings of driving motors of electric linear motors
B65G 47/68 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor and to transfer them in individual layers to more than one conveyor, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor
B65G 47/84 - Star-shaped wheels or devices having endless travelling belts or chains, the wheels or devices being equipped with article-engaging elements
50.
ORDER FULFILLMENT METHOD AND SYSTEM WITH SORTATION AT INDUCT BACKGROUND OF THE INVENTION
An order fulfillment system and method includes storing a plurality of inventory items in a warehouse and a plurality of customer orders in a data base, wherein the inventory items make up the customer orders. Some of the orders being a single item order having only one inventory item assigned to that order and other of the orders being multiple item orders having multiple inventory items assigned to that order. Inventory items withdrawn from the warehouse are identified with an identifier and the identity of each withdrawn inventory item applied to the data base and matched item with a customer order. Inventory items are combined together that make up an order with a sortation system. The sortation system has an induct subsystem and the induction subsystem has an input. Inventory items are transported from the warehouse to the induction subsystem input with a transportation system. Inventory items assigned to multiple- item orders are forwarded to the sortation system with the induct subsystem responsive to the data base. Inventory items assigned to single item orders are forwarded to a packing station bypassing the sortation system responsive to the data base.
G06Q 10/08 - Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
B07C 5/00 - Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
B65G 47/46 - Devices for discharging articles or materials from conveyors with distribution, e.g. automatically, to desired points
A motor driven roller support assembly (20) includes a motorized roller (22) having a cylindrical outer surface (40) that is configured to rotate, a support frame (24) within which the roller (22) is mounted, and a roller support (26) connected to the support frame (24) and engaging the outer surface (40) of the motorized roller (22). The roller support (26) may include a pair of support wheels (80) for contacting the outer surface (40) of the motorized roller (22), and include a pivot whereby the roller support (26) is moveable relative to the support frame (24). The assembly (20) may be integrated with a transfer conveyor, such as a right angle transfer (28) having transfer blades (36) that include belts (38) driven by the motorized roller (22). The roller support (26) engages the motorized roller (22) in a direction that is generally opposite from the direction in which the belts (38) engage the motorized roller (22) to thereby counteract forces imparted by the belts (38) on the motorized roller (22).
B65G 21/10 - Supporting or protective framework or housings for endless load-carriers or traction elements of belt or chain conveyors movable, or having interchangeable or relatively- movable parts; Devices for moving framework or parts thereof
B65G 21/14 - Supporting or protective framework or housings for endless load-carriers or traction elements of belt or chain conveyors movable, or having interchangeable or relatively- movable parts; Devices for moving framework or parts thereof to allow adjustment of length or configuration of load-carrier or traction element
B65G 21/20 - Means incorporated in, or attached to, framework or housings for guiding load-carriers, traction elements or loads supported on moving surfaces
B65G 39/12 - Arrangements of rollers mounted on framework
B65G 41/00 - Supporting frames or bases for conveyors as a whole, e.g. transportable conveyor frames
B65G 47/53 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices between conveyors which cross one another
B65G 47/74 - Feeding, transfer, or discharging devices of particular kinds or types
52.
PICK OR PUT STATION WITH CONTROLLABLE RECEPTACLE EXCHANGE
A receptacle exchange for a pick or put receptacle and method for exchanging a pick or put receptacle includes a process location at which an operator processes a receptacle by picking articles from or putting articles to a receptacle. A lift moves a receptacle from a supply location to the process location. An extractor retrieves a receptacle from the process location to an extracted location. A first drive elevates the lift between the supply location and process location and moves the extractor between the process location and extracted location. A second drive moves an inclination of the extractor. A control controls the first and second drives.
A method for managing container information in a warehouse system. The method includes identifying a container identification (ID) of a container with a scanner communicatively coupled to a portable computing device. The container ID is sent from the portable computing device to a warehouse server via a network. The container information is received at the portable computing device from the warehouse server in response to the container ID. The container information is communicated to a heads up display communicatively coupled to the portable computing device. Delivering the container to a target destination in the warehouse, based in part on the container information for the container. A delivery confirmation is initiated at the heads up display for the warehouse server when the container is delivered to the target destination. The delivery confirmation occurs at the time of delivery to the target destination.
