CN113272836A - Systems and methods for separating objects using vacuum steering with one or more object handling systems - Google Patents
Systems and methods for separating objects using vacuum steering with one or more object handling systems Download PDFInfo
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- CN113272836A CN113272836A CN202080008347.4A CN202080008347A CN113272836A CN 113272836 A CN113272836 A CN 113272836A CN 202080008347 A CN202080008347 A CN 202080008347A CN 113272836 A CN113272836 A CN 113272836A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/74—Feeding, transfer, or discharging devices of particular kinds or types
- B65G47/82—Rotary or reciprocating members for direct action on articles or materials, e.g. pushers, rakes, shovels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/52—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices
- B65G47/525—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices using fluid jets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
- B65G1/02—Storage devices
- B65G1/04—Storage devices mechanical
- B65G1/137—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
- B65G1/1373—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses
- B65G1/1378—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses the orders being assembled on fixed commissioning areas remote from the storage areas
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
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- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Discharge Of Articles From Conveyors (AREA)
- Control Of Conveyors (AREA)
- Sorting Of Articles (AREA)
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Abstract
A dispensing system for use in an import system for use with an object handling system. The distribution system provides the dissimilar objects to one of the plurality of receiving units. The dispensing system includes an air intake system having an opening at a fixed distance from the conveyor section that assists in moving objects on the conveyor section from the conveyor section to one of the plurality of adjacent conveyor units.
Description
Priority
This application claims priority to U.S. provisional patent application serial No.62/789,775, filed on 8/1/2019; and this application claims priority to U.S. patent application serial No.16/661,820 filed on 23/10/2019, U.S. patent application No.16/661,820 claims priority to U.S. provisional patent application serial No.62/884,351 filed on 8/2019 and U.S. provisional patent application serial No.62/749,509 filed on 23/10/2018; and this application further claims priority from U.S. patent application serial No.16/543,105 filed on 16.8.2019, U.S. patent application No.16/543,105 is a continuation of U.S. patent application serial No.15/956,442 filed on 18.4.2018, U.S. patent application No.15/956,442 claims priority from U.S. provisional patent application serial No.62/486,783 filed on 18.4.2017, the disclosures of all of which are hereby incorporated by reference in their entireties.
Background
The present invention relates generally to automated (e.g., programmable motion) and other processing systems, and in particular to programmable motion (e.g., robotic) systems intended for use in environments requiring various objects (e.g., articles, packages, or packages) to be processed (e.g., sorted and/or otherwise distributed) to several output destinations.
Many object dispensing systems receive objects in an orderly or unordered stream, which may be provided as individual objects or aggregated into groups, such as in bags, that arrive on any of a number of different vehicles, typically conveyors (coveyors), trucks, pallets, garlors (gaylords), containers, or the like. Each object must then be distributed to the correct destination container, which is determined by the identification information associated with the object, typically determined by a label printed on the object. The destination container may take a variety of forms, such as a bag or a container or tote bag (tote).
The handling of such objects is conventionally done by a worker, for example, scanning the object with a hand-held bar code scanner and then placing the object at the assigned location. For example, many order fulfillment operations achieve high efficiency by employing a process known as wave picking. In wave picking, orders are picked from warehouse racks and placed at locations that house a plurality of orders sorted downstream (e.g., into a bin). In the processing stage, individual objects are identified and multiple object orders are consolidated, for example, into a single container or pallet location so that they can be packaged and then shipped to a customer. The handling (e.g., sorting) of these objects is traditionally done by hand. A human sorter picks up an object from an incoming bin, finds a bar code on the object, scans the bar code with a hand-held bar code scanner, determines a suitable bin or rack location for the item from the scanned bar code, and then places the item into the determined bin or rack location, wherein all objects for the order are defined as belonging to the bin or rack location. An automated system for order fulfillment is also presented. See, for example, U.S. patent application publication No.2014/0244026, which discloses a robotic arm and the use of an arch that is movable into reach of the robotic arm.
In conventional package sortation systems, a worker or automated system typically retrieves objects in order of arrival and sorts each object into a collection bin based on a given set of heuristics. For example, all objects of a similar type may go to one collection container, or all objects in a single customer order, or all objects destined for the same shipping destination, etc. Workers or automated systems are required to receive the objects and move each object to their assigned collection bin. If the number of different types of input (received) objects is large, a large number of collection bins are required.
Such systems have inherent inefficiencies and inflexibility as the desired goal is to match incoming objects to the assigned collection container. Such systems may require a large number of collection bins to some extent (and thus a large amount of physical space, large capital costs, and large operating costs), as it is not always most efficient to sort all objects at once to all destinations.
Some partially automated sorting systems involve the use of a recirculating conveyor and tilted trays, where the tilted trays receive objects by manual sorting (manual introduction) and each tilted tray moves past a scanner. Each object is then scanned and moved to a predefined position assigned to the object. The tray is then tilted to drop the object into position. Further, partially automated systems (such as bomb bay recirculation conveyors) involve having the trays open a door on the bottom of each tray when the tray is positioned over a predefined chute, and then objects fall from the tray into the chute. Again, the object is scanned while in the tray, assuming that any identification code is visible to the scanner.
Such partially automated systems are lacking in key areas. As mentioned above, these conveyors have discrete trays that can carry objects; they then pass through a scanning tunnel that scans the object and associates the object with the tray on which it is located. When the pallet passes the correct container, the trigger mechanism causes the pallet to dump the object into the container. However, such systems have the disadvantage that an actuator is required for each turn, which adds mechanical complexity, and the cost per turn can be very high.
An alternative is to use human labor to increase the number of turns or collection bins available in the system. This reduces system installation costs, but increases operational costs. Multiple units can then work in parallel, effectively linearly increasing throughput while keeping the number of expensive automation turns to a minimum. Such steering does not identify objects nor steer them to a particular location, but rather they work in conjunction with beam breaks or other sensors to try to ensure that an undifferentiated cluster of objects is properly steered. The lower cost of such steering combined with the small number of turns keeps the overall system steering cost low.
Unfortunately, these systems do not address the limitation on the total number of containers in the system. The system simply diverts (subvert) equal portions of all objects to each of the parallel manual units. Each parallel sorting unit must therefore have all the same collection bin assignments; otherwise the object may be delivered to a cell of the container to which no object is mapped. There remains a need for a more efficient and cost effective object sorting system that sorts objects of various sizes and weights into appropriate fixed size collection bins or trays, yet is efficient for handling such objects of different sizes and weights.
Furthermore, such systems require human personnel to supervise the introduction of objects, where the processing system may receive objects that it may not be able to manipulate effectively or at all.
Disclosure of Invention
According to one aspect, the present invention provides a dispensing system for use in an import system for use with an object handling system. The distribution system provides dissimilar objects to one of a plurality of receiving units. The dispensing system includes an air intake system having an opening at a fixed distance from the conveyor section, the air intake system assisting in moving objects on the conveyor section from the conveyor section to one of the plurality of adjacent conveyor units.
According to another aspect, the present invention provides a dispensing system for use in an import system for use with an object handling system. The distribution system provides dissimilar objects to one of a plurality of receiving units. The dispensing system includes an air transport system including a forced air system and an air intake system that together assist in moving objects on the conveyor section from the conveyor section to one of a plurality of adjacent conveyors.
According to a further aspect, the present invention provides a method of distributing dissimilar objects to one of a plurality of receiving units in a pre-processing system for use with an object handling system. The method includes providing an air transport system opposite an air intake system, and engaging the air transport system with the air intake system to assist in moving objects on the conveyor section from the conveyor section to one of a plurality of adjacent conveyors.
Drawings
The following description may be further understood with reference to the accompanying drawings, in which:
FIG. 1 shows an illustrative diagrammatic view of a processing system and an import system according to an embodiment of the invention;
FIG. 2 shows an illustrative diagrammatic view of an input station of the import system of FIG. 1;
3A-3D show illustrative diagrammatic views of stages of an object being moved by a sensing unit at the input station of FIG. 2;
4A-4D show illustrative diagrammatic side views of stages of an object moving in the input station of FIGS. 3A-3D;
FIG. 5 shows an illustrative diagrammatic bottom side view of the sensing unit of FIG. 1;
6A-6C show illustrative diagrammatic views of an object from the sensing unit of FIG. 5 employing imaging (FIG. 6A), edge detection (FIG. 6B), and volume scanning (FIG. 6C);
FIG. 7 shows an illustrative diagrammatic view of a tag including a specially processed word in accordance with an aspect of the system;
FIG. 8 shows an illustrative diagrammatic view of a labeled object in which the label includes special treatment image(s), in accordance with an aspect of the system;
FIG. 9 shows an illustrative diagrammatic view of a treatment system and an introduction system including a deformable object introduction limiting system in accordance with another embodiment of the invention;
10A-10C show illustrative diagrammatic side views of the object being processed in the deformable object introduction limiting system of FIG. 9;
FIG. 11 shows an illustrative diagrammatic view of a processing system and an import system that includes a programmable motion device at an input station in accordance with further embodiments of the present invention;
FIG. 12 shows an illustrative diagrammatic view of an input station of the system of FIG. 11;
FIG. 13 shows an illustrative diagrammatic view of the programmable motion device of the input station of FIGS. 11 and 12, including an additional optional engaged object sensing unit (not shown in FIGS. 11 and 12);
FIG. 14 shows an illustrative diagrammatic view of a grasped object with the additional optional engaged object sensing unit of FIG. 13;
FIG. 15 shows an illustrative diagrammatic view of the grasped object of FIG. 14 with a set of illumination sources and an engaged sensing unit in accordance with an aspect of the invention;
FIG. 16 shows an illustrative diagrammatic side view of the system of FIG. 14 showing two sets of sensing units;
FIG. 17 shows an illustrative diagrammatic side view of the system of FIG. 15 showing two sets of sensing units shown in FIG. 16;
FIG. 18 shows an illustrative diagrammatic view of a 3D scanner system used in accordance with another aspect of the invention;
FIG. 19 shows an illustrative diagrammatic view of a plurality of 3D scanner systems being used in accordance with a further aspect of the present invention;
FIG. 20 shows an illustrative diagrammatic view of a 3D scanning process of an end effector grasping an object;
fig. 21 shows an illustrative diagrammatic view of a net 3D scan of an object and a portion of an end effector that is grasping the object, showing a portion of the 3D scan of the end effector to be removed;
22A-22D show illustrative diagrammatic views of an object undergoing a deformability test in accordance with an aspect of the present invention;
