AU2018101189A4 - Rack controller to sorter to guide items into rack storage places - Google Patents

Abstract

Abstract - 2018101189 The present invention concerns a rack controller to a sorter to guide items into rack storage places including at least a first storage place and a second storage place in a rack, a first entry to the first storage place, and a second entry to the second storage place, the sorter comprising the following: an automated scanner to read bar codes from items, including at least a first item and a second item that are addressed to a certain delivery area, a dimensioning device to measure dimensions of items, a sorter line to sort items by delivery areas, a take-away line for the certain delivery area to receive items from the sorter line such that a mutual order of the items received remains the same as in the sorter line, and a sorter control system that is configured to receive bar code data from the automated scanner and item dimension data from the dimensioning device. The rack controller is coupled to the sorter control system such that the rack controller has an access to bar code data and item dimension data, and the rack controller has rack data about dimensions of storage places in the rack, and by combining the bar code data, the item dimension data, and the rack data the rack controller has an ability to make a fill plan for items on the take away line, the fill plan including at least placing the first item into the first storage place in the rack. FG 1"10 104 ftt I ft:t. 102,10 **f ftf FIG. 1 103, 106 --. 206 112 **-, .. ,

Description

Rack controller to sorter to guide items into rack storage places

Area of technology: an invention relates to sorting of items; the invention especially relates to manners to reduce manual work related to handling of items.

Background of the technology

Postal parcels are one example of items which are picked and placed (by employees) into storage places. The storage places are located, for example, in a frame that is a part of a fixed packet automaton described in WO2016185094, or a frame is a part of a moveable packet automaton described in WO2018046603. An alternative term for a set of storage places is “SKU”. In the field of inventory management a stock keeping unit (SKU) is a distinct type of item for sale but the term SKU also refers to a device that is intended for storing and moving items. A corresponding device is termed an “inventory holder” in US2008166217 and said publication describes a robot that is also known as an automated guided vehicle (AGV). AVGs are intended for moving or propelling inventory holders and they are used in logistics tasks, for example, in industry and in warehouses. A sorter is an automated sorting system or apparatus for sorting items in warehouses or in distribution centers. A sortation hub is one example of a distribution center. A known hub-and-spoke model resembles a bicycle wheel with spokes and in this distribution model the transportations are performed along spokes connected to the hub. A distributed sorting model is an alternative distribution model and sometimes it works better than hub-and-spoke model, because it requires less delivery time than the hub-and-spoke model. Many e-commerce services promise a same-day delivery for the products ordered, which prefers use of the distributed sorting model.

The sorter comprises separated devices, such as a sorter line and a number of takeaway lines besides the sorter line. The sorter can move parcels from the sorter line to a certain take-away line. In one delivery method those parcels end into a trolley. In the next phase of this delivery method, an employee pushes the trolley into a delivery vehicle. At a delivery site the same or another employee moves the trolley on its wheels from the delivery vehicle to a conventional packet automaton. Finally, the employee takes parcels one by one from the trolley, reads by a scanner a bar code from a parcel, opens a locker door of the conventional packet automaton, and places the parcel into the locker. A drawback of the above-described delivery method is that it includes quite many manual tasks to be performed at the delivery site, where an employee, for example, fdls the conventional packet automaton with parcels.

Another drawback of the above-described delivery method is that the delivery vehicle is manually loaded with trolleys. Especially, a sortation hub comprises a large area and thus the walking distances there are long and time-consuming.

Summary of the invention

An objective of the invention is to solve the above-mentioned drawbacks when storage places for items are located in frames or in other types of racks.

Another objective of the invention is to avoid use of a manual bar code reader. Some sorters comprise an automated scanner and they have an ability to remain the mutual order of the items. This ability can be utilized with racks such that each item ends at the sortation site to its final destination, i.e. into a certain storage place in a certain rack.

