Automated item sortation and container handling systems

Patent metadata

Field	Value
Publication number	US-11208272-B2
Application number	US-201916455069-A
Country	US
Kind code	B2
Filing date	Jun 27, 2019
Priority date	Jun 27, 2019
Publication date	Dec 28, 2021
Grant date	Dec 28, 2021

Abstract

Systems, methods, and computer-readable media are disclosed for automated item sortation and container handling. In one embodiment, an example method may include determining, by a controller, a first item identifier of a first item at an induction portion of a sortation system, determining an order identifier associated with the first item identifier, and determining a first container associated with the order identifier. The method may include causing a first mobile carrier unit to receive the item, and causing the first mobile carrier unit to deliver the first item to the first container.

First claim

That which is claimed is:

1. An item sorting system comprising:
a container matrix comprising a first container slot at a first level and a second container slot at a second level;
a first container disposed at the first container slot, wherein the first container is configured to receive items associated with a first order;
a second container disposed at the second container slot, wherein the second container is configured to receive items associated with a second order;
an inbound item portion at which a first item to be sorted by the item sorting system is located;
a first mobile carrier unit configured to secure the item;
a first track at the first level, wherein the first mobile carrier unit is configured to move along the first track;
a second track at the second level, wherein the first mobile carrier unit is configured to move along the second track;
a first ramp coupled to the inbound item portion and the first track;
a second ramp coupled to the inbound item portion and the second track, wherein the first mobile carrier unit is configured to move along the first ramp to access the first track, and to move along the second ramp to access the second track; and
a controller in communication with the first mobile carrier unit, the controller configured to:
determine that the first item is associated with the first order;
cause the first mobile carrier unit to move to the inbound item portion;
cause the first mobile carrier unit to retrieve the first item; and
cause the first mobile carrier unit to deliver the first item to the first container using the first track.

2. The item sorting system of claim 1 , further comprising:
a container elevator configured to move items and containers between the first level and the second level;
wherein the controller is further configured to cause the container elevator to receive a second container at an empty container inbound portion, and to cause the first mobile carrier unit to receive the second container from the container elevator.

3. The item sorting system of claim 1 , wherein the controller is further configured to:
determine that each of the items associated with the first order is in the first container; and
cause a second mobile carrier unit to retrieve the first container; and
cause the second mobile carrier unit to deliver the first container to an outbound portion of the item sorting system.

4. A system comprising:
a container matrix comprising a first level and a second level, the first level comprising a first plurality of container slots configured to receive individual containers, and the second level comprising a second plurality of container slots configured to receive individual containers;
an inbound portion at which items or containers can be received by the system;
a first track disposed at the first level;
a first ramp coupled to the inbound portion and the first track;
a second track disposed at the second level;
a second ramp coupled to the inbound portion and the second track;
a first mobile carrier unit comprising a conveyor belt, the first mobile carrier unit configured to move along the first track and the second track, wherein the first mobile carrier unit is configured to (i) deposit items into containers on the first level or the second level using the conveyor belt, and (ii) receive full containers from container slots using the conveyor belt; and
a controller configured to control operation of the first mobile carrier unit;
wherein the first mobile carrier unit is configured to access the first track using the first ramp, and to access the second track using the second ramp.

5. The system of claim 4 , wherein the inbound portion comprises a queuing track, and
wherein the first mobile carrier unit is configured to move between the first track and the second track via the queuing track.

6. The system of claim 5 , wherein the queuing track forms a closed loop that passes through the container matrix.

7. The system of claim 4 , wherein the first level is a lower level, and the second level is an upper level, the system further comprising:
a chute disposed between the first track and a container in a container slot on the lower level;
wherein items deposited into the chute by mobile carrier units on the second track are directed into the container.

8. The system of claim 4 , wherein each of the first plurality of container slots and the second plurality of container slots further comprises:
a lift mechanism configured to adjust an angle of a container; and
an extender arm, drive rollers, or a conveyor belt configured to move full containers from a container slot onto the first mobile carrier unit.

9. The system of claim 4 , further comprising:
a second mobile carrier unit configured to move along the second track;
wherein the first track and the second track form respective closed loops.

10. The system of claim 9 , wherein the first mobile carrier unit is configured to move bidirectionally along the first track.

11. The system of claim 4 , further comprising:
a container elevator configured to move vertically between the first track and the second track, the container elevator comprising motorized rollers;
wherein the container elevator is configured to deliver empty containers or items to the first mobile carrier unit, or to receive full containers from the first mobile carrier unit.

12. The system of claim 4 , wherein the first mobile carrier unit further comprises:
at least two sidewalls on opposite sides of the first mobile carrier unit; and
a first door disposed transverse to the at least two sidewalls, wherein the first door in an open position forms a chute angled towards a container;
wherein the first mobile carrier unit is configured to automatically open and close the first door.

13. The system of claim 12 , wherein the first mobile carrier unit further comprises:
a second door disposed opposite the first door;
wherein the first mobile carrier unit is configured to automatically open and close the second door.

14. The system of claim 4 , further comprising:
an outbound portion configured to transport full containers out of the system.

15. The system of claim 14 , further comprising:
an empty container intake portion configured to transport empty containers into the system;
wherein the induction portion, the outbound portion, and the empty container intake portion comprise conveyor belts that are disposed adjacent to each other.

16. A system comprising:
a container matrix comprising a first level and a second level, the first level comprising a first plurality of container slots configured to receive individual containers, and the second level comprising a second plurality of container slots configured to receive individual containers;
a queueing track;
a first track disposed at the first level;
a first ramp coupled to the queueing track and the first track;
a second track disposed at the second level;
a second ramp coupled to the queueing track and the second track;
a first mobile carrier unit comprising a conveyor belt, the first mobile carrier unit configured to move along the first track and the second track, wherein the first mobile carrier unit is configured to (i) deposit items into containers on the first level or the second level using the conveyor belt, and (ii) receive full containers from container slots using the conveyor belt; and
a controller configured to control operation of the first mobile carrier unit;
wherein the first mobile carrier unit is configured to access the first track using the first ramp, and to

Assignees

• Amazon Tech Inc

Inventors

• Battles Jon S
• Krishnamoorthy Ganesh
• Maylone Sean O
• Narayanan Vivek S
• Malik Mohit

Classifications

• G06Q30/0635

  replenishment orders; recurring orders · CPC title

• G06Q10/08355

  Routing methods · CPC title

• B65G11/023

  for articles · CPC title

• B65G1/1378

  the orders being assembled on fixed commissioning areas remote from the storage areas · CPC title

• B65G1/10

  with relatively movable racks to facilitate insertion or removal of articles {(cabinets with means for moving compartments up and down A47B51/00; cabinet system, e.g. consisting of cabinets arranged in a row with means to open or close passages between adjacent cabinets A47B53/02)} · CPC title