An automated order fulfillment system and automated method for fulfilling orders includes a donor-handling system having at least two donor buffers and a recipient-handling system having at least one recipient buffer. An item-handling system includes a vision system and an item manipulator. The vision system has a field of view encompassing the at least two donor receptacle buffers. A control causes the vision system to scan items in a donor receptacle at one of the donor buffers to obtain a pick list of location data of items in the scanned donor receptacle. The control causes the manipulator to pick an item from a donor receptacle at the other of the donor buffers under guidance of the vision system and place the picked item to a recipient receptacle at the at least one recipient buffer using the location data of items in that donor receptacle.
A method and apparatus for supplying a unit of work in a material-handling process includes a set-point of work units desired at a material-processing station and an actual measure of work units at the material-processing station. A feedback control algorithm is performed to establish the set point of work units at the material-processing station and an error between the work units at the material-processing station and the set-point of work units at the material-processing station. The feedback control algorithm also determines a desired amount of units that should be supplied to the material-processing station as a function of the error. The feedback control algorithm causes a work unit to be released from the inventory store for a particular processing station when the actual amount of work units supplied to that processing station is less than the amount of work units that should be supplied to that processing station.
B65G 1/137 - Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
G06Q 10/06 - Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
A right angle transfer and method of transferring articles includes a plurality of conveying members that define a conveyance surface and are driven to convey objects in a conveyance direction and a plurality of diverting members. The diverting members are driven to divert objects at an angle from the conveyance surface. A frame mounts the diverting members for general vertical movement with respect to the conveying members. A lifting system including a plurality of spaced apart vertical actuators selectively raises and lowers the frame with respect to the conveying members. Each of the vertical actuators may include a cylinder that is positively driven in each of opposite directions by application of a fluid to opposite sides of the cylinder in order to positively drive the frame to both a raised state and a lowered state. The diverting members may be driven prior to being vertically moved into contact with an article being diverted.
A method and apparatus for fulfilling orders with a system having an automated warehouse that is adapted to store a plurality of inventory receptacles. The automated warehouse includes a plurality of vehicles that are adapted to storing inventory receptacles and retrieving inventory receptacles and an outbound device that is adapted to exchanging inventory receptacles between a pick station and the vehicles. Orders of items are received with an order queue. Orders are disbursed from the order queue to a vehicle queue associated with each vehicle. Inventory receptacles are retrieved with the vehicles having items for at least one of the orders. The inventory receptacles are retrieved according to the vehicle queue for that vehicle. Inventory receptacles are deposited by the vehicles to an outbound queue associated with the outbound device and forwarded from the outbound device to the pick station according to the requirements of the pick station. Items are retrieved from the product receptacles at the pick station and put into transportation receptacles.
A method of fulfilling orders and order fulfillment system includes a mobile assembly cart having a plurality of order assembly positions and a pointer assembly. The pointer assembly generates a beam and directs the beam to at least one of said assembly positions for selectively identifying at least one of the assembly positions for putting an item to or retrieving an order from each identified position. The assembly cart can be positioned with respect to the pointer assembly for the picking or putting and moved away from the pointer assembly after the picking or putting.
A mixed article sortation system and method of sorting the bulk flow of mixed articles being of various sizes and shapes to separate destinations includes at least two bulk flow singulators, each configured to receive a bulk flow of mixed articles and arrange the articles to respective first and second single-file flows. A first article induct arranges the first flow of articles from one of the singulators to a first flow of gapped articles and a first article sensor senses the identity and weight of each article. A second article induct arranges the single-file flow of articles from the other singulator to a second flow of gapped articles and a second article sensor senses the identity and weight of each article in said second single-file flow. A combiner combines the first and second single-file flow of articles into a third single-file flow of articles. A sorter receives the third single-file flow of mixed articles and sorts the articles to separate destinations.
