Automated method for filling orders with cartridge dispensers

• US 5,768,139 A
• Filed: 06/19/1996
• Issued: 06/16/1998
• Est. Priority Date: 08/13/1990
• Status: Expired due to Fees

• Current Assignee: Siemens Dematic Postal Automation LP (Siemens AG)
• Original Assignee: Electrocom Automation L.P. (Siemens AG)
• Inventors: Pippin, James Moody, Erwin, Jerry Dale
• Primary Examiner(s): RUGGIERO, JOSEPH F
• Application Number:
  US08/667,234
• Time in Patent Office: 727 Days
• Field of Search: 364/478.04, 364/478.18, 364/479.01, 364/479.12, 364/479.13, 221/829, 221/2, 221/5, 221/6, 221/9, 186/55, 186/69, 186/19, 186/20, 198/358, 198/349.6, 198/349.7, 414/273, 414/278
• US Class Current: 700/216
• CPC Class Codes: B65G 1/1376 the orders being assembled on a commissioning conveyor
• CPC Class Codes: B65G 2205/02 where the stop device is adaptable to the size of the article or array
• CPC Class Codes: B65G 47/8823 Pivoting stop, swinging in or out of the path of the article
• CPC Class Codes: B65G 47/8884 Stops acting asynchronously, e.g. one stop open, next one closed or the opposite

Abstract

An automated method for filling orders using an automated ordering system having a product conveyor, a computer controller, and a plurality of dispensers for dispensing products arrayed in a matrix in rows and columns, wherein the method of filling orders comprises the steps of: coupling each dispenser in a row to a first common control element in the controller; coupling each dispenser in a column to a second common control element in the controller, where the column of dispensers shares a common dispenser with the row of dispensers; and actuating the first and the second control elements simultaneously to dispense a product from the common dispenser onto the conveyor.

Claims

1. A method for filling orders of products using a product dispensing system comprising the steps of:

entering order data into a computer;

defining order zones on a conveyor in accordance with data from the computer;

moving the conveyor;

tracking the defined order zones as the conveyor moves;

actuating one of a plurality of first relays, the actuated first relay individually coupled with a first plurality of actuators;

actuating simultaneously with the actuated first relay one of a plurality of second relays, the actuated second relay individually coupled with a second plurality of actuators; and

dispensing onto the conveyor a product from a selected one of a plurality of product dispensers having an actuator that is both one of the first plurality of actuators and the second plurality of actuators, and which actuator is coupled to an actuated first relay and an actuated second relay, wherein the product is dispensed to an order zone associated with the order.

2. The method of claim 1 further including the steps of:

defining buffer zones between the defined order zones on the conveyor; and

dispensing products from the product dispensers only in the defined order zones.

3. The method of claim 1 further comprising the steps of:

moving the order zones relative to the product dispensers with the conveyor; and

repeating as many times as necessary to complete the order the steps of moving the conveyor and dispensing onto the conveyor a product.

4. The method of claim 1 further comprising the steps of:

detecting a failure to dispense the desired product from the selected product dispenser; and

generating a notification signal in response to the detection of a failure to dispense.

5. The method of claim 3 further comprising the steps of:

selecting one or more order zones on the conveyor for transporting a specific order;

dispensing one or more products in the order into the selected one or more order zones; and

collecting the products for a specific order from the one or more order zones into a receptacle.

6. The method of claim 5 further comprising the steps of:

detecting a failure to dispense a product from the selected product dispenser; and

diverting products making up an order which should have included a product for which the failure to dispense was detected to a correction area in response to the detection of a failure to dispense.

7. The method of claim 1 wherein the conveyor comprises a linearly moving belt and the order zones comprise surface areas on the belt.

8. The method of claim 7 wherein the order zones and buffer zones span the width of the belt surface.

9. The method of claim 1 wherein the product dispensers comprise hollow, elongated cartridges for storing stacks of products to be dispensed.

10. The method of claim 9 wherein the product dispensers form a rectangular array above the conveyor.

11. The method of claim 10 wherein each first relay is connected to a corresponding row of the array of product dispensers, each product dispenser in the row is coupled with one of the first actuators, each second relay is connected to a corresponding column of product dispensers, and each product dispenser in the column is coupled with one of the second actuators.

12. The method of claim 9 wherein the step of dispensing comprises opening the bottom end of a cartridge and allowing one product to fall onto the conveyor surface in a selected order zone.

13. The method of claim 12 wherein the actuators comprise electromechanical devices.

14. The method of claim 13 wherein the electromechanical devices are reciprocating rotary solenoids.

15. The method of claim 1 further comprising the step of generating dispenser control signals in a control processor for actuating one of the first plurality of relays and for actuating one of the second plurality of relays.

16. A method for filling orders using a product dispensing system, comprising the steps of:

selecting a product dispenser from a plurality of product dispensers disposed above a conveyor, each product dispenser comprising a hollow, elongated cartridge for storing a stack of products to be dispensed, the selected product dispenser corresponding to a desired product to be dispensed;

actuating one of a first plurality of relays to energize a plurality of actuators for a first subset of the product dispensers;

actuating one of a second plurality of relays coincidentally with the actuation of one of the first plurality of relays, said one of the second plurality of relays coupled to a plurality of actuators for a second subset of product dispensers, where an intersection of the first subset and the second subset comprises the selected product dispenser;

dispensing the desired product from the selected product dispenser onto the conveyor by opening a bottom end of the selected product dispenser so that a product falls onto an upper surface of the conveyer; and

verifying dispensing of a desired product from the selected product dispenser.

17. The method of claim 16, wherein the product dispensers are arranged in a rectangular array above the conveyor, and the first subset and the second subset comprise rows and columns of the product dispensers.

18. The method of claim 16, wherein the dispensing step further comprises actuating a mechanism to dispense a bottommost product in the product dispenser and retain products stacked above the bottommost product.

19. A method for filling orders of products using a product dispensing system comprising the steps of:

actuating one of a plurality of first relays individually coupled with a first plurality of actuators to energize one of the first plurality of actuators;

actuating simultaneously with the actuated first relay one of a plurality of second relays to energize the actuated second relay, each second relay individually coupled with a second plurality of actuators;

actuating an electrically powered product dispenser by means of an electrical current supplied through the actuated first relay and the actuated second relay to one of the actuators included as one of the first plurality of actuators and the second plurality of actuators;

dispensing onto a conveyor a product from the actuated product dispenser coupled to an actuated first relay and an actuated second relay; and

verifying the dispensing of a product by a sensor positioned to respond to the corresponding row of product dispensers.

20. A method for filling orders of products using a product dispensing system comprising the steps of:

actuating one of a plurality of first relays individually coupled with a first plurality of actuators to energize one of the first plurality of actuators;

actuating simultaneously with the actuated first relay one of a plurality of second relays to energize the actuated second relay, each second relay individually coupled with a second plurality of actuators;

actuating an electrically powered product dispenser by means of an electrical current supplied through the actuated first relay and the actuated second relay to one of the actuators included as one of the first plurality of actuators and the second plurality of actuators;

dispensing onto a conveyor a product from the actuated product dispenser coupled to an actuated first relay and an actuated second relay; and

generating an operator notification signal when a product has not been dispensed.