The present invention concerns a rack controller to a sorter to guide items into rack storage places including at least a first storage place and a second storage place in a rack, a first entry to the first storage place, and a second entry to the second storage place, the sorter comprising the following: an automated scanner to read bar codes from items, including at least a first item and a second item that are addressed to a certain delivery area, a dimensioning device to measure dimensions of items, a sorter line to sort items by delivery areas, a take-away line for the certain delivery area to receive items from the sorter line such that a mutual order of the items received remains the same as in the sorter line, and a sorter control system that is configured to receive bar code data from the automated scanner and item dimension data from the dimensioning device.

The rack controller is coupled to the sorter control system such that the rack controller has an access to bar code data and item dimension data, and the rack controller has rack data about dimensions of storage places in the rack, and by combining the bar code data, the item dimension data, and the rack data the rack controller has an ability to make a fill plan for items on the take-away line, the fill plan including at least placing the first item into the first storage place in the rack.

The present invention further concerns a sortation arrangement.

Brief description of the drawings

For a more complete understanding of examples and embodiments of the present invention, reference is now made to the following descriptions taken in connection with the accompanying drawings in which: FIGURE 1 shows a sorter and a rack controller to guide items into a rack, FIGURE 2 shows a robot arm to place an item into a rack, FIGURE 3 shows a put-to-light device comprising push buttons, FIGURE 4 shows a put-to-light device comprising motion detectors, FIGURE 5 shows a sortation arrangement for guiding items into a rack, FIGURE 6 shows a put-to-light device having light-source-and-light-sensor pairs, FIGURE 7 shows a take-away line and a rack.

Detailed description of the invention

It is appreciated that the following embodiments are exemplary. Although the specification may refer to “one” embodiment, the reference is not necessarily made to the same embodiments), or the feature in question may apply to multiple embodiments.

In the present application a term “rack” refers to a frame, a SKU, an inventory holder, or a corresponding mechanical structure that includes storage places for items and is automatically movable, for example, by a conveyor or by an automated guided vehicle (AGV). A rack may include legs or wheels, or a rack is implemented without any legs or wheels. The storage places in a rack may be of the same size, or they are of different sizes. A shipment includes at least one item, and at least one storage place in a rack will be reserved for the shipment.

In the present application the term “item” refers to a (postal) parcel, a product, a set of products, or a shopping bag, or some other package with content. If an item is a shopping bag, the shopping bag can be placed in a box to enable its handling in a sorter.

Generally speaking, sorters are in the distributed model smaller in size and capacity than in the hub-and-spoke model, but the operation principle of the sorters is basically the same in the both models. The sorter described in the present application is not limited to any specific distribution model. FIGURE 1 shows a rack controller 100 to a sorter 101 to guide items into rack storage places. The rack storage places includes at least a first storage place 102 and a second storage place 103 somewhere in a rack 104, a first entry 105 to first storage place 102, and a second entry 106 to second storage place 103. In this simple example, rack 104 comprises only two storage places but usually rack 104 comprises a number of storage places. In one embodiment the rack storage places are located in a number of racks. In one embodiment a rack controller 100 is configured to guide filling of various racks.

Sorter 101 comprises an automated scanner 107 the other devices that are discussed next. Automated scanner 107 is intended for reading bar codes from items, including at least a first item 108 and a second item 109 which both are addressed to a certain delivery area. Second item 109 is in this example the last item addressed to the certain delivery area.

Usually, automated scanners can read the bar codes from items only if the items are placed on a conveyor such that theirs bar codes are upwards. This (manual) task is termed “orientation” and it may include a task which is termed “spacing”. The spacing means that the items locate on the conveyor and there is a free space between each item. “Auto spacer” is a conveyor feature and it refers to such conveyor that can equate spacing between consecutive items. Alternatively, this feature is termed “dynamic spacing”. A dimensioning device 110 is intended for measuring the dimensions of items and possibly the item weights. There are at least two reasons for the measuring. One reason is checking that an item payment corresponds with the item dimensions (and the weight). The (postal) payment is higher for large and/or heavy items.

It is possible to guide items into rack 104 by utilizing sorter 101 and thus another reason to measure the item dimensions is to check that each item to be delivered in rack 104 is small enough to fit into a storage place, such as first storage place 102. A sorter line 111 is intended for sorting items by delivery areas. Sorter line 111 refers to conveyors and also devices which can remove items from sorter line 111. At least the following conveyors are suitable for sorter line 111: a conveyor belt, a cross belt conveyor, and tilt tray conveyor.