B65G 47/68 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor and to transfer them in individual layers to more than one conveyor, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor
An automated warehouse system and method of storing articles to and retrieving articles from an automated warehouse system includes at least two stacked longitudinally extending racks that are laterally separated by an aisle, each of said racks having a plurality of levels, with storage locations on each of the levels. An automated carriage at each of said levels travels longitudinally along the associated aisle and is adapted to store articles to and retrieve articles from each of the racks at that level. A lift arrangement for delivering articles to and retrieving articles from the levels of the stacked racks includes more than one lift assembly for at least one of the racks.
A method of filling orders and order fulfillment system includes storing inventory receptacles in an automated warehouse, some having a plurality of different types of inventory items. A queue of orders is maintained in a computer system, each including at least one inventory item. Each order is selected from the queue and assigned to a pick station. The computer system retrieves inventory receptacle(s) from the automated warehouse for the selected order and supplies the receptacle(s) to the pick station. The computer system identifies to an operator which inventory item is to be segregated with the selected order in at least one put receptacle. One or more of the put receptacles receives inventory items for at least one individual order and is directed to a secondary order processing station where items are separated into individual orders. The operator may be provided the capability to consolidate inventory items from inventory receptacles while picking orders to consolidate partially filled inventory receptacles in a consolidated inventory receptacle.
An article sorter and method of sorting articles includes a conveyor having a conveying surface travelling in a longitudinal direction and a plurality of lanes extending laterally from the conveyor. A plurality of tilting devices are each adapted to tilt the conveying surface in the direction of one of the lanes in order to discharge an article to that lane. An electro-adhesion system is adapted to be applied to the conveying surface adjacent to at least one of the lanes in order to retain an article at the conveying surface while the conveying surface is being tilted by one of the tilting devices to discharge another article.
A sorter drive for propelling travelling members of a sorter along a path, in which the sorter has a plurality of interconnected travelling members that travel along a path and sortation members carried by the travelling members, with the sortation members adapted to discharge articles to particular destinations, according to an aspect of the invention, includes an endless drive member and an electro-adhesion system. The endless drive member engages the travelling members. The electro-adhesion system increases attraction of the endless drive member and the travelling members.
A method of sorting articles using a positive displacement sorter (111) having a plurality of slats (112) arranged in parallel to define a conveying surface (113) moving in a longitudinal direction, a plurality of pusher shoes (114), each of the shoes (114) travelling laterally along at least one of the slats (112) and a diverting station (115) comprising at least one diverting rail (116) arranged diagonally under the conveying surface (115) and at least one diverting switch (118) for selectively diverting at least two pusher shoes (114) to the diverting rail (116) whereby the pusher shoes (114) travel laterally across the conveying surface (113) in a diagonal path in order to divert an article (1, 2, 3, 4) to a take-away lane (120) includes pre-orienting articles prior to the diverting station (115) wherein a side of each article is oriented at approximately a same orientation as the diagonal path and operating the at least one diverting switch and diverting at least one article that is pre-oriented.
B65G 47/84 - Star-shaped wheels or devices having endless travelling belts or chains, the wheels or devices being equipped with article-engaging elements
A method and system for fulfilling orders includes establishing a queue of orders that are available to be filled, each order in the queue containing at least one unique item type. An order from the order queue is selected and opened as a first order. Another order from the order queue is selected and opened as a second order. Inventory containers each having a unique item type for at least one of the orders are delivered and an operator picks the unique item type from the inventory container. The orders are assembled at order assembly locations that are a particular distance from the operator. The orders are selected and/or the assembly locations assigned in a manner that improves order fulfillment productivity, such as by reducing order fulfillment time, reducing operator travel distance, and the like.
An order-picking method includes autonomously routing a plurality of mobile robotic units in an order fulfillment facility and picking articles to or putting articles from the robotic units in the order fulfillment facility. A material-handling robotic unit that is adapted for use in an order fulfillment facility includes an autonomous mobile vehicle base and a plurality of article receptacles positioned on the base. A visual indicator associated with the receptacle facilitates picking articles to or putting articles from the robotic unit.
