Material handling apparatus and method for sorting items using a dynamically configurable sorting array

Patent metadata

Field	Value
Publication number	US-11607713-B2
Application number	US-201715586204-A
Country	US
Kind code	B2
Filing date	May 3, 2017
Priority date	May 3, 2016
Publication date	Mar 21, 2023
Grant date	Mar 21, 2023

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.

First claim

What is claimed is:

1. A material handling system for sorting a plurality of items of inventory managed by a warehouse management system (WMS), wherein the warehouse management system is configured to assemble lists of items to form respective groups, identify when corresponding sort destination areas become available to receive items of each respective group, and form a plurality of sort destination reservations by associating each corresponding list of items with an available sort destination area, wherein items of each respective group are identifiable by a product characterizing indicium thereof, comprising:
a plurality of sort destination areas, wherein each sort destination area is dimensioned and arranged to receive successive groups of items;
an induct module having a first conveyor, a second conveyor, and a scanning station operative to identify the product characterizing indicium of each item, the scanning station including a plurality of scanning elements dimensioned and arranged at different locations relative to the first and second conveyors and operable to acquire the product characterizing indicium thereof, wherein the plurality of scanning elements includes a first scanning element dimensioned and arranged to acquire the product characterizing indicium through a gap between the first conveyor and the second conveyor as each item passes between the first conveyor and the second conveyor;
a plurality of visible indicators, wherein at least one visible indicator of the plurality of visible indicators is aligned with a corresponding sort destination area of the plurality of sort destination areas;
a plurality of delivery vehicles,
wherein each delivery vehicle is configured to travel vertically and horizontally and into a position of alignment with any of the sort destination areas,
wherein each delivery vehicle defines a support surface dimensioned and arranged to receive a respective item of the plurality of items and is operable to transport a received item to any sort destination area corresponding to a sort reservation determined by the WMS, and
wherein each vehicle comprises a power source for driving the vehicle and a transfer mechanism operative to transfer a received item to a selected sort destination area; and

a controller including a memory and a processor for executing instructions, stored in memory, for
determining when the sort destination areas are present and available to receive items, and for implementing the sort destination reservations of the WMS, by
operating the scanning station to identify presence of a first product characterizing indicium of a first item;
initiating a database query to determine that a WMS association exists between the first product characterizing indicium and a first sort destination area of the plurality of destination areas;
directing movement of a first vehicle along a path to convey and transfer the first item to the first sort destination area,
operating the scanning station to identify presence of the first product characterizing indicium of a second item;
initiating a database query to determine that a WMS association exists between the first product characterizing indicium and a second sort destination area of the plurality of destination areas;
directing movement of a second vehicle along a path to convey and transfer the second item to the second sort destination area,
operating the scanning station to identify presence of the first product characterizing indicium on a third item;
initiating a database query to determine that a WMS association exists between the first product characterizing indicium and the first sort destination area of the plurality of destination areas;
directing movement of a third vehicle along a path to convey and transfer the third item to the first sort destination area,
monitoring operation of the vehicles to determine that conveyed items have been transferred;
determining that the third item is a final item needed to complete a group specified by the WMS; and
activating a first visible indicator aligned with the first sort destination area in response to a notification received following accumulation of the first item and the third item at the first sort destination area.

2. The material handling system of claim 1 , wherein each delivery vehicle includes a sensor configured to sense when a sort destination area is present and available to receive items and wherein the memory of a controller further includes instructions executable by the processor for deactivating the first visible indicator in response to a determination that the first sort destination area is available and ready to receive items again.

3. The material handling system of claim 1 , wherein the memory further includes instructions executable by the processor for controlling the speed and movement of each delivery vehicle based on information stored in a central database about items being conveyed.

4. The material handling system of claim 1 , wherein the visible indicator associated with the first destination area is adjacent to the first destination area.

5. The material handling system of claim 1 , wherein the controller processes instructions, stored in memory, for selectively energizing the visible indicator in accordance with a set of stored event annunciation rules.

6. A material handling system, for sorting a plurality of items of inventory managed by a warehouse management system (WMS), wherein the warehouse management system processes a queue of orders for fulfillment by assembling lists of items to form respective groups, comprising:
a plurality of sort destination areas, wherein each of the sort destination areas is dimensioned and arranged to receive successive groups of items corresponding to multiple orders processed by the warehouse management system;
an induct module having a first conveyor, a second conveyor, and a scanning station operative to identify an item characterizing indicium of each item, the scanning station including a first scanning element dimensioned and arranged to acquire an item characterizing indicium of each item through a gap between the first conveyor and the second conveyor whereby a lower surface of each item is scanned as each item passes between the first conveyor and the second conveyor, and the scanning system including a plurality of additional scanning elements at respectively different locations relative to an upper surface of the first and second conveyors, wherein the scanning elements of the scanning station are dimensioned and arranged to read an item characterizing indicia on any of a plurality of surfaces of the items and wherein a product identifying marking comprises at least one of a UPC and a SKU number corresponding to a discrete item of inventory; and
a plurality of delivery vehicles,
wherein each delivery vehicle is configured to travel vertically and horizontally and into alignment with any of the sort destination areas,
wherein each delivery vehicle defines a support surface dimensioned and arranged to receive a respective item of a plurality of items from the first and second conveyors and each delivery vehicle is operable to transport a received item to any of the sort destination areas corresponding to a sort reservation, and
wherein each vehicle comprises a power source for driving the delivery vehicle and a transfer mechanism operative to transfer a received item to a selected sort destination area; and

a controller including a memory and a processor configured to execute instructions, stored in memory, for implementing sort destination reservations by
operating the scanning station to identify presence of a first item characterizing indicium of a first item;
initiating a database query to determine that an association exists between the first p

Assignees

• Opex Corp

Inventors

• Mcvaugh Monty
• Ressler David
• Dietrich Douglas
• Stevens Alexander
• O'Mara Kerry
• Cherry Kevin
• Hodge Robert
• York Michael
• Dewitt Robert

Classifications

• B07C5/36 Primary

  Sorting apparatus characterised by the means used for distribution {(sorting according to destination B07C3/003, B07C3/02)} · CPC title

• B07C5/38 Primary

  Collecting or arranging articles in groups · CPC title

• B07C3/10 Primary

  Apparatus characterised by the means used for detection ofthe destination (methods or arrangements for reading and recognising printed or written characters or geometric figures G06V30/00) · CPC title

• B07C3/02

  Apparatus characterised by the means used for distribution · CPC title

• B65G1/1378

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