Delivery vehicle for material handling system

Patent metadata

Field	Value
Publication number	US-10865053-B2
Application number	US-201916669003-A
Country	US
Kind code	B2
Filing date	Oct 30, 2019
Priority date	Jan 11, 2016
Publication date	Dec 15, 2020
Grant date	Dec 15, 2020

Abstract

A method and apparatus are provided for sorting items to a plurality of sort destinations. The items are fed into the apparatus at an input station having a scanning station. The scanning station evaluates one or more characteristics of each item. The items are then loaded onto one of a plurality of independently controlled delivery vehicles. The delivery vehicles are individually driven to sort destinations. 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. A re-induction conveyor may be provided for receiving select items from the vehicles and conveying the items back to the input station for re-processing. Additionally, a controller is provided to control the movement of the vehicles based on a characteristic each item being delivered by each vehicle. The system may also include vehicles having an assembly for detecting items being loaded onto or discharged from the vehicles.

First claim

The invention claimed is:

1. A delivery vehicle cooperable with a material handling system for delivering items to a plurality of sort locations positioned along a track, wherein the delivery vehicle comprises:
a support surface for supporting one of the items to be delivered;
a transfer mechanism configured to load an item onto the support surface or to discharge an item from the surface;
a plurality of wheels configured to cooperate with the track to drive the vehicle vertically;
a motor operable to drive the plurality of wheels;
an edge-detection assembly for detecting an edge of an item when the item is conveyed onto or discharged from the vehicle, wherein the edge-detection assembly comprises:
an emitter for emitting a beam toward the support surface; and
a plurality of detectors for detecting the beam;
wherein one of the emitter and the plurality of detectors is adjacent a discharge end of the support surface and below the discharge end of the support surface so that the emitter and plurality of detectors form a detection plane that is transverse a plane defined by the support surface;
wherein the emitter or the plurality of detectors are positioned so that an object intersecting the detection plane affects the beam received by the detectors; and

a controller for controlling operation of the vehicle, wherein the controller is configured to control operation of the transfer mechanism in response to signals from the edge-detection assembly.

2. The delivery vehicle of claim 1 wherein the emitter and plurality of detectors are positioned so that the detection plane extends below the support surface.

3. The delivery vehicle of claim 2 wherein the emitter and the plurality of detectors are positioned so that the detection plane is at the discharge end.

4. The delivery vehicle of claim 3 wherein the emitter and the plurality of detectors are configured so that the detection plane is substantially normal to the support surface.

5. The delivery vehicle of claim 1 wherein the plurality of detectors comprises a linear array of aligned detectors.

6. The delivery vehicle of claim 1 comprising a mirror wherein the emitter emits the beam of light toward the mirror and the mirror reflects the beam toward the plurality of detectors.

7. The delivery vehicle of claim 6 wherein the emitter and the plurality of detectors are mounted on a first support element and the mirror is mounted on a second support element spaced apart from the first support element.

8. The delivery vehicle of claim 1 wherein the first support element is mounted adjacent a first edge of the surface and the second support element is mounted adjacent a second edge of the surface so that the first and second support are on opposite sides of the vehicle.

9. The delivery vehicle of claim 1 wherein the emitter comprises a lens for dispersing the beam to create a beam having sufficient height to impinge on each of the detectors.

10. The delivery vehicle of claim 1 wherein the transfer mechanism comprises a conveyor belt or a plurality of rollers and wherein the conveyor belt or rollers comprises an outer surface forming the support surface.

11. A delivery vehicle for delivering items to a plurality of sort locations, wherein the delivery vehicle comprises:
a transfer mechanism configured to load an item onto a generally horizontal surface or to discharge an item from the horizontal surface;
a plurality of wheels configured to cooperate with a track to drive the vehicle vertically;
a motor operable to drive the plurality of wheels;
a sensing assembly for sensing an item when the item is conveyed onto or discharged from the vehicle, wherein the sensing assembly comprises:
an emitter for emitting a beam toward the surface, wherein the emitter is positioned below the surface so that the beam is projected transverse the horizontal surface; and
a plurality of detectors for detecting the beam;
wherein one of the emitter and the plurality of detectors is adjacent a discharge end of the surface and below the discharge end of the surface and wherein the emitter and plurality of detectors cooperate to form a detection plane that is transverse a plane defined by the horizontal surface;
wherein the emitter or the plurality of detectors are positioned so that an object intersecting the detection plane affects the beam received by the detectors; and

a controller for controlling operation of the vehicle, wherein the controller is configured to control operation of the transfer mechanism in response to signals from the sensing assembly.

12. The delivery vehicle of claim 11 wherein the plurality of wheels comprise a first set of wheels configured to cooperate with a first track and a second set of wheels configured to cooperate with a second track so that the delivery vehicle is moveable within an aisle between the first track and the second track.

13. The delivery vehicle of claim 11 wherein the transfer mechanism comprises a conveyor belt or a plurality of rollers and wherein the conveyor belt or rollers comprises an outer surface forming the horizontal surface.

14. The delivery vehicle of claim 11 wherein the plurality of detectors comprise a plurality of photodetector elements disposed in a linear array.

15. The delivery vehicle of claim 14 comprising a lens system dimensioned and arranged to receive optical energy from the emitter and to collimate the received optical energy into a line aligned with the plurality of photodetector elements, wherein optical energy of the line is received by each photodetector element of the plurality of photodetector elements unless an amount of optical energy above a sensitivity threshold is absorbed, reflected or refracted by an object intersecting the detection plane.

16. The delivery vehicle of claim 11 wherein the emitter and plurality of detectors are positioned so that the detection plane extends below the support surface.

17. The delivery vehicle of claim 11 wherein the emitter and the plurality of detectors are configured so that the detection plane is substantially normal to the support surface.

18. The delivery vehicle of claim 17 wherein the plurality of detectors comprises a linear array of aligned detectors.

19. A vehicle for conveying objects along a conveying path in a material handling system, comprising:
a pair of shafts comprising a first shaft and a second shaft extending in a direction transverse to an object transfer direction;
a conveyor belt supported by the pair of shafts, the conveyor belt defining an object support surface;
an electric motor for driving at least one of the shafts and causing movement of the conveyor belt and any object disposed on the object support surface following movement of the vehicle along the conveying path to an object transfer location; and
a sensing arrangement for sensing an intersection between an object and a detection plane transverse to a plane defined by the object support surface, the sensing arrangement including:
a plurality of photodetector elements disposed in a linear array;
a light source; and
a lens system dimensioned and arranged to receive optical energy from the light source and to collimate the received optical energy into a line aligned with the plurality of photodetector elements,

wherein optical energy of the line is received by each photodetector element of the plurality of photodetector elements unless an amount of optical energy above a sensitivity threshold is absorbed, reflected or refracted by an object disposed on the object support surface;

Assignees

• Opex Corp

Inventors

• Dewitt Robert R
• Stevens Alexander
• Mcvaugh Monty
• Walsh James
• Wilson Gregory

Classifications

• B65G2203/044

  Optical · CPC title

• B65G43/08 Primary

  Control devices operated by article or material being fed, conveyed or discharged {(and controlling the discharging devices B65G47/42)} · CPC title

• B65G13/02

  having driven rollers · CPC title

• B65G1/1373

  for fulfilling orders in warehouses · CPC title

• B65G1/0492

  with cars adapted to travel in storage aisles · CPC title