A material-handling system and method includes at least one first processing station, each having an input and an output. A linear transfer system made up of a plurality of transfer units that travel in unison in a linear motion past the input and output of the first processing station(s) either receives articles from the output and discharges articles to the input or transfers articles between the first processing station and a second processing station. A control sequences articles between the transfer units and the first input and output or between the first processing station and a second processing station in a manner that enhances operation of the processing station(s).
A conveyor assembly (20) comprising a main conveyor (22) having a first side frame (26a) and a second side frame (26b), with the first and/or second side frames including a side portion (70) and a support surface (28). One or more input conveyors (24) having a discharge end (30) are joined to the main conveyor (22) with a bottom portion (98) of the discharge end (30) being positioned on the support surface (28) whereby the input conveyors (24) are accurately mounted in close proximity to the main conveyor (22) to promote the conveyance of items from the input conveyors (24) onto the main conveyor (22).
A picking method includes having in a mobile device data and an application running on the mobile device. An order made up of a number of items to be picked from the warehouse is communicated from a host to a client application of the mobile device. The mobile device provides instructions of a sequence of locations to pick and the items to be picked at each location without further communications from the host. A corresponding picking system is provided.
A conveyor underguard that is adapted for use with a conveyor having a pair of spaced apart side channels, each having a lower flange and a plurality of openings on each flange, includes a guard surface and a pair of mounting members, each extending outwardly generally parallel to the guard surface and defining fastener openings. The fastener openings are spaced apart in a manner that aligns with the through-openings of the conveyor.
A conveyor singulator includes a conveying surface defined by a plurality of lanes, each made up of freely rotatable rollers that are skewed with respect to a longitudinal direction. A drive system for each of the lanes is adapted to driving the rollers in that lane. The drive system includes an endless belt, a motor assembly that is adapted to propel the belt and a plurality of guide assemblies that are each adapted to bias the belt against the rollers. Each guide assembly includes a stationary block of low-friction polymers and a support that is adapted to press the block against an upper run of the belt to press the belt against the rollers in that lane.
B65G 47/31 - Devices influencing the relative position or the attitude of articles during transit by conveyors arranging the articles, e.g. varying spacing between individual articles during transit by a series of conveyors by varying the relative speeds of the conveyors forming the series
72.
CROSSBELT SORTER SYSTEM AND METHOD OF SORTING ARTICLES
A crossbelt sorter system and method of sorting articles includes a track assembly and a plurality of carriers attached to each other to travel along the track assembly. Each of the carriers includes at least front and rear corner portions thereof and a trolley at each of the front and rear corner portions. Each trolley is configured to travel along the track assembly. A hitch assembly joins adjacent ones of the carriers. A propulsion system propels the carriers along the track assembly. Each trolley is mounted to the associated carrier to pivot in at least two different directions. In this manner, the track assembly may have one or more spiral portions thereof. Each trolley is adapted to pivot in the two different directions to support the associated carrier as it moves through the spiral portion.
B65G 17/00 - Conveyors having an endless traction element, e.g. a chain, transmitting movement to a continuous or substantially-continuous load-carrying surface or to a series of individual load-carriers; Endless-chain conveyors in which the chains form the load-carrying surface
A positive displacement sorter includes a plurality of parallel laterally extending slats and a pair of wheel assemblies, each interconnecting common end portions of the slats thereby defining an endless web that travels in a longitudinal direction. An upper surface of the web defines an article-conveying surface. A plurality of pusher shoes travel along the slats in order to laterally displace articles on the conveying surface. A plurality of attachment mechanisms are provided. Each of the attachment mechanisms attaches an end portion of one of the slats to one of the wheel assemblies. Each of the attachment mechanisms includes a shoulder and a collar and at least one locking member. The collar engages the shoulder thereby providing retention of the slat to the wheel assembly. The locking member provides retention of the collar on the shoulder.