In one embodiment sorter line 111 comprises the conveyor belt and robot arms for removing items from sorter line 111, for example, such that there is one robot arm per a delivery area. A pop-up sorter is an alternative for a robot arm. In another embodiment sorter line 111 is implemented as the cross belt conveyor comprising multiple belts each of which can remove an item locating on it. In another embodiment sorter line 111 is implemented as a tilt tray conveyor. The tilt tray conveyor comprises multiple trays each of which can tilt such that an item locating on it drops.

Sorter line 111 may be a straight line. Alternatively, sorter line 111 may be an oval loop, or a loop having multiple curves. A take-away line 112 is intended for receiving items from sorter line 111 (take-away line is also termed a reject line). Take-away line 112 may look like a slide through which items slide downwards. Alternatively, take-away line 112 is composed of rollers that are placed contiguously one after another. Take-away line 112 to be used the present invention is able to receive items from sorter line 111 remaining their mutual order, i.e. the mutual order of the items received remains on take-away line 112 the same as on sorter line 111. For example, the above-mentioned auto spacer can remain the mutual order of items. A controllable roller is an alternative device for remaining the mutual order of items. Then the controllable roller is one of the rollers included in take-away line 112. The controllable roller comprises an electric motor for rotating itself in take-away line 112. The controllable roller further comprises a control unit that is configured to receive measuring data from a speed detector and to calculate on the basis of the measuring data an appropriate rotation speed for the controllable roller such that the controllable roller accelerates or deaccelerates an item approaching it. In addition to the auto spacer and the controllable roller, a man skilled in the art can find other solutions for remaining the mutual order of items.

Sorter 101 comprises a sorter control system 113 that is configured to receive bar code data 114 from automated scanner 107 and item dimension data 115 from the dimensioning device 110. Bar code data 114 discloses the bar codes of the items locating on sorter line 111 and item dimension data 115 discloses the dimensions of those items.

Sorter control system 113 controls sorter line 111 and items locating on sorter line 111, thus sorter control system 113 has real-time location data about the items. In addition, sorter control system 113 has data about the location of take-away line 112 besides sorter line 111. For example, when first item 108 is reaching take-away line 112, and almost located at there, sorter control system 113 sends a command for removing first item 108 from sorter line 111. If sorter line 111 is implemented as a tilt tray conveyor, the command results in that a certain tray in the tilt tray conveyor tilts, and first item 108 drops from it, and ends to takeaway line 112. Therefore, sorter control system 113 can move items, such as first item 108 and second item 109, from sorter line 111 to take-away line 112.

The above described sorter devices can be implemented in various manners. For example, in one embodiment sorter line 111 comprises “auto spacer” feature and in another embodiment “auto spacer” is implemented as a separated device. Fig. 1 shows an example of sorter 101. The mutual order of items can be remained and should be remained to avoid use of manual bar code reader. One benefit of rack controller 100 and sorter 101 is avoiding the use of manual bar code reader. The item, such as first item 108, can be placed into rack 104 by an employee or by a robot arm. Another benefit of rack controller 100 and sorter 101 is that when an item is placed into rack 104, employees don’t need to open and close locker doors of packet automatons, which saves the work time.

Rack controller 100 is coupled to sorter control system 113 such that rack controller 100 has an access to bar code data 114 and item dimension data 115. In addition, rack controller 100 has rack data 116 about the dimensions of the storage places in the rack. Therefore, by combining bar code data 114, item dimension data 115, and rack data 116 rack controller 100 can make a fill plan 117 for items on take-away line. Fill plan 117 includes at least placing first item 108 into first storage place 102 in rack 104.

In one embodiment the all racks are of the same kind. In another embodiment, there are various racks and rack controller 100 is configured to receive rack data 116 for making fill plans, including fill plan 117.