FIG. 23 shows an illustrative diagrammatic view of an object handling system for use with a pre-processing system in accordance with an aspect of the present invention;
FIG. 24 shows an illustrative diagrammatic side view of the object handling system of FIG. 23;
FIG. 25 shows an illustrative diagrammatic rear view of the object handling system of FIG. 23;
FIG. 26 shows an illustrative diagrammatic view of a processing station in the object processing system of FIG. 23;
FIG. 27 shows an illustrative diagrammatic front view of the primary perception system in the object handling system of FIG. 23;
28A-28C show illustrative diagrammatic views of a turning station in the object handling system of FIG. 23 showing an object on a conveyor (FIG. 28A), engaged by a turning paddle (FIG. 28B), and discharged into a carriage (FIG. 28C);
FIG. 29 shows an illustrative diagrammatic view of a destination portion in the object handling system of FIG. 23;
FIG. 30 shows an illustrative diagrammatic view of the destination portion of FIG. 29 with the carriage moving along the track and discharging the object into the destination bin;
FIG. 31 shows an illustrative diagrammatic layout model view of an import system in accordance with an aspect of the subject invention;
FIG. 32 shows an illustrative diagrammatic layout model view of another import system showing a layout similar to that of the system of FIG. 9, in accordance with another aspect of the present invention;
FIG. 33 shows an illustrative graphical model view of an import system that includes a classification system, according to another aspect of the subject invention;
FIG. 34 shows an illustrative diagrammatic view of an import system and multiple processing systems in accordance with an embodiment of the invention;
FIG. 35 shows an illustrative diagrammatic view of an import system and multiple processing systems in accordance with another embodiment of the invention;
FIG. 36 shows an illustrative diagrammatic view of an import system and multiple processing systems in accordance with a further embodiment of the present invention;
FIG. 37 shows an illustrative diagrammatic view of a plurality of import systems and a plurality of processing systems in accordance with an embodiment of the present invention;
FIG. 38 shows an illustrative diagrammatic view of a plurality of different import systems and a plurality of processing systems in accordance with another embodiment of the present invention;
39A and 39B show illustrative diagrammatic views of a weight-sensing transmitter portion including a weight scale in accordance with an aspect of the present invention;
40A and 40B show illustrative diagrammatic views of a weight sensing transmitter portion including a load cell or force torque sensor in accordance with an aspect of the present invention;
41A-41D show illustrative diagrammatic views of a weight sensing conveyor section that further determines the center of mass of an object in accordance with an aspect of the present invention;
42A and 42B show illustrative diagrammatic views of a weight-sensing conveyor section including a plurality of scales in accordance with an aspect of the present invention;
43A-43C show illustrative diagrammatic views of a weight sensing transmitter portion including a plurality of rollers with either a load cell or a force torque sensor in accordance with an aspect of the present invention;
FIG. 44 shows an illustrative diagrammatic view of an end effector including any of a load cell or a force-torque sensor used in accordance with an aspect of the present invention;
FIG. 45 shows an illustrative diagrammatic view of an end effector, including a magnetic sensor, used in accordance with an aspect of the present invention;
FIG. 46 shows an illustrative diagrammatic view of an end effector including a vacuum flow and/or pressure sensor used in accordance with an aspect of the present invention;
FIG. 47 shows an illustrative diagrammatic view of a weight-sensing carriage used in accordance with an aspect of the present invention;
FIG. 48 shows an illustrative diagrammatic side view of the weight-sensing carriage of FIG. 47;
FIG. 49 shows an illustrative diagrammatic view of a lead-in system including a tilted conveyor having a conveyor portion including a bomb bay lift gate in accordance with an aspect of the invention;
FIGS. 50A and 50B show illustrative diagrammatic views of the conveyor portion of FIG. 49 above a horizontal conveyor in accordance with an aspect of the present invention;
FIGS. 51A and 51B show illustrative diagrammatic end views of the conveyor portion of FIGS. 50A and 50B;
FIGS. 52A and 52B show illustrative diagrammatic views of a conveyor section used in accordance with an aspect of the invention, including a bomb bay door above a further inclined conveyor;
FIG. 53 shows an illustrative diagrammatic view of a gas-permeable conveyor portion with a vacuum roll used in accordance with an aspect of the present invention;
FIG. 54 shows an illustrative diagrammatic view of a lead-in system including a gas-permeable conveyor portion and a vacuum roll in accordance with an aspect of the present invention;
55A-55D show illustrative diagrammatic side views of the air permeable conveyor portion and vacuum roll of FIG. 54 in a system that provides weight sorting;
FIG. 56 shows an illustrative diagrammatic view of an import system that includes a conveyor-to-conveyor transport station in accordance with an aspect of the present invention;
FIG. 57 shows an illustrative diagrammatic view of a gas permeable conveyor portion having a blower and a vacuum source used in accordance with an aspect of the present invention;
FIG. 58 shows an illustrative diagrammatic side view of the gas permeable conveyor portion, blower and vacuum of FIG. 57;
FIGS. 59A-59C show illustrative diagrammatic side views of the gas permeable conveyor portion, blower and vacuum of FIG. 57 for moving an object;
FIG. 60 shows an illustrative diagrammatic view of a gas permeable conveyor section with a side blower and a side vacuum source used in accordance with an aspect of the present invention;
FIG. 61 shows an illustrative diagrammatic view of a gas permeable conveyor section having a side blower and a side vacuum source and a bottom side blower source for use in accordance with an aspect of the present invention;
FIG. 62 shows an illustrative diagrammatic view of a conveyor section having a side blower and a side vacuum source used in accordance with an aspect of the present invention;
FIG. 63 shows an illustrative diagrammatic view of the conveyor portion of FIG. 62 with opposing chutes, side blowers and a side vacuum source used in accordance with an aspect of the present invention;
FIG. 64 shows an illustrative diagrammatic view of the conveyor section, side blower, side vacuum source and opposing chute of FIG. 63;
FIG. 65 shows an illustrative diagrammatic view of a conveyor section used in accordance with an aspect of the present invention, the conveyor section including a bidirectional roller and a pair of opposed chutes;
66A and 66B show illustrative diagrammatic views of a conveyor section used in accordance with an aspect of the present invention, the conveyor section including a bidirectional roller and a pair of opposed chutes with bomb bay doors;
FIG. 67 shows an illustrative diagrammatic view of a conveyor section used in accordance with an aspect of the present invention, the conveyor section including a side blower and a side vacuum source and a pair of opposed chutes having bomb bay doors;
FIGS. 68A and 68B show illustrative diagrammatic views of a conveyor section having side paddles and a pair of opposing chutes used in accordance with an aspect of the present invention;
FIG. 69 shows an illustrative diagrammatic view of a conveyor section having a side paddle and an opposing chute, one of which includes a bomb bay door, used in accordance with an aspect of the invention;
FIG. 70 shows an illustrative diagrammatic view of a plurality of processing systems used with the import system employing manual and automated processing stations as disclosed with reference to FIGS. 1, 9, 11, 34-38, 49, 54, 56, and 63-69;
FIG. 71 shows an illustrative diagrammatic view of an object handling system for use with a lead-in system employing an automated carrier and automated processing station as disclosed with reference to FIGS. 63-69;
FIG. 72 shows an illustrative diagrammatic view of an object handling system for use with an import system employing an automated carrier and manual processing station as disclosed with reference to FIGS. 63-69; and
FIG. 73 shows an illustrative diagrammatic view of an object handling system for use with an import system that employs an automation carrier as disclosed with reference to FIGS. 63-69, the import system including both manual and automated processing stations;
the drawings are shown for illustrative purposes only.
Detailed Description
According to one embodiment, the present invention provides an import filter system in which objects (e.g., packages) are shielded and restricted from entering an object handling system. According to certain aspects of the invention, only objects that meet the defined criteria may be processed by the object handling system. The import filter system includes at least one evaluation system and a plurality of processing paths, at least one of which leads to an object processing system according to some aspects of the invention.
Automated package sorting systems need to be able to singulate and sort individual packages in order to route them to a particular destination. Some package sortation systems use robotic pick systems to manipulate packages. The robot takes a grip on the package, separates the package from a stack of other packages to a position where the package can then be scanned and sends the package to a sorting location. Such automated package handling systems inevitably encounter packages that are not handled, e.g., packages that exceed the packaging specifications of the system. For example, robots or grippers can only pick up items within weight specifications. Thus, items that it cannot handle may include items that are too light or too heavy, too large or too small, or that otherwise cannot be handled by the system.
These incompatible packages may clog the system. If they are too large, they may get stuck on the conveyor system while passing through the robotic package sortation system, thereby preventing other packages from flowing past. Incompatible packaging can also reduce the effective throughput of the sorting system. If they do pass and are presented to the robotic pick system in a stack, the robot may attempt to pick incompatible packages. If the package exceeds the specifications of the system, the resulting grip on the object may be insufficient to safely transport the goods, the robot may drop the package and may damage the package. Alternatively, if it were able to successfully pick and transport packages, in doing so it may somehow damage the robotic pick system while forcefully moving out-of-specification packages.
Compatible packaging specifications may include: effective package weight range, compatible package size range, a set of effective label types (e.g., whether printed or stickers are used), exclusion of items marked as fragile items, exclusion of items marked as insured high value and therefore preferably sorted more carefully by hand, exclusion of items marked as containing hazardous materials (such as lithium ion batteries), and exclusion of packages that may be marked in the database as requiring exception or manual handling for any other reason. It would be desirable to provide a system that filters out incompatible packages before they reach a package handling system and/or improves the ability of the package handling system to specifically identify incompatible packages so that robotic pick up is not attempted on objects that require manual manipulation.
According to an embodiment, the present invention provides an import system that restricts and manages import of an object to an object handling system. In certain aspects, the system provides methods to automatically reroute incompatible packages before they reach a package sorting system comprised of one or more robotic pickers, or to minimize the impact of them if they reach a robotic pick area.
For example, FIG. 1 shows an import system 10 that filters (e.g., limits or manages) objects being fed to an object handling system 12. The import system 10 includes an input station 14 to which the objects are presented, for example, in the form of a single stream on a conveyor 22. Any of the conveyors of the systems of fig. 1, 9, 11, 23, 34-38, 49, 56, and 70 may be cleated or unbooked and the system may monitor the movement of the conveyors (and thus the objects thereon) via a plurality of sensors and/or a conveyor speed control system. The response assessment portion 16 of the conveyor 22 includes one or more sets of transport rollers 30 and one or more disturbance rollers 32, as shown in FIG. 2. With further reference to fig. 3A-3D, a sensing unit (e.g., camera or scanner) 18 is oriented horizontally toward the conveyor portion 16 and a sensing unit (e.g., camera or scanner) 20 is oriented downward toward the conveyor portion 16.
Referring to fig. 4A-4D, as an object travels along transport rollers 30, the object will contact dancer rollers 32 (as shown in fig. 4B). The dancer roller(s) 32 may be any of the larger diameter rollers or may be elevated relative to the transfer roller 30 and may rotate at a faster rotational speed than the transfer roller 30. In this manner, and using the sensing units 18, 20, the system may determine (along with the computer processing system 100) a wide variety of characteristics of the object 34. For example, the roller 32 may be mounted on a force-torque sensor (as discussed further below with reference to fig. 40A-42C), and the system may determine the estimated weight when it is determined (using the sensing unit 18) that the object 34 is balanced on the roller 32. The roller(s) 32 on the force-torque sensor can thus be used to determine the weight of the object as it passes over the roller(s).
