Automated work center

• US 5,222,855 A
• Filed: 09/16/1992
• Issued: 06/29/1993
• Est. Priority Date: 01/02/1986
• Status: Expired due to Fees

• Current Assignee: Computer Aided Systems, Inc.
• Original Assignee: Computer Aided Systems, Inc.
• Inventors: Perry, Daniel C., Bernard, Clay II
• Primary Examiner(s): Werner, Frank E.
• Application Number:
  US07/945,829
• Time in Patent Office: 286 Days
• Field of Search: 414/331, 414/278, 414/285, 414/286, 414/273, 414/274, 414/287, 414/222, 364/478, 211/1.5, 211/122, 198/469.1, 198/475.1, 198/474.1, 198/478.1, 198/481.1, 198/793, 198/794, 198/797, 198/798, 198/799, 198/800, 198/339.1, 198/340, 198/345, 198/346.2 , 198/855, 198/575, 198/570, 198/571, 198/572, 198/502.2, 198/465.1, 198/435, 198/803.01, 198/364
• US Class Current: 414/331.03
• CPC Class Codes: B65G 1/0485 Check-in, check-out devices
• CPC Class Codes: B65G 1/1371 with data records
• CPC Class Codes: B65G 2201/02 Articles

Abstract

An automated work center for use in materials handling operations is disclosed. The work center includes a randomly accessible vertically moving temporary storage queue 11 for receiving containers 25 that hold material goods. A fixed loading ramp 20 is arranged to receive containers 20 from an external system and to load the received containers onto the storage queue 11. A work area 5 having a plurality of rotatable work tables 7 provides an gives the operator access to the containers. A delivery system 14 transfers containers between the storage queue 11 and the work tables 7 and a takeaway system 16 transfers containers between the work area and the conveyor network. An automated control system 17 coordinates the delivery of containers between the temporary storage queue 11 and the work area 5. A consolidation queue 18 having a multiplicity of vertically spaced shelfs may be disposed opposite the work tables 7 to facilitate the consolidation of ordered goods.

Claims

1. An automated work station for use in material handling operations including a conveyor network for carrying containers, said work station comprising:

a randomly accessible vertically moving storage queue having a multiplicity of vertically spaced shelves arranged about an endless loop for temporarily holding said containers, drive means for rotating the shelves about the endless loop and means for maintaining said containers on said shelves;

loading means for receiving containers from said conveyor network and for loading received containers onto shelves of said storage queue;

a plurality of side-by-side work tables accessible by an operator for providing the operator access to the containers to selectively add or withdraw articles from said containers;

delivery means for transferring selected containers from said storage queue to said work tables;

takeaway means for transferring containers from said work tables to said conveyor network; and

control means for coordinating movement of containers between said storage queue and said work tables.

2. An automated work station as recited in claim 1 wherein said control means includes:

an electrical communication network for directing specific movements of said storage queue, said loading means, said work tables, said delivery means, and said takeaway means for the transfer of containers from said storage queue to said work tables by said delivery means, for the loading of containers onto the shelves of said storage queue by said loading means, and for the transfer of containers from said work tables to said conveyor network by said takeaway means; and

computer means connected to the communication network for generating communication signals according to a predetermined program, the communication signals directing the communication network to direct specific tasks.

3. An automated work station as recited in claim 1 wherein said loading means includes a gravity motivated loading ramp for transferring containers between a supply conveyor and said storage queue.

4. An automated work station as recited in claim 3 wherein said loading ramp includes a receiving end disposed adjacent said supply conveyor for receiving containers from the supply conveyor and a discharge end disposed adjacent said endless loop for loading containers onto said shelves, said discharge end being lower than said receiving end, a plurality of rollers for supporting said containers on the loading ramp, and a power operated blocker for selectively retaining containers on said loading ramp, said power operated blocker having a first operable position that retains said containers on the loading ramp and a second operable position wherein said containers are free to pass over the power operated blocker.

5. An automated work station as recited in claim 3 further including means for absorbing momentum of containers transferred to said loading ramp.

6. An automated work station as recited in claim 1 wherein said loading means includes a loading ramp for transferring containers between a supply conveyor and said storage queue, said loading ramp including a plurality of power actuated rollers and means for driving said rollers.

7. An automated work station as recited in claim 1 wherein said drive means is reversible so the shelves may be rotated about the endless loop in either a clockwise or counterclockwise direction.

8. An automated work station as recited in claim 1 wherein said delivery means includes a loading ramp for transferring containers from a delivery conveyor to a selected one of said work tables.

9. A control system for an automated material handling work station, the control system directing a work station that includes a randomly accessible temporary storage queue for holding containers, a work area for providing an operator with access to the containers, delivery means for transferring containers between said temporary storage queue and said work area, and takeaway means for transferring containers away from said work area, the control system comprising:

a queue control means for directing movements of the temporary storage queue, the temporary storage queue having a multiplicity of vertically spaced shelves arranged about an endless loop for temporarily holding said containers, drive means for rotating the shelves about the endless loop and means for maintaining said containers on said shelves;

a first control means for directing movements of the delivery and takeaway means to transfer containers between said temporary storage queue and said work area, and away from said work area, said work area including a plurality of side-by-side work tables accessible by an operator for providing the operator access to the containers to selectively add or withdraw articles from said containers;

a second control means for managing the activities of the queue control means and the first control means and for coordinating communication with the operator to provide the operator with access to the containers; and

a local area communications network that facilitates communication between the second control means, the queue control means and the first control means.

