Method for inducting and singulating items to a sorter

• US 9,555,447 B2
• Filed: 09/06/2013
• Issued: 01/31/2017
• Est. Priority Date: 09/06/2013
• Status: Active Grant

• Current Assignee: BEUMER Group A/S (BEUMER Group GmbH & Co. KG)
• Original Assignee: BEUMER Group A/S (BEUMER Group GmbH & Co. KG)
• Inventors: Lykkegaard, Uffe, Staun, Jrgen
• Primary Examiner(s): Randazzo, Thomas
• Application Number:
  US14/916,753
• Publication Number:
  US 20160199884A1
• Time in Patent Office: 1,243 Days
• US Class Current: 1/1
• CPC Class Codes: B07C 2501/0063 Using robots
• CPC Class Codes: B07C 3/003 Destination control; Electro-mechanical or electro- magnetic delay memories
• CPC Class Codes: B07C 5/02 Measures preceding sorting, e.g. arranging articles in a stream orientating sorting and transport of caps B67B3/06
• CPC Class Codes: B25J 9/0093 co-operating with conveyor means
• CPC Class Codes: G05B 19/4182 manipulators and conveyor only

Abstract

The invention provides a method and a system for inducting items to a sorter (SRT) from a stream of items (IT1, IT2), e.g. mail or parcels, arriving at a feeding conveyor (FC). A processor (PCR) executes a control algorithm (C_A) with at least information (I_1) regarding the stream of items arriving at the feeding conveyor (FC) as input. In response, the control algorithm (C_A) generates an output (O1) indicating where to place an item picked up by a robot (R1) from the feeding conveyor (FC). The control algorithm (C_A) selects between two or more of: 1) a first induction (I1) arranged for transporting items to the sorter (SRT), 2) an empty space (E_S) on the sorter(SRT), 3) the feeding conveyor (FC), e.g. singulating bulk items on the feeding conveyor (FC), and 4) a weighing unit (W1) arranged for weighing items. By controlling the robot (R1) accordingly, it is possible to provide effective use of existing pick-and-place robots as part of a sorter induction system, where a high capacity can be obtained with a small requirement for space. E.g. it may be possible to save space for inductions, compared to what is required for manual handling with the same sorting capacity, especially this may be advantageous for items with a maximum weight of 2-3 kg.

Claims

1. A method of inducting items to a sorter from a stream of items arriving at a feeding conveyor, the method comprising:

providing a plurality of input parameters comprising at least information regarding the stream of items arriving at the feeding conveyor,

processing said input parameters in a processor according to a control algorithm, wherein the control algorithm is configured to generate at least one output, in response to said input parameters, indicating where to place an item, selecting between at least two of;

a first induction arranged for transporting items to the sorter,

an empty space on the sorter,

the feeding conveyor, but at a different position and/or orientation than where it was picked up, and

a weighing unit configured to weigh items, and

controlling at least a first robot in accordance with the output of the control algorithm, wherein the first robot is configured to pick up an item from the feeding conveyor, and to place the item in accordance with the output of the control algorithm.

2. The method according to claim 1, comprising selecting an item to be picked up by the first robot, from a plurality of items available on the feeding conveyor, in response to the plurality of input parameters.

3. The method according to claim 1, wherein the plurality of input parameters further comprise at least one of:

information regarding an empty space on the sorter,

information regarding an empty space for at least one item on the first induction,

information regarding an empty space for at least one item on a second induction,

information regarding characteristics of the one or more items arriving on the feeding conveyor, wherein the characteristics comprise at least one of;

a shape, a weight, a size, a center of gravity, an orientation, a surface property, or whether or not the item is a top most item in a bulk,

information indicative of a position of an empty space on the sorter, or

information indicative of a velocity of an empty space on the sorter.

4. The method according to claim 1, wherein the control algorithm is configured to generate the output, in response to said input parameters, indicating to place an item on a second induction configured to transport items to the sorter, and within the reach of the first robot.

5. The method according to claim 1, wherein at least the first robot is configured to singulate items arriving at the feeding conveyor.

6. The method according to claim 1, wherein the control algorithm is configured to generate an output, in response to said input parameters, indicating that at least the first robot should let an item pass by on the feeding conveyor without picking it up.

7. The method according to claim 1, further comprising manually picking up an item from the feeding conveyor at a position downstream of the first robot for manually inducting the item on the sorter or for performing other processing of the item.

8. The method according to claim 1, wherein the control algorithm is configured to determine, in response to at least one input, if the first robot is able to place an item on an empty space on the sorter, and to control the first robot accordingly.

9. The method according to claim 1, wherein the control algorithm is configured to determine, in response to at least one input, if the first robot is able to place an item on an empty space on the first induction or on the weighing unit, and to control the first robot accordingly.

10. The method according to claim 1, wherein the stream of items arriving at the feeding conveyor comprises at least one of:

1) bulk items,

     2) singulated items,

     3) singulated and aligned items, and

     4) singulated, aligned and oriented items.

11. The method according to claim 1, wherein the stream of items arriving at the feeding conveyor comprises at least one of:

mail pieces, parcels, baggage, items handled at a warehouse distribution, or items handled at a mail order distribution centre.

12. The method according to claim 1, comprising providing a second robot that is configured to pick up an item from the feeding conveyor in accordance with a second output from the control algorithm.

13. The method according to claim 12, wherein the control algorithm is configured to generate the second output in response to an activity of the first robot.

14. The method according to claim 1, wherein the control algorithm is configured to control the first robot, so as to place an item on an empty space on the sorter with a relative velocity to said empty space being below a predetermined threshold.

15. The method according to claim 14, wherein the control algorithm is configured to calculate if the first robot is able to place an item on an empty space on the sorter or the first induction with a relative velocity being below said predetermined threshold.

16. The method according to claim 1, wherein the control algorithm is configured to generate said at least one output indicating where to place an item, in response to a predetermined priority list of places.

17. The method according to claim 16, wherein the control algorithm is configured to determine at which places the first robot is able to place an item, and to select among these, a highest priority on the predetermined priority list of places, and to control the first robot accordingly.

18. A system comprising:

at least one feeding conveyor arranged to transport a stream of items,

at least one sorter,

at least a first induction arranged for transporting items to the sorter,

at least a first robot arranged to pick up an item from the feeding conveyor, and to place the item according to a control input, and

at least one processor configured to process input parameters according to a control algorithm, and to generate a control output to control the first robot in accordance with claim 1.

19. The system according to claim 18, comprising at least one vision based system serving to provide input to the control algorithm.

20. The system according to claim 18, wherein the control algorithm is arranged to receive at least one input parameter from at least one of:

a control system serving to control the sorter, a control system serving to control at least the first induction, and a control system serving to control the at least one feeding conveyor, and wherein the at least one processor is arranged to receive input to the control algorithm therefrom.

21. The system according to claim 18, wherein the first robot is positioned within the reach of all of:

the feeding conveyor, the sorter, and at least the first induction.

22. The system according to claim 18, wherein at least the first robot comprises at least one manipulation arm comprising at least two axes.

23. The system according to claim 18, wherein at least the first robot is controlled such that it can let an item pass by on the feeding conveyor if a predetermined criterion is fulfilled.

24. The system according to claim 18, comprising a second robot positioned within the reach of the feeding conveyor and at least one of:

the first induction, and the sorter.

25. A method for sorting mail items in a mail sorting centre comprising sorting mail on the system according to claim 18.