Further, if the roller(s) 32 rotate at a faster rotational speed, the system may determine the inertial value of the object 34 as the roller(s) engage and disengage the object from the roller(s). A variety of further characteristics may also be determined or estimated, such as, for example, using the roller(s) in conjunction with the sensing unit to determine or estimate the center of mass (COM), as discussed herein and further below. The system may further use the sensing unit and roller(s) 32 (along with the computer processing system 100) to determine whether the object is a collapsible bag by observing whether the object separates and/or changes shape as it moves over the roller(s) 32, and/or again use the sensing unit(s) and roller(s) 32 to determine whether the assumed object 34 is actually a multi-pick (including multiple objects). According to a further aspect of the invention, the transport rollers 30 may be replaced by conveyor sections located below the level of the dancer rollers 32.
The import system 10 can further include a multi-purpose sensing unit 24 located above (higher than) the conveyor 22 for viewing objects 27 as shown in fig. 1. The sensing unit 24 includes a light 74 and one or more sensing units 76 (e.g., scanners or cameras) for detecting any identifying indicia (e.g., bar codes, QR codes, RFID, tags, etc.) on the objects on the conveyor 22.
The sensing unit 24 also includes scanning and receiving units 80, 82, and an edge detection unit 84 for capturing various characteristics of selected objects on the conveyor 22. Fig. 6A shows a view from the capture system and knowing the recorded volume of the view of the empty conveyor 22, the volume V of the object 27 can be estimated27. In particular, as shown in FIG. 6C, the object 27 is scanned volumetrically. The volume is compared with the recorded data or recorded object data about the item identified by the identification tag provided by the sensing unit 18, 20.
According to a further aspect of the invention, the system may additionally employ an edge detection sensor 84, the edge detection sensor 84 (again with the processing system 100) being used to detect an edge of any object in the cargo box, e.g., using data regarding any of intensity, shadow detection, or echo detection, etc., and may be used to determine any of a size, shape, and/or contour, for example, as shown in fig. 6B.
The volume scan may be performed using a scanning unit 80 and a receiving unit 82 (together with the processing system 100 shown in fig. 1), the scanning unit 80 and the receiving unit 82 sending and receiving signals (e.g., infrared signals). Referring to fig. 6C, the volumetric data may be acquired, for example, using any of a light detection and ranging (LIDAR) scanner, a pulsed time-of-flight camera, a continuous wave time-of-flight camera, a structured light camera, or a passive stereo camera.
39A-43C, the weight of the object may also be determined using the weight-sensing conveyor portion. For example, the weight-sensing conveyor portion 55 of fig. 1 may be used to determine the weight of the object 8 (again, as discussed below). As the object is fed through the input station, the object will pass through the response assessment portion 16 and the multi-purpose sensing unit 24 (e.g., object 28), and may then be assessed by the weight-sensing conveyor portion.
Referring again to fig. 1, the import system 10 can provide the unidentified objects (and objects identified as unsuitable for processing) 36 through the conveyor 35 to the exception bin 50. If an object (e.g., 40, 42) is identified as being suitable for processing, the object is diverted by the multi-directional conveyor 33 toward the conveyor 38. Conveyor 38 may direct the object(s) toward in-feed conveyor 46 via multi-directional conveyor 44, or the system may determine that the object (e.g., object 49) should be directed along conveyor 48 toward any of the additional processing stations (e.g., similar to processing station 12 but capable of handling different types of objects). For example, as discussed in more detail below, the system may employ multiple processing stations, each capable of manipulating a different object (such as an object of a different size or weight range).
According to yet a further aspect of the present invention, the system may employ Optical Character Recognition (OCR) to read the tags and detect, for example, trigger words such as "paint" or "danger not? : is "or" frangible "as shown at 110 in fig. 7. In a further aspect, the system may identify images, such as the trigger image shown at 112 in fig. 8, indicating that the contents are flammable, are required to remain upright, or are otherwise dangerous or require special handling, making such contents unsuitable for processing by object processing system 12. Using such a process allows for the detection of objects that are incompatible with the processing system due to their contents indicated by the trigger marks on the external tag. This may involve reading the tag as described above and not picking up the object or moving the object to an exception handling area, or may involve simply identifying the object. For example, if the system includes a database of objects, the system may identify a tag (such as a bar code) and then look for information about the scanned code (such as the object containing hazardous materials or otherwise requiring special handling). In this case, the system routes the object towards the abnormal area.
Fig. 9 shows an introduction system 11 that can provide selected objects to an object handling system 12. The import system 11 includes an input station 14 as discussed above with reference to fig. 1-8, the input station 14 including a conveyor 22 (with a response assessment portion 16 including transport rollers 30, disturbance rollers 32, and sensing units 18, 20), and a multi-purpose sensing unit 24, and a weighing conveyor 55 for assessing objects 34, 27, 28, and 29 as discussed above. Again, the system may determine which of the feed objects is provided as a bag, for example, by observing the objects as they pass over the disturbance roller(s) using the sensing unit(s), and in particular, observing the rate or amount of change of the speed and/or shape of the objects as they are processed.
In the import system of fig. 9, as each object reaches the infeed multi-directional routing conveyor 132, it is subjected to any one of the following: to the out-of-spec conveyor 134 (e.g., object 136), to the in-spec conveyor 138 (e.g., object 140, 142), or to the bag-handling conveyor 144 (e.g., object 146, 151, 153). When the object is provided as a bag (e.g., a shipping bag made of polyethylene), determining the dimensions or other handling parameters of the object may be more difficult. If the object is identified as a bag (or other flexible, malleable object), such object (again, e.g., 146, 148, 151, 153) is diverted to a bag handling system.
In particular, the conveyor 144 leads to a deformable object introduction limiting system 194, which deformable object introduction limiting system 194 includes a programmable motion device, such as an articulated arm 192 having an end effector 193, which end effector 193 has a load cell or force torque sensor 195 (shown in fig. 10A-10C). In particular, the system will move the end effector 193, wherein the object 191 is brought into contact with the opening formed by the sloped wall 133. If the load cell or force-torque sensor 195 detects an excessive force (above the sensor threshold) when the object contacts the sloped wall 133, the system may reject the object for processing. The object will then be placed on a conveyor 196 connected to the conveyor 134 to provide access to an area of the object not being processed by the system 12, such as, for example, a collection bin or a manual processing station. Thus, the system may limit acceptance of objects that are deformable but still too rigid for processing by the system 12. The load cell or force torque sensor 135 may also be disposed on the sloped wall as shown at 133 (without the use of the load cell or force torque sensor 195 or in conjunction with the use of the load cell or force torque sensor 195) or at the base of the sloped wall as shown at 135. On the other hand, if the movement of object 191 into the opening provided by inclined wall 133 does not trigger any load cells or force-torque sensors above the threshold, the system may move object 191 to conveyor 198 leading to processing system 12.
If the object 191 is determined to be not sufficiently flexible for processing by the object handling system 12 (referring again to FIG. 9), the object may be placed onto the off-spec conveyor 196 by the articulated arm 192 (the off-spec conveyor 196 may be connected to the conveyor 134). If the object 191 is determined to be sufficiently flexible for processing by an object handling system (or another system coupled thereto as discussed in more detail below), the object 191 is placed by an articulated arm 192 onto a conveyor 198 leading to the bi-directional conveyor 45. The object is directed towards the conveyor 19 if the object is to be processed by the object handling system 12, and the object (e.g. 43) is directed towards the further conveyor 47 if the object is to be processed by the further object handling system (as discussed below, for example, with reference to fig. 36). Again, this operation is controlled by one or more computer processing systems 200.
For example, FIG. 11 illustrates a further import system 13, according to an embodiment of the present invention, that import system 13 restricts or manages the packaging that is fed to the object handling system 12. The import system 13 includes an input station 114, and the input station 114 includes import input programmable motion devices, such as an articulated arm 116 and an end effector 118 (shown in fig. 12 and 13), that are designed to be able to grasp and move a wide variety of objects. In particular, the articulated arm 116 may be designed to grasp and move objects that are, for example, too large or too heavy to be manipulated by the processing system 12, as well as objects designed to be manipulated by the processing system 12. The objects (either individually or in a container 120) are provided to the articulated arm 116 on an in-feed conveyor 122. Any of a variety of detection units 117 may also be positioned around the end effector 118 of the articulated arm 116 and oriented toward the end effector 118, as discussed further below.
For example, the input system may determine which of the feed objects to provide as a bag by viewing the objects as they are held by the end effector 118, as discussed further below with reference to fig. 22A-22D. In the import system of fig. 11, as each object (e.g., object 128 on conveyor 130 or object 129 on weight-sensing conveyor section 155) arrives at in-feed multi-directional routing conveyor 132, the object is subjected to any of the following: to the out-of-spec conveyor 134 (e.g., object 136), to the in-spec conveyor 138 (e.g., object 140, 142), or to the bag-handling conveyor 144 (e.g., object 146, 151, 153), as discussed above with reference to fig. 9. When the object is provided as a bag (e.g., a shipping bag made of polyethylene), determining the dimensions or other handling parameters of the object may be more difficult. If the object is identified as a bag (or other flexible, malleable object), such object (again, e.g., 146, 148, 151, 153) is diverted to a bag handling system.
Again, the conveyor 144 leads to a deformable object introduction limiting system 194, which deformable object introduction limiting system 194 includes a programmable motion device, such as an articulated arm 192 having an end effector with a load cell or force torque sensor (as discussed above with reference to FIGS. 10A-10C). The system will move the end effector wherein the object is brought into contact with the opening formed by the sloped wall. If the load cell or force-torque sensor detects an excessive force (above the sensor threshold) when the object contacts the sloped wall, the system may reject the object for processing. The object will then be placed on the conveyor 196 connected to the conveyor 134 to provide access to areas of the object not being processed by the system 12. Again, the conveyor 134 may lead, for example, to a collection bin or a manual handling station. Thus, the system may limit acceptance of objects that are deformable but still too rigid for processing by the system 12. The load cell or force torque sensor may also be arranged on the slanted wall (without or in conjunction with the use of the load cell or force torque sensor 195) or at the base of the slanted wall. On the other hand, if the movement of the object into the opening provided by the sloped wall does not trigger any load cells or force-torque sensors above the threshold, the system may move the object to a conveyor 198 leading to the processing system 12.
If the object is determined to be not sufficiently flexible for processing by the object handling system 12, the object may be placed onto the off-spec conveyor 196 by the articulated arm 192 (again, the conveyor 196 may be connected to the conveyor 134). If the object is determined to be sufficiently flexible for processing by the object handling system (or another system coupled thereto as discussed in more detail below), the object is placed by the articulated arm 192 onto a conveyor 198 leading to the bi-directional conveyor 59. If the object is to be processed by the object handling system 12, the object is directed towards the conveyor 51, and if the object is to be processed by a further object handling system (as discussed below, for example, with reference to fig. 37), the object (e.g., 53) is directed towards a further conveyor 57. Again, this operation is controlled by one or more computer processing systems 200.