In one embodiment rack controller 100 is configured to receive a fill notification 118 when the last item on take-away line 112 is handled. Then rack controller 100 informs sorter control system 113 that take-away line 112 is free, after which sorter control system 113 can move new items from sorter line 111 to take-away line 112.

From a point of view of sorter 101, rack controller 100 is a subsystem for filling of the rack storage places. In one embodiment rack controller 100 is coupled wirelessly or with a wire to sorter control system 113. In this embodiment rack controller 100 and sorter control system 113 uses different computers.

In another embodiment rack controller 100 is coupled as software to sorter control system 113. In this other embodiment rack controller 100 and sorter control system 113 may use the same computer which has at least one processor and memory. FIGURE 2 shows a robot arm 201 to place first item 108 and other items into rack 104 (not shown). Robot arm 201 is located at take-away line 112 and it is able to fill rack 104 in accordance with fill plan 117. Rack controller 100 is coupled to robot arm 201 wirelessly, with a wire, or as software. Fill plan 117 is originated from rack controller 100. In one embodiment robot arm 201 sends fill notification 118 to rack controller 100 when robot arm 201 has placed the last item from take-away line 112 into rack 104. In the example shown in Fig. 2, robot arm 201 comprises a shoulder 202, an elbow 203, and a wrist 204 which functions similarly as in a human arm. Robot arm 201 further comprises a rotatable base 205, to which shoulder 202 is attached, and a gripper 206 attached to wrist 204.

Gripper 206 is covered with rubber to increase friction and to get a grip on an item. Alternatively, gripper 206 comprises suction cups for holding the item. FIGURE 3 shows a put-to-light device 301 comprising lamps 302, 303, wherein lamps 302, 303 operate as push buttons. Rack controller 100 is coupled to put-to-light device 301 wirelessly, with a wire, or as software. Put-to-light device 301 includes as many lamps 302, 303 as there are storage places in rack 104. Put-to-light device 301 has switched lamp 302 on and put-to-light device 301 shows by light 304 of lamp 302 that an item should be placed into first storage place 102. After placing the item an employee pushes lamp 302, which turns off light 304. In Fig. 3 rack controller 100 is assumed to have sent fill plan 117 to put-to-light device 301. When the last item is placed in rack 104 put-to-light device 301 will send fill notification 118 to rack controller 100.

In an alternative embodiment rack controller 100 fully controls put-to-light device 301 and switches on and off lamps 302, 303 of put-to-light device 301. Therefore, sending fill notification 118 is an option.

When using put-to-light device 301 an employee may unintentionally place an item into a wrong storage place. For example, the employee may place the item into second storage place 103 and then push lamp 302 at first storage place 102. FIGURE 4 shows an alternative implementation for the put-to-light device to solve the above-mentioned placement error. Put-to-light device 401 comprises motion detectors 402, 403 to detect whether the item, such as first item 108, ends into the correct storage place. Put-to-light device 401 further comprises at least one light source 404 to indicate that first item 108 should be placed into first storage place 102. A first motion detector 402 is located at first entry 105 to first storage place 102 such that first motion detector 402 is able to detect an object thereat. The object is basically any object which can be detected by first motion detector 402. Correspondingly, a second motion detector 403 is located at second entry 106 to second storage place 103 such that second motion detector 403 is able to detect an object thereat. Rack controller 100 is coupled to put-to-light device 401 wirelessly, with a wire, or as software.

In one embodiment first motion detector 402 is activated when an employee is expected to place first item 108 into first storage place 102 in rack 104. Then, in response to detecting an object by first motion detector 402, first motion detector 402 is deactivated. For example, if the employee is expected to place first item 108 into first storage place 102, at least one light source 404 indicates first storage place 102. If the employee places first item 108 into first storage place 102, first motion detector 402 detects first item 108, after which first motion detector 402 is deactivated. FIGURE 5 shows a sortation arrangement 500 comprising sorter 101, rack controller 100, and put-to-light device 401. Compared to use of robot arm 201, sortation arrangement 500 suits better certain items, such as fragile items. Compared to use of put-to-light device 301, or use of some other push-to-light device that comprises push buttons, put-to-light device 401 eliminates the most placement errors and thus enhances the reliability.