B65G 15/52 - Endless load-carriers consisting of a series of parallel ropes or belt strips interconnected by transverse slats
B65G 17/06 - Conveyors having an endless traction element, e.g. a chain, transmitting movement to a continuous or substantially-continuous load-carrying surface or to a series of individual load-carriers; Endless-chain conveyors in which the chains form the load-carrying surface having a load-carrying surface formed by a series of interconnected, e.g. longitudinal, links, plates, or platforms
74.
VERTICAL ACTION SORTER AND METHOD OF SORTING ARTICLES
A vertical action sorter is provided along a transport conveyor for selectively diverting articles from the conveyor to a different location, such as a bin or another conveyor. Each sorter includes a sorter module that is selectively raised and lowered in response to an actuator, such as a linear actuator, that drives actuator members along respective tracks associated with the sorter module. Each track includes a contoured surface that controls the rate at which the sorter module will be raised and lowered in response to the linear actuator. A cross member may be provided for evenly supporting the sorter module as it is raised and lowered.
A positive displacement sorter includes a plurality of interconnected parallel slats defining an endless web that travels in a longitudinal direction. The web has upper and lower runs and transition sections between the runs. An upper surface of the upper run of the web defining an article-conveying surface. A plurality of pusher shoes travels along the slats in order to divert articles on the conveying surface. Each shoe has a diverting member extending below the conveying surface. A plurality of diverting rails below the conveying surface may engage the diverting member to cause the associated shoe to travel to divert an article. A plurality of diverters diverts a diverting member from a non-diverting path extending longitudinally along the sorter to one of the diverting rails in a diverting state. A propulsion system propels the web and includes at least one drive assembly engaging a surface of a run.
B65G 17/06 - Conveyors having an endless traction element, e.g. a chain, transmitting movement to a continuous or substantially-continuous load-carrying surface or to a series of individual load-carriers; Endless-chain conveyors in which the chains form the load-carrying surface having a load-carrying surface formed by a series of interconnected, e.g. longitudinal, links, plates, or platforms
A conveyor having at least one curved portion includes a pair of spaced apart side channels that are curved at the curved portion of the conveyor. A plurality of rollers are supported between the side channels. An endless drive member, which is propelled by a motor, drives the rollers. A guide system made up of a plurality of guide members guides the drive member. Each of the guide members includes a guide surface that provides substantial non-slip engagement with the drive member.
B65G 15/00 - Conveyors having endless load-conveying surfaces, i.e. belts and like continuous members, to which tractive effort is transmitted by means other than endless driving elements of similar configuration
B65G 37/00 - Combinations of mechanical conveyors of the same kind, or of different kinds, of interest apart from their application in particular machines or use in particular manufacturing processes
77.
GOODS-TO-PERSON PICKING STATION AND PICKING METHOD
A goods-to-person picking station and method of picking goods from a product container and placing the goods in at least one order container includes a product container-handling mechanism and at least one order container-handling mechanism juxtaposed with the product container-handling mechanism. The product container handling mechanism supplies a product container to a pick area. The at least one order container-handling mechanism supplies at least one order container to the pick area. In this manner, an operator can pick goods from a product container at the pick area and place the goods selectively to the at least one order container at the pick area. The product container-handling mechanism includes a product container elevator assembly and a product container extractor assembly. The elevator assembly elevates a product container from the feed area to the pick area. The extractor assembly transfers a product container from the pick area.
A conveyor system and method of laterally displacing articles includes a conveyor defining a conveying surface and conveying articles in a longitudinal direction with the conveying surface. A diverting assembly is positioned diagonally at least partially across the conveying surface. The diverting assembly travels generally vertically between a non-actuated position below the conveying surface and an actuated position extending above the conveying surface. The diverting assembly has a diverting surface that is adapted to laterally displace articles on the conveying surface when in the actuated position.
A conveyor system includes a transport member having a conveying surface that is configured to transport articles in a transport direction, an endless strip and a drive for propelling the endless strip. A power tap off is provided between the strip and the transport member. The power tap off has an input that is driven by the strip and an output that drives the transport member. The power tap off provides a positive transfer of power from the strip to the transport member.