Referring to fig. 12 and 13, the perception system 124 captures perception data about objects below the perception system 124 (whether or not in the cargo box 120). The object 128 is identified by the perception system 124 and then grabbed and placed on the routing conveyor 130. The empty containers 120 are routed along an empty container conveyor 126. Note the placement of the objects on the conveyor 130 (and again each of the conveyors may also be a cleated conveyor). Referring to fig. 11, as each object reaches the feed diverter 132, the object is subjected to any one of the following: to the out-of-spec conveyor 134 (e.g., object 136), to the in-spec conveyor 138 (e.g., object 140, 142), or to the bag-handling conveyor 144 (e.g., object 146, 148, 151, 153). The conveyor 130 may also include a weight-sensing conveyor portion 155 for determining the weight of the object 129, as discussed below with reference to fig. 39A-43C. The end effector 118 may further include a force torque sensor 154 and/or an internal air pressure and/or air flow sensor as discussed further below with reference to fig. 46, the force torque sensor 154 being used to determine the weight of an object held by the end effector 118, as discussed further below with reference to fig. 44 and 45.
Again, determining the dimensions and handling parameters of the object may be more difficult when the object is provided as a bag (e.g., a shipping bag made of, for example, polyethylene). If the object is identified as a bag (or other flexible, malleable object), such object(s) (again, e.g., 146, 148, 151, 153) are diverted to a bag handling system, as discussed further above. The end effector 118 may also include a load cell or force-torque sensor 154 (as discussed in more detail below with reference to fig. 44 and 45) for determining the weight of the object being gripped, and in a further aspect, the conveyor 30 may include a weighing section 155 (again, as discussed below with reference to fig. 39A-43C), at which weighing section 155 each object may be weighed.
According to a further aspect, the system may estimate the volume of the object while the object is held by the end effector. In particular, the system may estimate a volume of the picked item while the picked item is held by the gripper and compare the estimated volume to a known volume. One approach is to estimate the volume of one or more items while the gripper is holding the object 197 (or multiple objects). Referring to fig. 14 and 15, in such a system 150, one or more sensing units 152, 154, 156, 158 (e.g., cameras or 3D scanners) are placed around the scanning volume. With further reference to fig. 16 and 17, across each sensing element are illumination sources 162, 164, 166, 168 and a diffusing screen 172, 174, 176, 178 in front of each illumination source.
As shown in fig. 17, perception data about an object 197 backlit by an illumination source (e.g., 168) and a diffuser (e.g., 178) will be captured by each perception unit (e.g., 158). According to various aspects, three sensing units one hundred twenty degrees apart may be used, and according to further aspects, fewer sensing units (e.g., one or two) may be used, and the object may be rotated between data acquisition captures.
The scanned volume may be a volume above an area from which items are picked; or the scan volume may be strategically placed between the pick-up and placement locations to minimize travel time. Within the scan volume, the system takes a snapshot of the volume of the item held by the holder. As discussed above, the volume may be estimated in a variety of ways depending on the sensor type.
For example, if the sensors are cameras, two or more cameras may be placed in a ring around the volume and directed slightly upwards towards a backlight screen (as discussed above), possibly in the shape of a section of a ring, with the sandwiched volume held between all cameras and a brightly illuminated white screen. The brightly illuminated screen backlight illuminates one or more held objects so that the interior volume is black. Each sensing unit and associated illumination source may be activated in sequence such that no two illumination sources are turned on simultaneously. This allows for easy segmentation of the retained volume in the image.
The illumination may be provided as a specific wavelength not present in the room or the illumination may be modulated and the detector may demodulate the received perception data such that only illumination from the associated source is provided. The black region, once back projected into space, becomes a frustum of a cone (frustum), and the object is known to be located within the frustum of a solid. Each camera generates a separate frustum with the property that the volume of the item is a subset of all the frustums. The intersection of all frustums yields an upper limit on the volume of the object(s). The addition of cameras improves the accuracy of the volume estimation. The gripper may be visible within the camera and since the position of the gripper is known, the volume of the gripper may be subtracted from the frustum or volume estimate.
According to other aspects, a 3D scanner that acquires a 3D image of the scanned volume may be used, and then the volume estimate is obtained in a similar manner by fusing together the point clouds received from each sensor, but without the need to segment the image from the background using backlighting. Each 3D scanner returns a 3D image, returns depth for each pixel in the image, and again any of a light detection and ranging (LIDAR) scanner, a pulsed time-of-flight camera, a continuous wave time-of-flight camera, a structured light camera, or a passive stereo camera, etc. may be used.
For example, fig. 18 shows a 3D scanner 182 projecting a grid 188 onto the field of view. The 3D scanner 182 may be used in the system 180 shown in fig. 19 with one, two, or three other 3D scanners (two more shown at 184, 186). The 3D scanner is oriented toward a common volume in which the object 197 is positioned while attached to the end effector 118. Again, with three such 3D scanners, the scanners can be positioned one hundred twenty degrees apart (ninety degrees apart if four are used; opposite each other if only two are used). Referring to fig. 20 and 21, each 3D scanner (e.g., 182) captures 3D data about an object 197. Again, the volume of the end effector may be removed from the captured data.
According to a further aspect, the system may detect a change in the shape of the object as the object is jostled. This may be done when the object is first lifted (e.g., at the input station 114 in fig. 11 and/or at the deformable object introduction limiting system 194 in fig. 9 and 11). Referring to fig. 22A-22D, when an object (e.g., 145) is lifted from the container or conveyor by the end effector 118, the object 145 may be held as shown in fig. 22B and then subjected to a rapid shaking motion as shown in fig. 22C and 22D. If the shape of the object changes (by more than, for example, 2%, 5%, or 10%), the object may be classified as a deformable object, such as a polyethylene shipping bag. The scanning may be performed by any of the volume scanning, edge detection, LIDAR and camera image analysis systems discussed above. If the object is determined to be a deformable object, the object is routed to the conveyor 44 as discussed above.
Again, the conveyor 144 leads to a deformable object introduction limiting system 194. The deformable object introduction limiting system 194 comprises a programmable motion device, such as an articulated arm 192 having an end effector 193, the end effector 193 having a load cell or force torque sensor 195 (shown in fig. 10A-10C). In particular, the system will move the end effector 193 where the object is brought into contact with the opening formed by the sloped wall 133. If the load cell or force-torque sensor 195 detects an excessive force (above the sensor threshold) when the object contacts the sloped wall 133, the system may reject the object for processing. The object will then be placed on the conveyor 196 connected to the conveyor 134 to provide access to areas of the object not being processed by the system 12. Thus, the system may limit acceptance of objects that are deformable but still too rigid for processing by the system 12. The load cell or force torque sensor may also be disposed on the sloped wall as shown at 133 (without or in conjunction with the use of the load cell or force torque sensor 195) or at the base of the sloped wall as shown at 135. On the other hand, if the object 145 moves into the opening provided by the sloped wall 133 without triggering any load cells or force-torque sensors above the threshold, the system may move the object 145 to a conveyor 198 leading to the processing system 12.
For example, the processing system 12 may include an infeed area 201, and the objects may be provided by a processing infeed conveyor (e.g., 46, 19, 51) into the infeed area 201. An in-feed conveyor 202 conveys objects from the in-feed area 201 to an intermediate conveyor 204 at a processing station 206. The in-feed conveyor 202 may include cleats for assisting in lifting objects from the input area 200 to the intermediate conveyor 204.
The processing station 206 also includes a grasp perception system 208, the grasp perception system 208 viewing the object on the intermediate conveyor 204 and identifying a grasp location on the object as further shown in fig. 23. The processing station 206 also includes a programmable motion device 210 (such as an articulated arm) and a primary sensing system 212 (such as a drop sensing unit). The grasp perception system 212 looks at the object to identify the object when possible and determines a good grasp point. The object is then grabbed by device 210 and dropped into drop perception system 212 to ensure that the object is accurately identified. The object then falls through primary perception system 212 onto primary transport system 214 (e.g., conveyor). Primary transport system 214 payloads pass one or more diverters 216, 218, which one or more diverters 216, 218 may be engaged to divert objects from primary transport system 214 into any of carriages 220, 222, 224 (when the respective carriage is aligned with the diverter) or into input area 200. Each of the carriages 220, 222, 224 may reciprocate along a track running between rows of destination stations 226 of the shuttle portion 228 (as discussed in more detail below).
The flow of objects is diagrammatically shown in fig. 24, which shows the objects moving from an infeed area 201 to an intermediate conveyor 204. The programmable motion device 210 drops the object into the drop perception unit 212 and the object lands on the primary transport system 214. The objects are then conveyed by the primary transport system 214 to a diverter that selectively diverts the objects to a carriage (e.g., 220, 222, 224). The carriage carries the object to one of a plurality of destination stations 226 (e.g., a process cartridge or a process bin) and drops the object into the appropriate destination station. When the destination station is full or otherwise completed, the destination station is moved to the output conveyor.
Fig. 25 illustrates a rear view of the system of fig. 23, more clearly showing the programmable motion device and the drop perception system. The primary transport system 214 may be a cleated conveyor and the objects may fall onto the cleated conveyor such that each cleated section provides one object. The speed of the conveyors 202 and 214 may also be controlled to assist in providing a single stream of objects to the diverters 216, 218. The system may operate using a computer process control system 200, the computer process control system 200 in communication with a conveyor control system, a sensing unit, a programmable motion device, a diverter, a cassette or container removal system, and any and all sensors that may be provided in the system.
Referring to fig. 26, the processing station 206 includes a grasping and sensing system 208 mounted above the intermediate conveyor 204, the intermediate conveyor 204 providing the object to be processed. For example, the grabbing sensing system 20 may (on its underside) include a camera, a depth sensor and a light. A combination of 2D and 3D (depth) data is acquired. The depth sensor 74 may provide depth information that may be used with the camera image data to determine depth information about various objects in the view. The lights may be used to remove shadows and facilitate identification of object edges, and may be turned on all together during use, or may be illuminated according to a desired sequence to assist in object identification. The system uses these images and various algorithms to generate a set of candidate grasp locations for the object in the container, as discussed in more detail below.
The programmable motion device 210 may include a robotic arm equipped with sensors and computing, which when assumed incorporated herein, exhibits the following capabilities: (a) it can pick up objects from a single stream of objects using, for example, an end effector; (b) it can move an object to any position within its working area; and (c) it can generate a map of objects that can be picked up, represented as a candidate set of grasp points in the work cell, and a list of polyhedrons that spatially encapsulate the objects. The allowable objects are determined by the capabilities of the robotic system. Their size, weight and geometry are assumed to enable the robotic system to pick up, move and place them. These may be any kind of ordered goods, packages, parcels or other items that benefit from automated handling.