10. A control system as recited in claim 9 wherein the work tables are movable and said control system further comprises a table control means for controlling the movement of the work tables, said table control means communicating with said second control means over said local area communications network.

11. A control system as recited in claim 10 wherein said work tables are rotatable to facilitate presenting the containers to the operator in multiple orientations, and the table control means directs the rotation of the work tables, the control system further comprising an identification scanner for identifying containers delivered to the work station and determining their orientation.

12. A control system as recited in claim 10 wherein the work station further includes a loading ramp for loading containers onto a selected one of the work tables and wherein said table control means coordinates movement of a container from the loading ramp to said selected one of the work tables.

13. A control system as recited in claim 9 further comprises a consolidation control means for managing the activities of a rotational consolidation queue adapted to receive a multiplicity of article containing means, said consolidation queue including means for rotating the consolidation queue and means for presenting selected article containing means to an operator to allow the operator access thereto, said consolidation control means controlling the operation of said consolidation queue rotating means and said presenting means, and said consolidation control means communicating with said second control means over said local area communications network.

14. A control system as recited in claim 13 wherein said second control means instructs the consolidation control means to present selected article containing means, and the consolidation control means coordinates rotation of the consolidation queue and the presentation of the selected article containing means without any further instructions from said second control means.

15. A control system as recited in claim 13 wherein the work tables are movable and said control system further comprises a table control means for directing movements of the work tables, said table control means communicating with said second control means over said local area communications network.

16. A control system as recited in claim 15 further comprising display means directed by the second control means for communicating with the operator, wherein the display means displays instructions to the operator for facilitating a transfer of articles between said consolidation queue and a container.

17. A control system as recited in claim 16 wherein said display means further includes a plurality of signal lights, each said signal light being associated with a particular work table for indicating to the operator whether a selected container is on the work table.

18. A control system as recited in claim 16 wherein said display means further includes a plurality of pushbuttons, each said pushbutton being associated with a particular work table and actuatable by the operator to indicate that the operator is finished with the container disposed on the associated work table.

19. A control system as recited in claim 16 wherein said display means further comprises a plurality of displays, each said display being associated with an article containing means accommodating position on the consolidation queue, and herein the display associated with a particular article containing means accommodating position that holds an open article containing means displays instructions to the operator.

20. A control system as recited in claim 13 further comprising a printer means on said consolidation queue and means for moving said printer means from one article containing means to another, said printer means and said moving means directed by said consolidation control means so said printer means may be positioned near a selected article containing means.

21. A control system as recited in claim 9 wherein said second control means maintains a file that records a location of each of the containers within the work station, and an identity of any contents stored within each container.

22. A control system as recited in claim 9 wherein the work station further includes a supply conveyor and means for driving said supply conveyor for delivering containers to the temporary storage queue, a loading ramp for loading containers onto the temporary storage queue, and means for determining when a container is delivered to the loading ramp wherein when a container is delivered to the loading ramp, the queue control means proceeds to load the container from the loading ramp onto the temporary storage queue without receiving any instructions from the second control means.

23. A control system as recited in claim 22 wherein the second control means creates a container request list that indicates a plurality of containers located in the temporary storage queue that may be delivered to the work area and transmits the container request list to the queue control means, and the queue control means selects a particular container from the container request list and causes the selected container to be extracted from the temporary storage queue and moved onto the delivery means for transportation to the work area.

24. A control system as recited in claim 22 wherein the queue control means remember which shelves of the temporary storage queue are holding containers.

25. A control system as recited in claim 22 wherein said first control means directs movement of said supply conveyor.

26. A control system as recited in claim 9 wherein each container has a distinct identifying indicia and the control system includes means for detecting the indicia to identify a particular container within the work station.

27. A control system for an automated material handling work station, the control system directing a work station that includes a randomly accessible temporary storage queue for holding containers, a work area for providing an operator with access to the containers, delivery means for transferring containers between said temporary storage queue and said work area, and takeaway means for transferring containers away from said work area, the control system comprising:

a queue control means for directing movements of the temporary storage queue, the temporary storage queue having a multiplicity of vertically spaced shelves arranged about an endless loop for temporarily holding said containers, drive means for rotating the shelves about the endless loop and means for maintaining said containers on said shelves;

a first control means for directing movements of the delivery and takeaway means to transfer containers between said temporary storage queue and said work area, and away from said work area, said work area including a plurality of side-by-side work tables accessible by an operator for providing the operator access to the containers to selectively add or withdraw articles from said containers;

a second control means for managing the activities of the queue control means and the first control means and for coordinating communication with the operator to provide the operator with access to the containers;

a local area communications network that facilitates communication between the second control means, the queue control means and the first control means;

a master controller for coordinating the activities of said second control means; and

a second local area communications network that facilitates communication between said master controller and said second control means.

28. A control system as recited in claim 27 wherein the containers hold goods and said master controller maintains a record of the goods in the containers.

29. A control system as recited in claim 28 wherein the containers have multiple compartments for holding the goods and said master controller includes a listing of the goods in the compartments.

30. A control system as recited in claim 29 wherein the compartments have different sizes and locations in the containers, and said master controller maintains a list of containers having empty compartments along with an indication of the size and location of the empty compartments, said list provided to said second control means by said master controller.

31. A control system as recited in claim 28 wherein said master controller maintains a file which remembers the weight and dimensions of the goods.

32. A control system as recited in claim 27 wherein said master controller maintains a file that can be transmitted by said master controller to said second control means over said second local area communications network, the file including items and quantities of particular goods requested in an order and information for printing an invoice.