An induction subsystem for a conveying system includes a plurality of induction conveying units that are controlled by a plurality of controls in a manner that delivers articles to a release conveyor with gaps between the articles that approach a desired length. The conveying units may be controlled using algorithms that examine a planned release time for an article and a time at which the article would be released were it to complete the rest of its travel through the induction subsystem at one or more nominal speeds. The difference is used to determine an appropriate speed for at least one of the conveying units. The conveying unit may alternatively be controlled using algorithms that determine desired speed ratios for the conveying units, and which may seek to control the centerline to centerline spacing of articles as they reach the release point such that desired gaps are created.
B65G 47/26 - Devices influencing the relative position or the attitude of articles during transit by conveyors arranging the articles, e.g. varying spacing between individual articles
A positive displacement sorter and method of diverting articles includes providing a plurality of interconnected parallel slats defining an endless web that travels in a longitudinal direction, an upper surface of which defines an article-conveying surface and a plurality of pusher shoes. Each of the shoes travels along at least one of the slats in order to laterally divert articles on the conveying surface. Each of the shoes has a diverting member extending below the conveying surface. A plurality of diverting rails below the conveying surface are each capable of engaging the diverting member to cause the associated shoe to travel laterally to divert an article. A plurality of diverters are provided for selectively diverting at least one of the diverting members from a non-diverting path extending longitudinally along the sorter to one of said diverting rails in a diverting state. At least one of the diverters has a gate.
A conveying system may include a frame that supports a plurality of rollers which carry articles thereon. At least one of the rollers may be a motorized roller with first and second motors adapted to rotate an outer cylindrical shell of the motorized roller. A controller external to the motorized roller may send speed control commands to the motorized roller to control both the first and second motors in a manner that increases torque of the motorized roller. The motors may be controlled in four quadrant mode, or two quadrant mode, or a combination thereof. The motorized roller may be used in a right angle transfer mechanism, or in other components of a conveying system.
A stacking apparatus and method of multi-layer stacking of objects of different sizes on a support to form a stacked support includes providing a support handler. A support is elevated with the support handler and objects of different sizes and shapes are stacked on the support to form a stacked support. A stacked support is removed and an empty support supplied with the support handler. A placeholder is provided above the support handler. The placeholder has a first mode for receiving objects on the placeholder. The placeholder has a second mode for providing access to a support on the support handler. The placeholder is put in the first mode while the support handler removes a stacked support and supplies an empty support. The placeholder is put in the second mode when the support handler is elevating a support being stacked with articles. Objects that have been received on the placeholder during the first mode are deposited from the placeholder to the support when changing the placeholder from the first mode to the second mode.
An article sorter is made up of a web defined by a plurality of interconnected, laterally elongated, slats. An upper portion of the web defines a longitudinally extending conveying surface. Each of the slats has a generally planar upper surface forming a portion of the conveying surface. A plurality of pusher shoes travel laterally of the conveying surface to laterally displace articles on the conveying surface. A drive assembly is provided. The drive includes at least one sprocket and a motor. The motor is adapted to rotate the sprocket(s). The sprocket(s) engage the slats to propel the web.
A belt conveyor (10) includes opposite sidewalls (14a, 14b) and at least two rollers (16) positioned between the sidewalls with a continuous belt (18) reeved around the rollers. A tracking device (24) is mounted at one of the sidewalls and adjustably supports an end of an adjustable roller of the conveyor. The tracking device adjusts an angle of the adjustable roller relative to the sidewalls to track the belt with the rollers. The tracking device may include a biasing element (38) to urge the end of the adjustable roller to maintain tracking of the belt around the rollers.
A slug-building conveyor system and method includes providing a conveying surface defined by a plurality of tandem zones, each of said zones including an article sensor and a position encoder. The encoder produces a position signal proportional to movement of articles in that zone. The article sensor senses articles in that zone. A target position is set for an article in a zone as a function of a position of an article downstream of that article in the direction of article flow. The speed of that zone is adjusted to bring the article toward its target position such that gaps between articles are adjusted during transportation of the articles.