Sortation arrangement 500 comprises rack controller 100 to sorter 101 and put-to-light device 401 to guide items into rack storage places, the rack storage places including at least first storage place 102 and second storage place 103 in rack 104, first entry 105 to first storage place 102, and second entry 106 to second storage place 103, sorter 101 comprising automated scanner 107 to read bar codes from items, including at least first item 108 and second item 109 that are addressed to a certain delivery area, dimensioning device 110 to measure dimensions of items, sorter line 111 to sort items by delivery areas, take-away line 112 for the certain delivery area to receive items from sorter line 111 such that a mutual order of the items received remains the same as in sorter line 111, and sorter control system 113 that is configured to receive bar code data 114 from automated scanner 107 and item dimension data 115 from dimensioning device 110; and in sortation arrangement 500 rack controller 100 is coupled to sorter control system 113 such that rack controller 100 has an access to bar code data 114 and item dimension data 115 and rack controller 100 has rack data 116 about dimensions of storage places in rack 104, and by combining bar code data 114, item dimension data 115, and rack data 116 rack controller 100 is able to make fill plan 117 for put-to-light device 401 to handle items on take-away line 112, fill plan 117 including at least placing first item 108 into first storage place in rack 104, and put-to-light device 401 is located at take-away line 112 and comprises at least one light source 404 to indicate first storage place 102 intended for first item 108, first motion detector 402 at first entry 105 such that first motion detector 402 is able to detect an object thereat, and second motion detector 403 at second entry 106 such that second motion detector 403 is able to detect an object thereat (components 402 - 404 are shown in Fig. 4).

Sortation arrangement 500 further comprises a computer system 501 having at least one processor and memory. In one embodiment, rack controller 100, sorter control system 113, and/or put-to-light device 401 share computer system 501. In another embodiment rack controller 100, sorter control system 113, and/or put-to-light device 401 has its own processing capacity for performing tasks.

In one embodiment sortation arrangement 500 is configured to guide first item 108 into first storage place 102 indicating, by at least one light source 404, first storage place 102. Sortation arrangement 500 is further configured to detect by first motion detector 402 an object at the first entry and, in response to a signal from first motion detector 402, to determine that the object is first item 108. FIGURE 6 shows put-to-light device 401 having light-source-and-light-sensor pairs. In this implementation at least one light source 404 includes a first light source 601. A first light sensor 602 at first entry 105 represents first motion detector 402. First light source 601 and first light sensor 602 are located such that first light source 601 is able to form a first light beam 603 across first entry 105 towards first light sensor 602.

Let us assume that an employee is moving first item 108 towards first entry 105. When first item 108 is located at first entry 105 first light beam 603 hits to it and thus the light intensity in first light sensor 602 decreases below a predetermined level and first light sensor 602 signals “object detected”.

At least one light source 404 further includes a second light source 604. A second light sensor 605 at second entry 106 represents second motion detector 403. Second light source 604 and second light sensor 605 are located such that second light source 604 is able to form a second light beam across second entry 106 towards second light sensor 605. First light source 601 and second light source 604 are, for example, led lamps which are configured to emit colorful (red or green) light.

In addition to the implementation shown in Fig. 6, there are many other options to implement put-to-light device 401. These implementation options are described in details in AU2018101188. FIGURE 7 shows take-away line 112 and rack 104 having legs 701. In this example rack 104 includes altogether fifteen storage places, including first storage place 102 and second storage place 103. Put-to-light device 401 is compatible with rack 104 having legs 701. Therefore, put-to-light device 401 has as many motion detectors as there are storage places in rack 104 i.e. fifteen motion detectors, including first motion detector 402 and second motion detector 403. Put-to-light device 401 has legs 702, by which it is attached to a floor 703 besides take-away line 112. Rack 104 is placed by an automated guided vehicle (AGV) besides take-away line 112 and besides put-to-light device 401. A distance between rack 104 and put-to-light device 401 is short, for example, two cm.