The correct processing destination is determined by the symbol (e.g., bar code) on the object. It is assumed that the object should be marked with visually unique indicia, such as a bar code or Radio Frequency Identification (RFID) tag, at one or more locations on its exterior so that they can be identified with a scanner. The type of indicia depends on the type of scanning system used, but may include 1D or 2D bar code symbology. A number of symbologies or labeling methods may be employed. The type of scanner employed is assumed to be compatible with the labeling method. The string of symbols, which is typically a string of letters and numbers that identify an object, is encoded by a bar code, RFID tag, or other means of marking.
Once grasped, the object may be moved by the programmable motion device 210 to a primary perception system 212 (such as a drop scanner). The object may even fall into the perception system 212. In a further aspect, if a substantially single stream of objects is provided on the intermediate conveyor 204, the programmable motion device can be provided as a diverter (e.g., a push-pull rod) that diverts objects from the intermediate conveyor to the drop scanner. Additionally, the speed and direction of movement of the intermediate conveyor 204 (as well as the movement and speed of the in-feed conveyor 202) may be controlled to further facilitate providing a single stream of objects on the intermediate conveyor 204 adjacent to the drop scanner.
As further shown in fig. 27, the primary sensing system 212 may include a structure 234 having a top opening 236 and a bottom opening 238, and may be covered by an encapsulating material 240. The structure 234 includes a plurality of sources (e.g., illumination sources such as LEDs) 242 and a plurality of image sensing units (e.g., cameras) 244. The sources 242 may be provided in various arrangements, and each may be oriented toward the center of the opening. The sensing unit 244 is also generally oriented towards the opening, although some cameras are oriented horizontally, while others are oriented upwards, and some are oriented downwards. The system 212 also includes an entry source (e.g., infrared source) 246 and an entry detector (e.g., infrared detector) 247 for detecting when an object enters the perception system 212. Thus, the LEDs and camera surround the interior of the structure 234, and the camera is positioned to view the interior via a window that may include a glass or plastic cover (e.g., 248).
According to certain aspects, the present invention provides the ability to be identified via a bar code or other visual indicia of an object by employing a perception system into which the object may be dropped. The automated scanning system will not be able to see the barcode on the object presented in an unexposed or invisible manner. Thus, the system 212 is designed to view the object from a large number of different views very quickly, thereby reducing or eliminating the possibility that the system 212 cannot view the identifying indicia on the object.
After detection by the sensing unit 212, the object is now positively identified and falls on the primary transport system 214 (e.g., conveyor). Referring again to fig. 23 and 25, the primary transport system 214 moves the identified object toward the diverters 216, 218, or (if the object cannot be identified), the object may return to the input area 200 or may drop from the end of the conveyor 214 into a manual processing bin, which diverters 216, 218 are selectively engageable to divert the object from the conveyor to any of the carriages 220, 222, 224. Each of the carriers 220, 224, 226 is reciprocally moveable between destination containers 230 of one of a plurality of destination portions 228. According to certain aspects, space efficiency may be provided by first moving objects from the input area 201 along the in-feed conveyor 202 in the direction of a horizontal component and a vertical component. Then, the object falls through the drop scanner 212 (vertically) and lands on the primary transport conveyor 214, the primary transport conveyor 214 also moving the object in a direction having a horizontal component (opposite to the direction of the in-feed conveyor 202) and a vertical component. The object is then moved horizontally by the carriages 220, 222, 224 and dropped (vertically) above a target destination station 230, such as a destination container.
Referring to fig. 28A-28C, a diverter unit (e.g., 216) can be actuated to push an object (e.g., 250) from the conveyor 214 into a selected carriage (e.g., 220) traveling along a track 221 between destination locations (stations) 230. The diverter unit may include a pair of paddles 223 suspended by a frame 225, the frame 225 providing linearly actuatable paddles to move the object 250 out of the conveyor in either direction transverse to the conveyor. Again, referring to fig. 18, one direction for the diversion of diverter 216 is to return the object to feed area 201.
The system of various embodiments provides a number of advantages due to the inherent dynamic flexibility. The flexible correspondence between sorter outputs and destinations provides that sorter outputs may be fewer than destinations, and thus the overall system may require less space. The flexible correspondence between sorter outputs and destinations also provides that the system can select the most efficient order in which to manipulate the objects in a manner that varies with the particular mix and downstream requirements of the objects. By adding sorters, the system may also be easily scalable and more robust, as a failure of a single sorter may be dynamically handled even without stopping the system. It should be possible for sorters to prioritize objects that need to be quickly manipulated, or objects for which a given sorter may have a dedicated gripper, in terms of sequential contact decisions for the objects.
Fig. 29 shows a destination portion (e.g., such as any of the portions 228 of the system 12) that includes a movable carriage (e.g., 220) that can receive an object 252 from an end effector of a programmable motion device. The movable carriage 220 is reciprocally movable along the guide rails 221 between two rows of destination containers 230. As shown in fig. 29, each destination container 230 includes a guide chute that guides objects dropped therein into the underlying destination container 230. The carriage 220 moves along the track 221 and the carriage can be actuated to drop the object 252 into the desired destination container 230 via the guide chute (as shown in fig. 30).
Thus, the movable pallet may be moved back and forth between destination containers, and the/each pallet moves along the track and may be actuated to drop an object (e.g. 252) into the desired destination container. In certain aspects, the carrier (e.g., 220) may include a sensor (e.g., a transmitter and receiver pair 260 and/or 262) that may be used to confirm that the carrier has received an object or that the carrier has unloaded an object. In a further aspect, the carriage may be mounted to the rail mount via a load cell 264 such that the weight within the carriage may be determined from the load cell output sensor data, as discussed further below with reference to fig. 47 and 48. Knowledge of the weight within the pallet can be used to confirm that the pallet has received an object and that the pallet has unloaded the object. The knowledge of the weight may also confirm that the object in the carrier is indeed the object in the carrier that the system expects (where the system includes previously recorded data regarding the weight of each object).
According to one aspect, the present invention provides an automated material handling system that is partially tasked with routing objects carried in containers to a station where the objects are transported from one container to another container at an automated station using one or more programmable motion devices (such as articulated arms), and that may further include a manual station. The object may be provided in a container, which may be a container, tote bag, box, or the like. The overall goal of the system may be to sort and ship goods, perform order fulfillment, replenish storage inventory, or provide any general system that requires the transport of individual objects from one container to a processing system.
The object may be a package, box, flat item or plastic bag etc. in a shipping center, or a consumer product in an e-commerce order fulfillment center, or a product and warehouse packaging in a retail Distribution Center (DC). The transfer of the object or the container of objects may take many forms, including a belt or roller conveyor, a chute, a mobile robot, or a human worker. The pick-up station for transporting goods may be an automated system comprising a robotic system, or a station operated by a human being.
Fig. 31 shows a diagrammatic view of an introduction limiting system 300, the introduction limiting system 300 including an in-feed conveyor 302 leading to a classification system 304. Once classified by classification system 304, the object is directed toward routing system 306, and routing system 306 routes the object to one of a plurality of directions as shown at 308, 310, 312. For example, a model similar to the system shown in FIG. 11 is shown in FIG. 32. The system 320 of fig. 32 includes an in-feed conveyor 322 that directs objects to a sorting system 324. The sorting system 324, in conjunction with one or more of the computer processing systems 100, 200 and databases therein or coupled thereto, directs objects toward the routing system 330 (via the conveyor 328) and directs empty containers along the container outbound conveyor 326. The routing system 330 directs the object in one of three different directions. Objects accepted for processing are directed along conveyor 332 for processing by object processing system 334. Objects outside of the system specifications for processing are directed along the non-processable object conveyor 344 for processing by systems or methods other than the processing system 334. Certain objects that do not fall directly into either classification (e.g., objects provided in polyethylene bags) are provided to a bag handler 338 via a bag handling conveyor 336. At the bag handler 338, the objects are subjected to testing and, depending on the results, directed either toward the object handler 334 via handler 340 or toward the non-processable object station via conveyor 342.
The system of the present invention may be used in a wide variety of routing system applications. For example, the import restriction system of the present invention can be used with multiple routing and processing systems. For example, fig. 33 shows a system 350, the system 350 including an in-feed conveyor 352 that provides objects to a sorting system 354. The classification system 354 determines which of a plurality of processing systems (e.g., A, B or C as shown at 362, 370, 374) the object is to be sent to. In particular, the object first exits the sorting system 354 and travels along the conveyor 356 toward the first routing system 358. Certain objects (determined by the classification system 354) to be directed toward the processing system (a)362 are directed along the conveyor 360 toward the processing system (a) 362. All other objects are directed along the conveyor 364 toward the second routing system 366. Further objects (determined by the classification system 354) to be directed toward the processing system (B)370 are directed along the conveyor 368 toward the processing system (B) 370. All other objects are directed along conveyor 372 towards routing system 374. For example, either of processing systems A, B or C may be an automated processing station (e.g., designed for large or small/heavy or light objects) or a manual processing station (e.g., where a person may make decisions regarding object processing, or physically move an object to a destination location). In a further aspect, station C may be a pass-through exception container into which objects to be manually handled are placed.
By way of example, fig. 34 shows the import system 10 and object handling system 12, as discussed above with reference to fig. 1-8, and additional object handling systems 25 and 26 in series. In particular, the import system 10 includes an input station 14, the input station 14 having a response evaluation portion 16 of the conveyor 22, a multi-purpose perception unit 24, and a weight-sensing conveyor portion 55 for evaluating objects (e.g., 28), and providing the objects to the exception bin 50 (e.g., objects 35) or to the conveyor 41 (e.g., objects 40, 42) via the conveyor 35 using a multi-directional conveyor 53 as discussed above with reference to fig. 1-8.
The objects to be processed (e.g., objects 40, 42) are each assigned an object processing station (e.g., 12, 25, 26) toward which they are routed. In particular, the objects to be processed (again, e.g., 40, 42) may be routed to the appropriate processing stations based on any of a variety of parameters, such as size, weight, packaging material (boxes, bags, oddly-shaped objects, etc.), even shipping location, and each object processing station may, for example, include components specifically adapted for a certain size, weight, packaging material, etc. Some objects may be routed by multi-directional conveyor 44 along conveyor 46 to object processing station 12 while other objects (e.g., objects 49, 52, 54) are directed along conveyor 48 toward further processing stations. Some of those objects may be routed by the multi-directional conveyor 56 along the conveyor 58 toward the object processing station 25 while other objects (e.g., objects 61, 62, 63) are directed along the conveyor 60 toward further processing stations. Some of these objects may be routed by multi-directional conveyor 64 along conveyor 65 toward object processing station 26, while other objects (e.g., 67) are directed along conveyor 66 toward further processing stations. The operation of the system may be controlled by one or more computer processing systems (e.g., 100, 68, and 69).