B65G 47/26 - Devices influencing the relative position or the attitude of articles during transit by conveyors arranging the articles, e.g. varying spacing between individual articles
B65G 43/10 - Sequence control of conveyors operating in combination
B65G 47/31 - Devices influencing the relative position or the attitude of articles during transit by conveyors arranging the articles, e.g. varying spacing between individual articles during transit by a series of conveyors by varying the relative speeds of the conveyors forming the series
A skew detection and correction system, and method of correcting skew, in a conveyor system (25) having an endless web (26) that is propelled in a longitudinal direction, includes providing a skew detector (134) and determining if at least some of the cross members (28) of the web (25) are non-perpendicular to the longitudinal direction and providing a differential lubricant application. The lubricant applicator (50) is responsive to the skew detector (134) and applies a relatively greater amount of lubricant to one lateral side of the web than to the other side of the web. This causes the side of the web receiving less lubricant to stretch more than the other side to reduce the difference in the amount of stretch.
A sortation system and method of sorting product includes providing a sorter assembly and a supply system supplying product that is received by the sorter assembly. Product supplied to the sorter assembly is monitored and a parameter is determined that is indicative of the relationship between product supplied to the sorter assembly and product being sorted by the sorter assembly. The supply system is controlled as a function of a value of the parameter.
B65G 43/08 - Control devices operated by article or material being fed, conveyed, or discharged
B65G 43/10 - Sequence control of conveyors operating in combination
B65G 47/06 - Devices for feeding articles or materials to conveyors for feeding articles from a single group of articles arranged in orderly pattern, e.g. workpieces in magazines
A method and apparatus (200) for sorting or pre-sorting objects contains a system of conveyors and crossover diverters incorporating the topology of an omega network. The sorter interconnects a series of perfect shuffle networks (210), interleaved with banks (220) of crossover switches. Collision avoidance is implemented by controlling flow on accumulator conveyors entering the crossover switches. Extra banks of crossover switches may be added to provide redundancy and load-balancing capabilities to the system.
B65G 47/71 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor and to transfer them in individual layers to more than one conveyor, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor the articles being discharged to several conveyors
B65G 47/68 - Devices for transferring articles or materials between conveyors, i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor and to transfer them in individual layers to more than one conveyor, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor
A positive displacement sorter includes a conveying surface (11), a plurality of pusher shoes (26) capable of traveling laterally of the conveying surface travel direction, a diverting assembly selectively diverting the pusher shoes and a control. The pusher shoes are generally separated from each other and the travel of direction by a shoe pitch (P). The diverting assembly includes a plurality of diverting rails (17) extending generally diagonally under the conveying surface and a plurality of actuators associated with the diverting rails. The control (22) is capable of controlling at least two of the actuators in a manner that selectively diverts at least two of the pusher shoes that are spaced apart in integer increments of the shoe pitch notwithstanding that the actuators are separated from each other by more than the shoe pitch.
B07C 5/36 - Sorting apparatus characterised by the means used for distribution
B65G 47/84 - Star-shaped wheels or devices having endless travelling belts or chains, the wheels or devices being equipped with article-engaging elements
A roller shaft mount or support (20) secures a shaft (16b) of a conveyor roller (12) at and between opposite sidewalls (14) of a conveyor (10). The shaft support includes a mounting portion (22) mountable to a sidewall (14) of the conveyor and a clamping portion (24). The clamping portion (24) is movably attached to the mounting portion (22) and movable relative thereto. The shaft support (20) receives a roller shaft (16b) at least partially therethrough. The clamping portion (24) is movable relative to the mounting portion (22) so as to clamp the roller shaft (16b) within the shaft support (20) in response to movement of the clamping portion (24) relative to the mounting portion (22). The clamping portion (24) may move along a ramped surface (34a) toward and into engagement with the shaft (16b) of the roller (12) in response to adjustment of a fastener (26) to clamp the roller shaft (16b) within the shaft support (20).
A method of assigning device identification in a switched network, and the resulting switched network, includes designing a network having a design topology made up of network devices, constructing a network from the designed network and discovering the actual topology of the constructed network. The discovered topology is compared with the design topology to assign identifications to network devices of the constructed network.
patents
