Container depalletizing systems and methods

Patent metadata

Field	Value
Publication number	US-11299348-B1
Application number	US-201916658607-A
Country	US
Kind code	B1
Filing date	Oct 21, 2019
Priority date	Oct 21, 2019
Publication date	Apr 12, 2022
Grant date	Apr 12, 2022

Abstract

Container depalletization systems and methods may include various example depalletizing stations including a frame and a plurality of fork assemblies. For example, the frame may receive a stack of containers, and the plurality of fork assemblies may engage, lift, lower, and release layers of containers from the stack of containers to downstream stations or processes. In addition, the example depalletizing stations may include transfer elevator assemblies that may receive layers of containers from the plurality of fork assemblies and transfer the layers of containers to downstream stations or processes. Further, the example depalletizing stations may include movable frames that may move between a first position, at which layers of containers may be engaged and lifted by the plurality of fork assemblies, and a second position, at which layers of containers may be lowered and released by the plurality of fork assemblies and transferred to downstream stations or processes.

First claim

What is claimed is:

1. A container depalletizing station, comprising:
a frame configured to receive a stack of containers on a pallet;
a plurality of fork assemblies movably coupled to the frame, each of the plurality of fork assemblies configured to move vertically relative to the frame, and each of the plurality of fork assemblies configured to move between an extended position and a retracted position;
wherein the plurality of fork assemblies includes a first set of fork assemblies and a second set of fork assemblies that are vertically stacked relative to each other, individual ones of the first set and the second set configured to concurrently lift individual layers of containers of the stack of containers; and
wherein the first set of fork assemblies and the second set of fork assemblies respectively include at least one fork positioned on opposite sides of the frame to thereby concurrently lift respective individual layers of containers;
a transfer elevator positioned underneath the stack of containers and configured to move vertically relative to the frame; and
a controller configured to at least:
instruct the plurality of fork assemblies to move to respective extended positions to engage respective containers of the stack of containers;
instruct the plurality of fork assemblies to lift respective containers of the stack of containers to respective vertical positions relative to the frame;
instruct the transfer elevator to transfer the pallet to a pallet stacking station;
instruct the transfer elevator to move vertically relative to the frame to a position supporting a lowest layer of containers of the stack of containers;
instruct at least some of the plurality of fork assemblies to move to respective retracted positions to release respective containers of the lowest layer of containers of the stack of containers; and
instruct the transfer elevator to transfer respective containers of the lowest layer of containers to a downstream conveyor.

2. The container depalletizing station of claim 1 , wherein the controller is further configured to at least:
instruct the at least some of the plurality of forks assemblies to lower respective containers of the lowest layer of containers of the stack of containers to contact the transfer elevator at the position supporting the lowest layer of containers of the stack of containers.

3. The container depalletizing station of claim 1 , wherein the controller is further configured to at least:
instruct the transfer elevator to move vertically relative to the frame to a position aligned with the downstream conveyor.

4. The container depalletizing station of claim 1 , wherein each of the plurality of fork assemblies includes at least three forks configured to support ribs or edges of respective containers in the extended position.

5. A system, comprising:
a frame configured to receive a stack of containers;
a plurality of fork assemblies movably coupled to the frame, each of the plurality of fork assemblies configured to move vertically relative to the frame, and each of the plurality of fork assemblies configured to move between an extended position and a retracted position;
wherein each of the plurality of fork assemblies is configured to move to respective extended positions to engage and lift respective containers of the stack of containers;
wherein the plurality of fork assemblies includes at least two sets of fork assemblies that are vertically stacked relative to each other, individual ones of the at least two sets of fork assemblies configured to concurrently lift individual layers of containers of the stack of containers; and
wherein each of the at least two sets of fork assemblies includes at least one fork positioned on opposite sides of the frame to thereby concurrently lift respective individual layers of containers.

6. The system of claim 5 , further comprising:
a conveyor positioned under the stack of containers and configured to transfer containers to a downstream station;
wherein each of the plurality of fork assemblies in respective extended positions is configured to lower respective containers of the stack of containers onto the conveyor; and
wherein each of the plurality of fork assemblies is configured to move to respective retracted positions to release respective containers of the stack of containers to be transferred by the conveyor to the downstream station.

7. The system of claim 5 , wherein each of the plurality of fork assemblies includes:
at least one outer fork configured to engage and support an outer edge or rib of a respective container;
at least one inner fork configured to engage and support an inner edge or rib of a respective container;
wherein at least one of:
the at least one outer fork is movable toward or away from the at least one inner fork;
the at least one inner fork is movable toward or away from the at least one outer fork; or
the at least one outer fork and the at least one inner fork are passively rotatable relative to a respective container.

8. The system of claim 5 , wherein each of the plurality of fork assemblies includes:
at least one first actuator configured to move a fork assembly between a respective extended position and a respective retracted position; and
at least one second actuator configured to move a fork assembly vertically relative to the frame.

9. The system of claim 5 , further comprising:
a transfer elevator positioned under the stack of containers and configured to move vertically relative to the frame;
wherein the transfer elevator is configured to move vertically to support and receive respective containers of the stack of containers and transfer the respective containers to a downstream station.

10. The system of claim 9 , wherein each of the plurality of fork assemblies in respective extended positions is configured to lower respective containers of the stack of containers onto the transfer elevator; and
wherein each of the plurality of fork assemblies is configured to move to respective retracted positions to release respective containers of the stack of containers to be transferred by the transfer elevator to the downstream station.

11. The system of claim 9 , wherein the transfer elevator is configured to move vertically to align with a downstream conveyor to transfer the respective containers of the stack of containers to a downstream station.

12. The system of claim 9 , wherein the transfer elevator is coupled to at least one actuator configured to move the transfer elevator vertically relative to the frame.

13. The system of claim 5 , further comprising:
at least one rail to which the frame is movably coupled;
wherein the frame is configured to move along the at least one rail between a first position and a second position;
wherein the frame is configured to receive the stack of containers at the first position; and
wherein each of the plurality of fork assemblies is configured to move to respective extended positions to engage and lift respective containers of the stack of containers at the first position.

14. The system of claim 13 , further comprising:
a conveyor positioned at the second position and configured to transfer containers to a downstream station;
wherein each of the plurality of fork assemblies in respective extended positions is configured to lower respective containers of the stack of containers onto the conveyor; and
wherein each of the plurality of fork assemblies is configured to move to respective retracted positions to release respective containers of the stack of containers to be transferred by the conveyor to the downstream station.

Assignees

• Amazon Tech Inc

Inventors

• Bhardwaj Abhinav
• Kol Tolga
• Camelin Matteo
• La Rovere Stefano

Classifications

• B65G59/063 Primary

  comprising lifting means · CPC title

• B65G1/14 Primary

  Stack holders or separators · CPC title