Material handling apparatus and method for automatic and manual sorting of items using a dynamically configurable sorting array

• US 10,639,678 B2
• Filed: 10/21/2019
• Issued: 05/05/2020
• Est. Priority Date: 05/03/2016
• Status: Active Grant

• Current Assignee: Opex Corporation
• Original Assignee: Opex Corporation
• Inventors: Cherry, Kevin, McVaugh, Monty, Sauer, John, Stevens, Alexander
• Primary Examiner(s): Cumbess, Yolanda R
• Application Number:
  US16/658,849
• Publication Number:
  US 20200047218A1
• Time in Patent Office: 197 Days
• Field of Search: None
• CPC Class Codes: B07C 3/008 Means for collecting objects, e.g. containers for sorted mail items pile receivers in general B65H31/00
• CPC Class Codes: B07C 3/14 using light-responsive detecting means for information carriers G06K7/14
• CPC Class Codes: B07C 3/20 Arrangements for facilitating the visual reading of addresses, e.g. display arrangements coding stations
• CPC Class Codes: B07C 5/10 measured by light-responsive means sorting according to colour B07C5/342
• CPC Class Codes: B07C 5/3412 according to a code applied to the object which indicates a property of the object, e.g. quality class, contents or incorrect indication sorting according to size measured by light-responsive means B07C5/10; sorting according to optical properties B07C5/342; for packages B65D79/02; for information carriers G06K7/00
• CPC Class Codes: B07C 5/3422 using video scanning devices, e.g. TV-cameras
• CPC Class Codes: B07C 5/36 Sorting apparatus characterised by the means used for distribution sorting according to destination B07C3/003, B07C3/02

Abstract

A method and apparatus are provided for sorting items to a plurality of sort destinations. A scanning station evaluates one or more characteristics of each item fed into the apparatus. The items are loaded onto one of a plurality of independently controlled delivery vehicles. The delivery vehicles are individually driven to sort destinations. Once at the appropriate sort destination, the delivery vehicle ejects the item to the sort destination and returns to receive another item to be delivered. A re-induction conveyor may be provided for receiving select items from the vehicles and conveying the items back to the input station for re-processing. Additionally, a controller is provided to control the movement of the vehicles based on a characteristic each item being delivered by each vehicle. When an item to be manually sorted is encountered, a visual alert aligned with a selected destination is activated until manual transfer is confirmed.

Claims

1. A method of sorting items using a dynamically reconfigurable sorting array system, wherein the system includes a plurality of destination areas arranged into a series of columns extending generally vertically, a plurality of delivery vehicles, and an event annunciation system, the method comprising the steps of:

transferring, onto a delivery vehicle, an item to be delivered to a first destination area of the plurality of destination areas;

driving the delivery vehicle along a path to the first destination area;

initiating discharge of an item to the first destination area;

determining that an item is to be manually delivered to a second destination area of the plurality of destination areas;

upon determining that an item is to be manually delivered to a second destination area, operating the event annunciation system to provide a first visible alert;

determining that an item is manually delivered to the second destination area;

upon determining that an item is manual delivered to the second destination, operating the event annunciation system to at least one of discontinue the first visible alert or provide a second visible alert visibly distinguishable from the first visible alert;

wherein the second visible alert is provided when a last item required to complete a grouping of items at a destination area has been transferred.

2. The method of claim 1 including the step of operating a sensor of the material handling system to confirm discharge of an item to the first destination area.

3. The method of claim 1 wherein the step of driving the delivery vehicle comprises the step of driving the delivery vehicle up a vertical track.

4. A method of sorting items using a system that includes a plurality of delivery vehicles for delivering items to a plurality of destination areas arranged into a series of columns extending generally vertically, wherein the method comprises the steps of:

conveying items along a path;

scanning the items with a scanner to identify identification indicia on the items as they are conveyed along the path;

conveying scanned items from the scanner to the delivery vehicles;

loading scanned items onto the delivery vehicles;

determining that one of the scanned items is to be sorted manually rather than by a delivery vehicle;

identifying the destination area to which the item is to be sorted manually;

manually conveying the item to the identified destination;

independently controlling the operation of the delivery vehicles to drive the delivery vehicles to the destination areas to deliver scanned items, wherein the step of independently controlling comprises the step of driving the delivery vehicles up a vertical track.