By way of example, fig. 35 shows the introduction system 11 and the object handling system 12, as discussed above with reference to fig. 9 and 10, and the additional object handling systems 25 and 26 in series. In particular, the import system 11 includes an input station 14, the input station 14 having a response evaluation portion 16 of the conveyor 22, a multi-purpose perception unit 24, and a weight sensing conveyor portion 55 for evaluating objects and providing the objects to either an exception bin via the conveyor 134 or to the conveyor 138 or to the bag handling conveyor 144 using a multi-directional conveyor 132 as discussed above with reference to fig. 9 and 10. Any objects detected as being packed in the bag are directed to the conveyor 144 toward the deformable object introduction system 194 including the articulated arms 192, where the objects are tested at the deformable object introduction system 194 as discussed above with reference to fig. 9 and 10, and directed along the non-processable object conveyor 196 or along the processable object conveyor 198 as discussed above with reference to fig. 9 and 10.
Again, the objects to be processed are each assigned an object processing station (e.g., 12, 25, 26) toward which they are routed. In particular, the objects to be processed (e.g., 43, 52, 54) may be routed to the appropriate processing stations based on any of a variety of parameters, such as size, weight, packaging material (boxes, bags, oddly-shaped objects, etc.), and even shipping location, and each object processing station may, for example, include components specifically adapted for a particular size, weight, packaging material, etc. Some objects may be routed by multi-directional conveyor 45 along conveyor 19 to object processing station 12 while other objects (e.g., objects 43, 52, 54) are directed along conveyor 47 toward further processing stations. As discussed above with reference to fig. 34, some of those objects may be routed by the multi-directional conveyor 56 along the conveyor 58 toward the object processing station 25 while other objects (e.g., objects 61, 62, 63) are directed along the conveyor 60 toward further processing stations. Some of these objects may be routed by multi-directional conveyor 64 along conveyor 65 toward object processing station 26, while other objects (e.g., 67) are directed along conveyor 66 toward further processing stations. The operation of the system may be controlled by one or more computer processing systems (e.g., 200, 68, and 69).
Fig. 36 shows a system including an introduction system 13 and an object handling system 12, as discussed above with reference to fig. 11-22D, and additional object handling systems 25 and 26 in series. In particular, the import system 13 includes an input station 114, the input station 114 includes a pod infeed conveyor 122, a pod outfeed conveyor 126, an articulated arm 132, and an object infeed conveyor 13, and uses the multi-directional conveyor 132 to provide objects to either an abnormal pod via the conveyor 134 or to the conveyor 138 or to the bag handling conveyor 144 as discussed above with reference to fig. 11-22D. Any objects detected as being packed in the bag are directed to the conveyor 144 toward the deformable object introduction system 194 including the articulated arms 192, the objects are tested at the deformable object introduction system 194 as discussed above with reference to fig. 11-22D, and directed along the non-processable object conveyor 196 or along the processable object conveyor 198 as discussed with reference to fig. 11-22D.
Again, the objects to be processed are each assigned an object processing station (e.g., 12, 25, 26) toward which they are routed. In particular, the objects to be processed may be routed to the appropriate processing stations based on any of various parameters, such as size, weight, packaging material (boxes, bags, oddly shaped objects, etc.), even shipping location, and each object processing station may, for example, include components specifically adapted for a particular size, weight, packaging material, etc. Some objects may be routed by the multi-directional conveyor 59 along the conveyor 51 to the object processing station 12 while other objects (e.g., objects 52, 53, 54) are directed along the conveyor 47 toward further processing stations. As discussed above with reference to fig. 35, some of those objects may be routed by the multi-directional conveyor 56 along the conveyor 55 toward the object processing station 25 while other objects (e.g., objects 61, 62, 63) are directed along the conveyor 60 toward further processing stations. Some of these objects may be routed by multi-directional conveyor 64 along conveyor 65 toward object processing station 26, while other objects (e.g., 67) are directed along conveyor 66 toward further processing stations. The operation of the system may be controlled by one or more computer processing systems (e.g., 200, 68, and 69).
Fig. 37 shows the lead-in system 15 and the parallel object handling systems 12, 17, 21, 23. The import system 15 includes not only the input station 14 as discussed above with reference to fig. 1-8, the input station 14 including the response evaluation portion of the conveyor 22, the multi-purpose sensing unit 24, the weight sensing conveyor portion 55, and the multi-directional conveyor 53, the import system 15 further including multiple sets of the multi-purpose sensing unit, the weight sensing conveyor portion, and the multi-directional conveyor for evaluating the object (e.g., 28). Multi-directional conveyor 53 leads to conveyor 41 and multi-directional conveyor 44 for providing objects (e.g., 40, 42) to object handling system 12 via conveyor 46 and providing objects to any additional object handling systems (e.g., objects 49 on conveyor 48) in series with object handling system 12, as discussed above with reference to fig. 34.
In particular, conveyor 22 also includes an additional inspection station 86 having a multi-purpose sensing unit 85, a weight sensing conveyor portion 87, and a multi-directional conveyor 88 for evaluating objects (e.g., 81), and for optionally directing objects (e.g., 83, 89) along conveyor 31 toward multi-directional conveyor 90. The multi-directional conveyor 90 leads to a conveyor 91 for providing objects to the object handling system 17 and providing objects (e.g., objects 93) along a conveyor 92 to any additional object handling systems in series with the object handling system 17.
FIG. 38 illustrates a plurality of different types of introduction systems for use with a plurality of object handling systems. The introduction system 114 includes the input bin conveyor 122, the output bin conveyor 126, and the articulated arm 116, the weight-sensing side conveyor 155, the multidirectional conveyor 132, the deformable object introduction-limiting system 194, and the articulated arm 192, and the conveyors 57, 130, 138, 144, 196, 134, and 198 as discussed above with reference to fig. 11-22. The conveyors 138 and 198 lead to a multi-directional conveyor 59 where the objects are directed to the object handling system 12 via conveyor 51, or directed along conveyor 57 toward one of a plurality of further object handling systems (e.g., object 53), as discussed above with reference to fig. 36. However, the multi-directional conveyor 132 does not collect containers for non-disposable objects, but rather leads to further lead-in systems via the conveyor 181.
In particular, conveyor 181 leads to an introduction system 14, which introduction system 14 includes a response assessment section 16, a multi-purpose sensing unit 24, a weight sensing conveyor section, a multi-directional conveyor 132, and a deformable object introduction limiting system 194 and articulated arms 192, as discussed above with reference to fig. 9 and 10, and conveyors 19, 22, 138, 144, 196, and 198. Conveyors 138 and 198 lead to multi-directional conveyor 45 where the objects are directed to object handling system 177 via conveyor 19 or along conveyor 47 (e.g., objects 43) toward one of a plurality of further object handling systems, as discussed above with reference to fig. 35. Again, the multi-directional conveyor 132 does not collect containers toward non-disposable objects, but rather leads to a further lead-in system via conveyor 183.
Conveyor 183 leads to a further import system 14, which further import system 14 includes response assessment section 16, multi-purpose sensing unit 24, weight sensing conveyor section, multi-directional conveyor 132, and deformable object import restriction system 194 and articulated arm 192, as well as conveyors 22, 40, 46, 48, 35, and 198, as discussed above with reference to fig. 1-8. Conveyor 41 leads to a multi-directional conveyor 44 where the objects are directed to an object handling system 179 via conveyor 46 or along conveyor 48 toward one of a plurality of further object handling systems (e.g., object 49), as discussed above with reference to fig. 34. Unprocessed objects (e.g., objects 36) are provided to the unprocessed objects exception bin 50 via the conveyor 35.
Again, the objects to be processed are each assigned an object processing station (e.g., 12, 177, 179) toward which they are routed. In particular, the objects to be processed may be routed to the appropriate processing stations based on any of various parameters, such as size, weight, packaging material (boxes, bags, oddly shaped objects, etc.), even shipping location, and each object processing station may, for example, include components specifically adapted for a particular size, weight, packaging material, etc. The operation of the system may be controlled by one or more computer processing systems 100, 200, 301.
Any of a wide variety of detection systems may also be used in the above disclosed and further aspects of the present invention. For example, as discussed above with respect to the weight sensing transmitters discussed above, such weight sensing transmitters may be provided in a wide variety of systems. For example, referring to fig. 39A and 39B, a weight-sensing conveyor system 380 can be used in the import system of any of fig. 1, 9, 11, 34-38, 49, 56, and 70, the weight-sensing conveyor system 380 including a weight scale 382, the weight scale 382 including a base 384 and a scale 386 disposed between upper 388 and lower 390 portions of a conveyor portion 392. Thus, the objects on the conveyor can be weighed while the objects are on the conveyor.
Fig. 40A and 40B illustrate a weight-sensing conveyor system 400, which weight-sensing conveyor system 400 may be used in the lead-in system of any of fig. 1, 9, 11, 34-38, 49, 56, and 70, and which weight-sensing conveyor system 400 includes a conveyor portion 402 mounted on rollers 404, 406, each of which rollers 404, 406 is mounted at both ends of a pair of load cells 408, 410 (only one of the pair of load cells 408, 410 is shown at one end of each roller 404, 406). Damaged packages may also be identified by a sensing system, for example, if the package appears to be wet or leaking. By having the load cells 408, 410 include a humidity sensor, a humidity sensitive sensor can be used in conjunction with the transmitter 382 in any of the pretreatment systems in fig. 1, 9, 11, 34-38, 49, 56, and 70. In other embodiments, a camera capable of detecting humidity (e.g., a 1 trillion fps camera capable of tracking photons) may also be used in such an introduction system. Any moisture detected indicates that the object may have been damaged and requires exception handling.
Referring to fig. 41A-41D, in accordance with a further aspect of the present invention, the system 400 may further provide that the object 412 on the conveyor portion 402 not only can determine the weight of the object 412, but can further use the difference between the length end and the width end, as well as the weight sensed by each load cell 408, 410, to determine the centroid region of the object 412. For example, the system 400 may be used in any of the induction gas systems in fig. 1, 9, 11, 34-38, 49, 56, and 70.
Referring to fig. 42A and 42B, a weight scale (such as shown in fig. 39A-39B) may be provided as a plurality of scales. For example, fig. 42A and 42B illustrate a scale system 420, the scale system 420 including four scale portions 422, 424, 426, 428 on a scale base 430. The scale system 420 may be used in any of the pretreatment systems of fig. 1, 9, and 11. Using such a scale system, multiple scales may also be used to locate the center of mass of an object on the scale system 420.
Fig. 43A-43C show a scale system 440 that includes a plurality of rollers 442 mounted within a frame 444 on a base 446, wherein each roller 442 is mounted to the frame 444 via load cells or force torque sensors 446 on either end of each roller 442. The system 440 may be used in any of the pretreatment systems of fig. 1, 9, and 11. By monitoring the output of each of the load cells or force-torque sensors 446, the center of mass of the object on the roll can be determined.
