Method of sorting goods and system therefor

• US 4,835,702 A
• Filed: 05/11/1987
• Issued: 05/30/1989
• Est. Priority Date: 05/09/1986
• Status: Expired due to Fees

• Current Assignee: KAO Corporation
• Original Assignee: KAO Corporation
• Inventors: Tanaka, Nobuhiro
• Primary Examiner(s): RUGGIERO, JOSEPH F
• Application Number:
  US07/048,432
• Time in Patent Office: 750 Days
• Field of Search: 364/478, 364/479, 364/468, 198/349, 198/356, 198/358, 414/398, 414/288, 414/289, 414/273, 209/659, 53/390, 53/391, 53/504
• US Class Current: 700/217
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas
• CPC Class Codes: B65G 2209/02 Batch order forming, e.g. several batches simultaneously
• CPC Class Codes: B65G 47/54 at least one of which is a roller-way

Abstract

A method of sorting goods and a system therefor. An efficient method of sorting goods which arrive in the unit of items into groups which have been determined in advance in the order of delivery in a prescribed quantity so as to allow sequential loading of goods in a truck or the like in first-in-last-out manner. The loading order is dependent on the item and quantity for a destination and/or a number of destinations, and to deal with changes in orders which frequently occur.

The system applicable to this method includes plural assembling and storage conveyors for assembling goods in classified groups, a diverting conveyor which sort out goods arrived in the unit of items into said assembling and storage conveyors and a controlling system which controls said diverting conveyor and the sorting out operation.

Claims

1. A method for sorting a large number of goods substantially in an order which they will be delivered, comprising the steps of:

determining an order of delivery of said goods;

determining a number of groups based on data indicative of said goods and a storage space for said goods; and

arranging each of the goods into said groups substantially in the order of delivery.

2. The method for sorting goods as claimed in claim 1 including determing an indication of an amount of goods for each group to make said indication for each group substantially equal to an indication for each other group depending on the number of groups which have been formed in advance.

3. The method for sorting goods as claimed in claim 1 or 2 including the step of determining said indication of goods using a length of each good.

4. The method for sorting goods as claimed in claim 1 or 2 including the step of conveying goods, within each said group, in the order of size of the item units from a larger kind being conveyed first to a smaller kind being conveyed last.

8. A method as in claim 1 wherein said arranging goods step comprises the steps of:

determining a size of goods in each said group,

determining a group to be full when said size reaches a predetermined amount, and

beginning grouping goods into a next group when said group is determined to be full.

5. A system for sorting goods which sorts a large number of goods substantially in the order of deliveries, comprising:

a plurality of assembling and storage conveyors which form assembly groups for prescribed goods,

diverting conveyor means, receiving a plurality of goods for individually diverting each good into said assembling and storage conveyors, and

control means for controlling said diverting means by;

(1) determining an order of delivery of said goods,

(2) determining which of said assembly groups each of said goods should be conveyed so that said goods will be arranged substantially in the order of delivery, and

(3) controlling said diverting conveyor means to convey each said good to an appropriate assembling conveyor, cprresponding to a group.

6. The system for sorting goods as claimed in claim 5 wherein said assembling and storage conveyors and said diverting conveyor are provided in two layers.

7. The system for sorting goods as claimed in claim 5 or 6 wherein said control means includes a physical distribution control computer which generates sorting data, diverting data and assembly data, a facilites control computer which generates necessary control commands out of said sorting data, diverting data and assembly data from said physical distribution control computer and means which controls predetermined functions with said control commands from the facilities control computer.

9. A system as in claim 5 wherein each fo said plurality of assembly and storage covneyors hold goods for one of said groups.

10. A system as in claim 9 wherein said control means is also for determining a total size of goods in said group, and determining a group to be full when said total size reaches a predetermined amount.

11. A system as in claim 9 further comprising means for rearranging goods on each of said plurality of assembly and storage conveyors, and wherein said control means is also for commanding said rearranging means to sort goods within each group, so that larger goods are on the bottom and smaller goods are on the top.

12. Apparatus for loading a delivery vehicle so that items are arranged substantially in an order of delivery comprising:

a plurality of conveying means, each for storing a plurality of goods to be delivered;

first means, receiving goods to be delivered, for conveying each said good to an input end of one of said conveying means;

second means, adjacent an output end of said plurality of conveying means, for conveying goods from said conveying means to said delivery vehicle; and

control means for;

(1) determining a number and size of each said good, and a number of groups,

(2) assigning each said group to a portion of said delivery vehicle and to at least one of said conveying means;

(3) assigning each said good to one of said groups in a way such that said goods will be stored substantially in the order of delivery, and

(4) controlling said second means to convey said groups to said delivery vehicle, in order.

13. An apparatus as in claim 12 wherein said control means assigns each said group to one of said conveying means.

14. Apparatus as in claim 12 further comprising sorting means for sorting goods on each of said conveying means, and wherein said control means is also for commanding said sorting means to sort goods such that larger goods will be on the bottom and smaller goods will be on the top.

15. Apparatus as in claim 13 further comrising sorting means for sorting goods on each of said conveying means, and wherein said control means is also for commanding said sorting means to sort goods such that larger goods will be on the bottom and smaller goods will be on the top.

16. Apparatus as in claim 15 wherein an amount in each said group is determined by a length of said device.

17. A method for loading a delivery vehicle so that items are arranged substantially in an order of delivery, comprising the steps of:

determining a number and size of each good to be delivered;

determining a number of groups;

assigning each group to a portion of the delivery vehicle and to a conveying and storing device;

determining an order of delivery;

assigning each of said goods to one of said groups in a way such that each said good will be stored in said delivery vehicle substantialy in the order of delivery; and

storing goods in the delivery vehicle in group order, by emptying ones of said conveying devices serially.

18. A method as in claim 17 comprising the further step of sorting goods on each said conveyor device so that larger goods are stored below smaller goods.

19. A method as in claim 17 comprising the further step of determining each said group so that a height of each said group will be substantially equal to the height of all other groups.