5. The method of claim 4 wherein the step of identifying the destination area to which the item is to be sorted manually comprises the step of providing a visual signal indicative of the destination area to which the item is to be sorted manually.

6. The method of claim 5 wherein the step of providing a visual signal comprises illuminating a signal adjacent the destination area to which the item is to be sorted manually.

7. The method of claim 4 comprising the step of providing a visible alert when a last item required to complete a grouping of items at a destination area has been transferred to such destination area.

8. The method of claim 4 wherein a plurality of the destination areas are arranged to form an aisle between a first array of columns and a second array of columns and wherein the step of independently controlling the operation of the delivery vehicles comprises driving the delivery vehicles up the vertical track through the aisle to the deliver items to the destination areas.

9. The method of claim 4 comprising the step of controlling the delivery vehicles to discharge items to the destination areas.

10. The method of claim 4 wherein the step of determining that one of the scanned items is to be sorted manually rather than by a delivery vehicle comprises the step of determining that the item is to be sorted manually based on identification indicia detected during the step of scanning.

11. An apparatus for sorting items, comprising

a plurality of destination areas arranged in a plurality of generally vertical columns;

a plurality of delivery vehicles for delivering items to the plurality of destination areas;

a vertical track wherein the delivery vehicles are configured to cooperate with the vertical track to drive vertically to the destination areas;

an input conveyor for receiving the items and conveying the items toward a loading station;

a scanner for scanning the items as the items are conveyed toward the loading station, wherein the scanner is configured to scan the items for indicia identifying the items;

a central controller programmed to independently control the operation of the delivery vehicles to drive the delivery vehicles to the destination areas to deliver scanned items, wherein the central controller is programmed to determine whether one of the scanned items is to be sorted manually rather than by a delivery vehicle; and

a visual signal indicative of the destination area to which the item is to be sorted manually;

wherein the controller is programmed to control the visual signal in response to determining that one of the items is to be sorted manually.

12. The apparatus of claim 11 wherein the visual signal comprises a plurality of light elements adjacent the destination areas, wherein in response to the controller determining that an item is to be sorted manually the controller is programmed to actuate the light adjacent the destination area where the item is to be sorted manually.

13. The apparatus of claim 11 wherein a plurality of columns of destination areas are arranged to form a first array of columns and a second array of columns with an aisle between the first and second arrays, wherein the delivery vehicles are configured to drive up the vertical track through the aisle to deliver items to the destination areas.

14. The apparatus of claim 13 wherein each delivery vehicle comprises a loading/unloading mechanism configured to load an item onto the delivery vehicle at the loading station and discharge the item from the delivery vehicle at one of the destination areas.

15. The apparatus of claim 11 wherein the visual signal is configured to provide a first visual signal indicative of the destination area to which the item is to be sorted manually and a second visual signal indicative of the last item required to complete a grouping of items at the destination area being transferred to the destination area.

16. The apparatus of claim 15 wherein the first visual signal is a light signal having a first color and the second visual signal is a light signal having a second color.

17. An apparatus for sorting items, comprising

a plurality of destination areas arranged in a plurality of generally vertical columns;

a plurality of delivery vehicles for delivering items to the plurality of destination areas;

an input conveyor for receiving the items and conveying the items toward a loading station;

a scanner for scanning the items as the items are conveyed toward the loading station, wherein the scanner is configured to scan the items for indicia identifying the items;

a central controller programmed to independently control the operation of the delivery vehicles to drive the delivery vehicles to the destination areas to deliver scanned items, wherein the central controller is programmed to determine whether one of the scanned items is to be sorted manually rather than by a delivery vehicle; and

a visual signal indicative of the destination area to which the item is to be sorted manually;

wherein the controller is programmed to control the visual signal in response to determining that one of the items is to be sorted manually;

wherein the visual signal comprises a plurality of light elements adjacent the destination areas; and

wherein in response to the controller determining that an item is to be sorted manually, the controller is programmed to actuate the light adjacent the destination area where the item is to be sorted manually.

18. The apparatus of claim 17 wherein the visual signal is configured to provide a first visual signal indicative of the destination area to which the item is to be sorted manually and a second visual signal indicative of the last item required to complete a grouping of items at the destination area being transferred to the destination area.

19. The apparatus of claim 17 wherein the first visual signal is a light signal having a first color and the second visual signal is a light signal having a second color.