Thus, such systems that provide weight sensing in a presentation conveyor may include one or more load cells or weight-sensitive embedded in a surfaceA mechanism on which an object is presented to a programmable motion device, such as an articulated arm. The weight and/or observed density (weight/volume) of each object can be estimated using the camera of the programmable motion system or a distance sensor that can sense volume. When these values exceed specifications, the object may be diverted or otherwise bypass the processing system. To better locate incompatible objects (e.g., packaging), there may be a grid of such weight-sensitive mechanisms that is capable of sensing which of the pick-up zones contains one or more incompatible objects, and then allowing pick-up from any area other than where the incompatible object(s) are detected. In addition, the system can detect flow readings while holding the object. If air flow rate (F)1) Too high (expected flow (F) to a particular object2) By contrast), the system may allow the object to be diverted from or pass through the object handling system.
Thus, in a further aspect, an end effector of a programmable motion device (and as discussed herein with reference to fig. 9-22D, 35, 36, 38, 54, 70, and 71) can include an end effector 450 as shown in fig. 44, the end effector 450 including a load cell or force torque sensor 454 that separates a lower portion 458 from an upper portion 452 coupled to the programmable motion device. The system may employ a load sensitive device at the gripper to estimate the weight of the object. If the object exceeds the acceptable weight specification, the object is released into the flow directed toward the anomaly area. Also, any movement of the lower part relative to the upper part will be detected by the load cell. Thus, the weight of any object that is gripped by the flexible bellows 456 under vacuum can be determined. Although the object may move relative to the lower portion 458 (e.g., by using flexible bellows), any movement of the object that translates into a grasping of the lower portion 458 relative to the upper portion 452 will be detected by the load cell or force torque sensor 454. Thus, not only the weight, but also the balance/imbalance of the grip and any torque applied to the lower portion 458 will be detected. Again, if the sensed (estimated) weight of the gripped object exceeds the expected weight (exceeds a threshold), the system may release the object to simply divert from the processing station, or to direct to an abnormal area.
According to a further aspect, the system can limit the initial clamping force. For example, the system may employ a partially open gripper valve to limit the maximum gripping force (V) in the vacuum gripper 4501) Until the object is lifted. Once the object is lifted, the gripper valve can be fully closed, allowing the vacuum force to reach a greater vacuum (V)2) To perform safe and reliable transport of the object. Such handling ensures that the objects do not fall off during transport and limits the introduction of objects into the handling system that may risk falling or mishandling.
Fig. 45 shows an end effector 460 for use in a system according to another aspect of the present invention, the end effector 460 including a rigid portion 462 coupled to a programmable motion device and a flexible bellows 464 movable relative to the rigid portion. Attached to the lower portion of the flexible bellows 464 is a rigid support 466, which rigid support 466 includes a band portion surrounding the flexible bellows and a vertical portion 465 orthogonally disclosed with respect to the band portion. The top of the vertical portion includes a magnet or sensor and mounted on the end effector is the other of the magnet or sensor pair 468, 469. The magnet and sensor pair provides that the sensor system will detect any movement of the bottom of the end effector relative to the rigid portion 462 of the end effector. In this way, the weight of the object or a characterization of the grasp of any object (e.g., balance/imbalance or torque applied to the end effector) may also be determined. The end effector 460 may be used with any of the end effector systems discussed herein with reference to fig. 9-22D, 35, 36, 38, 54, 70, and 71.
Referring to fig. 46, a system may use an end effector 455 (such as any of the end effectors discussed herein) that includes a sensor 457 (such as a flow sensor or a pressure sensor). The system can calculate from observations of flow and/or pressure while holding the goods whether the gripper 459 has sufficient grip on the object. In particular, the system may measure flow readings while holding the object and determine whether the measured value is within a range of values for the pickable object. If the object is not pickable, the object may be passed to the anomaly area without processing. End effector 455 may be used with any of the systems discussed above with reference to fig. 10A-13 and 54.
Fig. 47 and 48 illustrate a bracket 470 for use in a system similar to that shown in fig. 23, 25, and 28A-30, according to an aspect of the present invention, the bracket 470 having a body 472 including a higher rear wall 474 against which an object may be redirected into the generally V-shaped body 472 of the bracket. The carriage 470 is mounted on a frame 480 via load cells or force- torque sensors 476, 478, and the movement of the carriage 470 along the rails and the tilt is controlled by an actuation system 482. Communication and electronic control is provided by an electronic processing and communication system 488 (shown in fig. 43). Again, load cells or force- torque sensors 476, 478 may be used to determine the weight of the contents of the cradle. For example, once the beam break transmitter and receiver pair 484, 486 detects an object, the system according to an embodiment will pair two load units (W)1，W2) Is calculated, the result is doubled, and the weight of body 472 is subtracted. According to other embodiments, the load cell itself may register a change, indicating that the carrier has received or ejected an object.
Many further filtering systems, diverter systems, testing systems, routing systems and processing systems may be used in the above aspects and in further aspects of the invention. For example, certain embodiments may relate to methods of filtering packages that are too heavy and do so before they reach one of the robotic pickers. Such systems may include passive bomb compartment dropping systems. Such systems may involve routing incoming packages over a chute having one or more bomb bay doors. The bomb bay door is kept closed by a spring whose stiffness is adjusted so that too heavy packages are dropped through the bomb bay door. A package whose weight is less than the limit cannot apply enough force to open the passive bomb door(s). The passive bomb bay door is mounted on the chute so that the package naturally falls or slides through the bomb bay without falling.
Thus according to a further aspect, the filtration system of the present disclosure may include an actuatable bomb bay dropping system (e.g., motor actuated or spring loaded). According to an aspect of the invention, the sensor measures the weight of the package as it travels over the bomb bay door(s), and the controller opens the bomb bay door(s) by opening the motor of the bomb bay or the mechanism that unlocks the bomb bay door, and then the motor closes the bomb bay door again.
Fig. 49 shows a lead-in system 487 with an object handling system 12. The import system 487 includes an input section 14 and an exception bin 21 for receiving a volume (e.g., 36) of non-treatable objects via a conveyor 35, the input section 14 including the response evaluation section 16 of the conveyor 22, the side sensing unit 18, the overhead sensing unit 20, the multi-purpose sensing unit 24, the weight sensing conveyor section 53, and the multi-directional conveyor 33, as discussed above with reference to fig. 1-8. The lead-in system 487 also includes a tilted conveyor 492, the tilted conveyor 492 comprising sections 495, 496, and 497 and traveling over a second lower conveyor 489. With further reference to fig. 50A and 50B, a weight sensor (e.g., a force torque sensor) 485 detects the weight of the object 499 as it travels from the transmitter portion 495 onto the transmitter portion 496. If the object is above or below the prescribed weight, the object drops onto the lower conveyor 489 and is routed via the multi-directional conveyor 493 toward the object handling system 12 via conveyor 491. As discussed above, the system may select whether objects that are too heavy or too light are dropped through bomb bay door 498 by a processing station coupled to conveyor section 497. The door may be actuated by a motor 483. Alternatively, the pod conveyor may be designed to operate via a spring mechanism that opens when the weight is above a threshold, and the conveyor 497 may lead to an appropriate object handling system.
Fig. 51A and 51B show end views of a bomb bay door 498 over a conveyor 494 with the door closed (fig. 51A) and opened (fig. 51B), such as by a spring or motor actuator, in response to input from a force torque sensor to drop an object 499 from an upper conveyor 496 to a lower conveyor 489. According to a further aspect, the door may include weight-activated flexible interlocking fingers or tines, such as shown in fig. 66A and 66B.
For example, fig. 52A and 52B illustrate a system 491 that includes an upper inclined conveyor system 492 that runs above a lower inclined conveyor system 494. The system 491 may be used with any of the import systems of fig. 1, 9, and 11, in place of one or more of the conveyors shown in fig. 1, 9, and 11, for example, as shown in the example of fig. 49. The lower conveyor 494 of such a system may instead lead to an exception bin. The upper conveyor 492 includes active conveyor portions 495, 497 and a set of bomb bay doors. The upper conveyor 492 (as well as the lower conveyor 494) may be tilted (extending in the X and Y directions) so that if an object 499 on top of the door 498 does not fall, the object 499 may slide on the door to the next conveyor section 497. Referring to fig. 52B, if the door 498 is a passive bomb bay door, and if the object 499 is too heavy (e.g., overcoming a spring mechanism), the door 498 will open, dropping the object 499 onto the lower conveyor 494. If the door 498 is a motor-actuated bomb bay door, and if the object 499 is determined to be too heavy (e.g., by a different weighing system as disclosed above, such as if the conveyor portion 495 is a weighing conveyor as discussed above), the door 498 will be opened by the motor, dropping the object 499 onto the lower conveyor 494.
Fig. 53 shows an air permeable conveyor 500 that includes a conveyor material 506 with openings 508 therein that allow air to flow through the material 506. The air permeable conveyor 500 may be formed of perforated, mesh, or woven material and driven over rollers 502, 504, with one roller (e.g., 502) including an opening 503 and a vacuum provided into the roller 502 through the opening 503. As shown in fig. 54, such a system may be used in a lead-in system 489 with an object handling system 12.
The import system 489 of fig. 54 includes the input portion 14 and the additional conveyor 509 leading to the air permeable conveyor 500, the input portion 14 including the response assessment portion 16 of the conveyor 22, the side sensing unit 18, the overhead sensing unit 20, the multi-purpose sensing unit 24, the weight sensing conveyor portion 53, and the multi-directional conveyor 33, as discussed above with reference to fig. 1-8. The free end of the gas permeable conveyor is positioned on two or more receiving stations, which may be conveyors, chutes or automated carriers. Three automation carriers 513, 515, 517 are shown in fig. 54. The objects to be processed may be routed by the multi-directional conveyor 33 to the conveyor 511, the conveyor 511 running between a pair of articulated arms 521, 523 and between a pair of conveyors 525, 527 which lead via further multi-directional conveyors 529, 533 to object processing conveyors 531 (to the object processing system 12) and 535.
With further reference to fig. 55A, the objects may be provided on the conveyor 500 with the vacuum applied, and heavier objects (e.g., object 503) may fall directly from the conveyor into a bin 513 as the objects pass around the exterior of the rollers, as shown in fig. 55B. Slightly lighter objects (e.g., 505) may travel farther into the container 515 under the rollers 502, as shown in fig. 55C, and very light objects (e.g., 507) may fall from the now inverted conveyor 506 into the container 517 only when the conveyor exits the vacuum provided by the rollers 502, as shown in fig. 55D. With such a system, objects also do not need to be separated on the conveyor, as objects that are adjacent to each other will fall according to their own response to the vacuum. Additionally, one or more sensing systems 692 may monitor the motion of an object falling from the conveyor and may communicate with one or more control systems 694 to adjust either the vacuum pressure 696 at the conveyor (via a vacuum controller) or the conveyor speed 498 (via a rotational speed controller). The systems of fig. 53 and 55A-5D may be used, for example, in further systems disclosed herein.