Take-away line 112 has received the items from sorter line 111 remaining their mutual order. In Fig. 5 first item 108 was the first item addressed to the certain delivery area and second item 109 was the last item addressed to the certain delivery area. Therefore, in Fig. 7 first item 108 is on take-away line 112 the first one and second item 109 is the last item. The certain delivery area is such site to which rack 104 will be transported after the employee has placed the items from take-away line 112 into rack 104. A first end 704 of takeaway line 112 is located at, for example, eighty cm from a floor 703. Then an employee can easily pick up first item 108 locating on first end 704 of take-away line 112. A second end 705 of take-away line 112 is coupled to sorter line 111, and in this example, second end 705 is located higher from floor 703 than first end 704. The next item 706 from first item 108 is located on take-away line 112 between first item 108 and second item 109. Because rack 104 includes fifteen storage places, take-away line 112 should be long enough such that there is space for at least fifteen items. A pick up place 707 is such place on take-away line 112 from which the employee is expected to pick up an item and place it into rack 104. In this example pick up place 707 is located at first end 704 of take-away line 112, farthest from sorter line 111.

As mentioned in the above, sortation arrangement 500 comprises computer system 501 and at least computer system 501 is usable in the following operations for controlling put to-light device 401 and take-away line 112.

In response to receiving first item 108 onto pick up place 707 on take-away line 112, the sortation arrangement is configured to indicate by at least one light source 404 first storage place 102 in rack 104. Now, the employee is expected to pick up first item 108 and place it into first storage place 102, which will cause signaling from first motion detector 402.

In response to receiving a signal from first motion detector 402 locating at first entry 105 to first storage place 102, sortation arrangement 500 is configured to move by take-away line 112 the next item 706 to pick up place 707. Assuming that take-away line 112 includes rollers, moving of the next item 706 is performed by rotating the rollers.

In response to receiving the signal from first motion detector 402, sortation arrangement 500 further is configured indicate by at least one light source 404 second storage place 103 in rack 104. Now, the employee is expected to pick up the next item 706 and place it into second storage place 103. This causes signaling from second motion detector 403 etc. Finally, the employee is expected to place the last item, i.e. second item 109, into a storage place selected by sortation arrangement 500.

While the present invention has been described in connection with a number of exemplary embodiments, and implementations, the present invention is not so limited, but rather covers various modifications, and equivalent sorters, which fall within the purview of prospective claims.

Claims (5)

1. Claims

   1. A rack controller to a sorter to guide items into rack storage places including at least a first storage place and a second storage place in a rack, a first entry to the first storage place, and a second entry to the second storage place, the sorter comprising the following: an automated scanner to read bar codes from items, including at least a first item and a second item that are addressed to a certain delivery area, a dimensioning device to measure dimensions of items, a sorter line to sort items by delivery areas, a take-away line for the certain delivery area to receive items from the sorter line such that a mutual order of the items received remains the same as in the sorter line, and a sorter control system that is configured to receive bar code data from the automated scanner and item dimension data from the dimensioning device, wherein the rack controller is coupled to the sorter control system such that the rack controller has an access to bar code data and item dimension data, and the rack controller has rack data about dimensions of storage places in the rack, and by combining the bar code data, the item dimension data, and the rack data the rack controller has an ability to make a fill plan for items on the take-away line, the fill plan including at least placing the first item into the first storage place in the rack.
2. 2. The rack controller as claimed in claim 1, wherein the rack controller is further coupled to such robot arm at the take-away line that is able to fill the rack in accordance with the fill plan.
3. 3. The rack controller as claimed in claim 1, wherein the rack controller is further coupled to such put-to-light device at the take-away line that is able to guide an employee to fill the rack in accordance with the fill plan.
4. 4. The rack controller as claimed in claim 1, wherein the rack controller is further coupled to a put-to-light device comprising at least one light source to indicate the first storage place intended for the first item, a first motion detector at the first entry to the first storage place such that the first motion detector is able to detect an object thereat, and a second motion detector at the second entry to the second storage place such that the second motion detector is able to detect an object thereat.
5. 5. The rack controller as claimed in claim 1, wherein the rack controller is configured to receive a fill notification when the last item on the take-away line is handled.