METHOD AND APPARATUS FOR SORTING ITEMS

• US 20080277243A1
• Filed: 01/14/2008
• Published: 11/13/2008
• Est. Priority Date: 01/12/2007
• Status: Active Grant

• Current Assignee: Opex Corporation
• Original Assignee: Opex Corporation
• Inventors: DeWitt, Robert R., Hayduchok, George
• Granted Patent: US 7,861,844 B2
• Time in Patent Office: Days
• US Class Current: 198/463.6
• CPC Class Codes: B07C 3/087 the objects being taken up in transport files or holders which are not part of the conveyor belts cable post B65G
• CPC Class Codes: B07C 7/005 Computer assisted manual sorting, e.g. for mail
• CPC Class Codes: B07C 7/02 Compartmented furniture, e.g. pigeon-holes B07C7/005 takes precedence; furniture per se A47B; storage racks B65G
• CPC Class Codes: B61B 13/02 Rack railways
• CPC Class Codes: B61C 11/04 tractive effort applied to racks
• CPC Class Codes: B65G 1/04 mechanical
• CPC Class Codes: B65G 1/065 with self propelled cars
• CPC Class Codes: B65G 67/02 Loading or unloading land vehicles
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 30/00 Transportation of goods or passengers via railways, e.g. energy recovery or reducing air resistance

Abstract

A method and apparatus are provided for sorting items to a plurality of sort destinations. The items are loaded onto one of a plurality of independently controlled delivery vehicles. The delivery vehicles follow a track that guides the delivery vehicles to the sort destinations, which are positioned along the track. 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.

Claims

1-25. -25. (canceled)

26. A sorter for sorting a plurality of items, comprising:

an input station for loading a plurality of items;

a plurality of separate sort locations for receiving the items;

a plurality of delivery vehicles for receiving and delivering the items to the sort locations, wherein each delivery vehicle comprises a receiving area for receiving an item, wherein the receiving area has an orientation relative to the horizon;

a track system for guiding the delivery vehicles from the input station to the sort locations, comprising;

a first section for guiding the delivery vehicles;

a second section for guiding the delivery vehicles, wherein the second section intersects the first section at intersections and the second section is disposed at an angle to the first section;

a plurality of gates selectively operable to provide continuous paths for the vehicles as the vehicles travel from the first section to the second section;

wherein the sort locations are positioned along the second section of the track system; and

a controller for directing the delivery vehicles to the appropriate sort location;

wherein each delivery vehicle comprises a drive system that interacts with the track system to drive the vehicle along the track, wherein the drive system for a vehicle is configured to interact with the track to maintain the orientation of the receiving area of the vehicle as the vehicle passes from the first section to the second section.

27. The sorter of claim 26 wherein the track system comprises a rearward track comprised of the plurality of horizontal rows and vertical column and a forward track comprising a plurality of horizontal rows and vertical columns that are substantially parallel to the portions of the rearward track such that the rearward track supports and guides a rearward portion of the delivery vehicles and the forward track supports and guides a forward portion of the delivery vehicles.

28. The sorter of claim 26 wherein the track system comprises a series of teeth formed along the rows and columns of track, and wherein the drive system for the delivery vehicle comprises gears having teeth that mesh with the teeth of the track system.

29. The sorter of claim 28 wherein the interaction between the gears of the drive system and the teeth in a vertical column of track is sufficient to maintain the vehicle in a vertical position when the gears are stopped.

30. The sorter of claim 29 wherein the drive system comprises a motor operable to drive the gears, wherein stopping the motor stops the gears.

31. The sorter of claim 26 wherein the delivery vehicles are operable to eject a piece forwardly toward a sort location disposed along a forward side of the track system, and wherein the delivery vehicles are operable to eject a piece rearwardly toward s rearward sort location disposed along a rearward side of the track system.

32. A material handling system for sorting a plurality of items, comprising:

an plurality of bins for receiving items;

a plurality of delivery vehicles for delivering item to the bins,

wherein each vehicle comprises;

a power source for driving the vehicle; and

an ejector for ejecting an item forwardly or rearwardly to eject an item into one of the bins;

a track for guiding the delivery vehicles to the bins, wherein the track comprises a plurality of horizontal sections intersecting a plurality of vertical sections to provide a plurality of interconnected vertical and horizontal paths

a destination module operable to identify the bin to which one item is to be delivered by one of the delivery vehicles, wherein the destination module identifies the bin based on a marking on the item; and

a controller for controlling the operation of the one vehicle as the vehicle delivers the item to the identified bin.

33. A material handling system for sorting a plurality of items, comprising:

a plurality of sort destinations for receiving the items;

a plurality of delivery vehicles for delivering the items, wherein each vehicle comprises an on-board motor for driving the vehicle; and

track for guiding the delivery vehicles, wherein the track comprises a vertical portion and a horizontal portion providing a continuous path from horizontal to vertical direction.

34. A delivery vehicle operable with a material handling system having a plurality of sort locations and a guide system, wherein the delivery vehicle comprises:

a platform for receiving an item to be conveyed to one of the sort locations;

a motor for driving the vehicle to one of the sort locations;

a drive system cooperable with the guide system to guide the vehicle to one of the sort locations, wherein the drive system is configured to maintain the orientation of the vehicle relative to the horizon as the vehicle changes from a first direction of travel to a second direction of travel, wherein the first direction is at an angle to the second direction.

35. The delivery vehicle of claim 34 wherein the drive system comprises a plurality of driven gears that interact with the guide system to control the position of the vehicle along the guide system.

36. The delivery vehicle of claim 35 comprising a pair of synchronously drive axles, wherein the gears are fixed to the axles so that the gears are synchronously driven to drive the vehicle along the guide system.