Again, the receiving station may be any of an automated carrier, a chute, or a conveyor. Fig. 56 shows a lead-in system 647 that includes an input portion 14, which input portion 14 includes the response evaluation portion 16 of the conveyor 22, the side sensing unit 18, the overhead sensing unit 20, the multi-purpose sensing unit 24, the weight sensing conveyor portion 53 and the multi-directional conveyor 33, as discussed above with reference to fig. 1-8, and an additional conveyor 509 leading to the air permeable conveyor 500. In this example, the gas permeable conveyor is positioned on the automation carrier 513', the chute 515' leading to the automation carrier 649, and the carrier 517 '. The objects to be processed may be routed by the multi-directional conveyor 33 to a conveyor 537, the conveyor 537 running between a pair of conveyors 541, 545, which pair 541, 545 leads via further multi-directional conveyors 551, 555 to object processing conveyors 553 (to the object processing system 12) and 557. Conveyors 537, 541, and 545 also pass through object transport station 547, as discussed further below with reference to fig. 57-69, and in some examples conveyors 541 and 545 are lower than conveyor 537, while in other examples each are at the same elevation. At the object transport station, the objects are transported from the conveyor to any of various further units, such as to other conveyors, chutes or mobile units.
For example, according to a further aspect of the invention, an intake system may be used that can differentiate between objects by conveying the objects with a blower that pushes lighter packages out of the stream, leaving heavier packages behind. The greater inertia of the heavier package overcomes the air resistance created by the blown gas. For lighter packages, the air resistance exceeds the low inertia of the lighter package. The air flow is adjusted so that, for the usual package types, the blown flow contains to the greatest extent the packages meeting the weight specification.
For example, fig. 57 shows an air-permeable conveyor 501 similar to that discussed above with reference to fig. 53, designed to allow a large amount of air to be blown through openings 508 in a web 506 moving along the rollers (providing the conveying surface). As shown in fig. 57, such a gas-permeable conveyor 501 may be used in a system 510 in which objects move along an access conveyor 512 and over the gas-permeable conveyor 501. Below the air-permeable conveyor 501 is a blower source 514 that blows air through the air-permeable conveyor 500, and above the air-permeable conveyor 501 is a vacuum source 516 that draws air through the air-permeable conveyor 501. Both the blower 514 and the vacuum source 516 may include a screen or an array of openings (partially shown in fig. 60). The combination of the blower 514 and the vacuum source 516 will cause some objects to be lifted off the conveyor 501. Objects that are too heavy to be lifted off the conveyor 501 will travel along the conveyor 501 and be transported to the following conveyor 518. The system 510 may be used in place of any of the conveyors in the systems of fig. 1, 9, and 11, wherein lighter objects are then routed to light object processing stations, as further discussed with reference to fig. 59A-59C.
Additionally, as shown in fig. 58, the system may further include one or more sensing systems 521, the one or more sensing systems 521 in communication with a vacuum control processor 523 coupled to the vacuum controller 525 and in communication with a blower control processor 527 coupled to a blower controller 529. In this way, the operation of the system can be monitored, and the air flow of the blower and vacuum can be adjusted as needed.
Referring to fig. 59A, as the object 520 is lifted toward the vacuum source 516, it is initially pushed by air from the blower source 514 and lifted by the vacuum source 516. Once the object contacts the screen on the vacuum source 516, the vacuum force will be strong enough that air from the blower no longer needs to hold the object against the vacuum source 516. The vacuum source 516 may be movably mounted on the track 522 such that the vacuum source 518 may be moved to be positioned over the conveyor 501 or either of the adjacent conveyors 524, 526, see fig. 59B, for example, the vacuum source 516 may be moved over the conveyor 524 while holding the object 520, and then the vacuum may be stopped, allowing the object to fall onto the conveyor 524, as shown in fig. 59C. The vacuum source 516 is then returned to a position above the conveyor 501. In this way, the vacuum source and/or blower source may be used to distinguish and separate objects having different characteristics (such as weight or mass).
According to a further aspect, the system may further provide for mass picking by such a vacuum system. The object may pass through an area where a large vacuum surface is suspended upside down above the object. The system can hold a large number of objects-many at a time-but only lift light objects, but heavy objects cannot be lifted from the stream. The balance of vacuum lifting force versus weight and packaging material can be adjusted so that all objects remaining have a minimum weight or all objects lifted are below a maximum weight.
An induction system according to a further embodiment of the invention may include a system 530, the system 530 including a blower source 532 and a vacuum source 534 positioned on either side of a gas permeable conveyor 536, as shown in fig. 60. The use of an air permeable conveyor may facilitate the drawing of certain objects toward the vacuum source 532 by allowing a greater airflow. Conveyor 536 feeds objects by in-feed conveyor 538 and provides objects (objects not removed from conveyor 536 by blower source 532 and vacuum source 534) to out-feed conveyor 539. Objects removed from the conveyor 536 fall on either of another conveyor below and to the side of the conveyor 536 or on a chute or other moving carrier, as discussed in more detail below. A monitoring and control system similar to that of fig. 58 may also be used with the system of fig. 60.
Referring to FIG. 61, system 540 according to a further embodiment of the present invention may include a blower source 542 and a vacuum source 544 positioned on either side of a gas-permeable conveyor 546, and another blower source 543. Conveyor 546 is fed objects by in-feed conveyor 548 and provides objects (objects not removed from conveyor 546 by blower sources 542, 543 and vacuum source 544) to out-feed conveyor 549. The blower source 543 can further facilitate moving the object with the blower source 542 and the vacuum source 544. Again, the objects removed from conveyor 546 fall on either one of the other conveyors below and to the side of conveyor 536, or on a chute or other moving carrier, as discussed in more detail below. A monitoring and control system similar to that of fig. 58 may also be used with the system of fig. 61.
In applications where the objects are so light that they can be removed from the non-perforated conveyor (and/or the blower and vacuum source are high), a system 550 may be provided that includes a blower source 552 and a vacuum source 554 positioned on either side of the conveyor 556, as shown in fig. 62. The conveyor 556 is fed objects by the in-feed conveyor 558 and provides objects (objects not removed from the conveyor 556 by the blower source 552 and vacuum source 554) to the out-feed conveyor 559. Again, the objects removed from the conveyor 556 fall on either one of another below and to the side of the conveyor 556, or on a chute or other moving carrier, as discussed in more detail below. A monitoring and control system similar to that of fig. 58 may also be used with the system of fig. 62.
As mentioned above, the objects may be routed to any of a chute, conveyor, moving carrier, or the like. For example, fig. 63 shows a system 560, the system 560 including a central conveyor having an in-feed conveyor portion 562, an out-feed conveyor portion 564, and a weight-sensing conveyor 566 as discussed above with reference to fig. 39A-43C. The system 560 also includes a pair of sources 568, 570 on either side of the weight-sensing conveyor 566, and each source 568, 570 can provide forced air (forced air) via a blower or vacuum so that objects can be moved out of the conveyor 566 in either direction by the blower-vacuum pair.
With further reference to the side view shown in FIG. 64, objects may be blown onto chute 572 leading to conveyor 574 (e.g., by engaging source 570 as a blower with source 568 as a vacuum source) or may be blown onto chute 576 leading to moving carrier 578 (e.g., by engaging source 568 as a blower with source 570 as a vacuum source). The selection of whether to move an object to the conveyor belt 574 or to the moving carrier 578 may be a result of the air flow between the sources 568, 570 or, in other aspects, may be triggered by the detected weight of the object on the conveyor 566. In a further aspect, a weight sensing conveyor 566 can be used to confirm the weight of the object and further provide feedback to the control system (e.g., 100) so that the sources can be adjusted (together or independently) to more finely adjust their object removal capabilities.
Fig. 65 shows a system 600, the system 600 including a central conveyor having an in-feed conveyor portion 602, an out-feed conveyor portion 604, and a weight-sensing multi-directional conveyor 606. The weight-sensing multi-directional conveyor 606 may include a weight-sensing roller 442 as discussed above with reference to fig. 39A-43C, and a series of orthogonally disposed narrow conveyor belts 608. Either the roller 442 or the belt 608 may be lowered/raised relative to the other to provide that objects may be left on the conveyor 606 and provided to the outfeed conveyor 604, or may be routed by the belt 608 to a chute 610 leading to a conveyor 612 or to a chute 614 leading to a moving carrier 616. The selection of whether an object is moved to the conveyor 612 or the carrier 616, or left on the conveyor 606, may be triggered by the detected weight of the object on the conveyor 606. The mobile carrier 616 may include a container or box into which received objects fall, and the mobile carrier 616 may move about a track system, as discussed in more detail below.
66A and 66B illustrate a system 620, the system 620 including a central conveyor having an in-feed conveyor portion 622, an out-feed conveyor portion 624, and a weight-sensing multi-directional conveyor 626, according to a further aspect of the invention. Again, the weight-sensing multi-directional conveyor 626 may include a weight-sensing roller 442 as discussed above with reference to fig. 39A-43C, and a series of orthogonally disposed narrow conveyor belts 628. Either the roller 442 or the belt 628 may be lowered/raised relative to the other to provide that objects may be left on the conveyor 626 or provided to the outfeed conveyor 624, or may be routed by the belt 628 to a chute 630 leading to a conveyor 632 or to a chute 634 leading to a moving carrier 636. Additionally, chute 630 includes a bomb bay door 638 that opens above a further conveyor 639. Bomb bay door 638 may be motor actuated or designed to be released by a spring at a certain weight threshold, as discussed above with reference to fig. 49-52B. The selection of whether an object is moved to the conveyor 612, the conveyor 639, or the carrier 616, or left on the conveyor 626 may be triggered by the detected weight of the object on the conveyor 606. Again, the mobile carrier 616 may include a container or box into which received objects fall, and the mobile carrier 616 may move about the track system, as discussed in more detail below.
Fig. 67 shows a system 560 similar to fig. 63, the system 560 including a central conveyor having an in-feed conveyor portion 562, an out-feed conveyor portion 564, and a weight-sensing conveyor 566 as discussed above with reference to fig. 39A-43C. The system 560 also includes a pair of sources 568, 570 located on either side of the weight-sensing conveyor 566, and each source 568, 570 can provide forced air via a blower or vacuum so that objects can be moved out of the conveyor 566 in either direction by the blower-vacuum pair. In addition to chute 576 leading to automated carrier 578, the system of fig. 67 includes a chute 573 having a pair of bomb door 577 (as discussed above with reference to fig. 49-51B) for selectively providing objects to conveyor 574 or dropping objects onto conveyor 575 adjacent conveyor 574.
Fig. 68A and 68B illustrate a system 580 that includes a central conveyor having an infeed conveyor section 582, an outfeed conveyor section 584, and a weight sensing conveyor 586 as discussed above with reference to fig. 39A-43C. The system 580 also includes a pair of paddles 588, 590 located on either side of the weight sensing conveyor 586 and each paddle 588, 590 can be used to push an object on the weight sensing conveyor 586 out of the conveyor 586 in either direction or the object can remain on the conveyor 586 and be moved to an outfeed conveyor portion 584. With further reference to fig. 68B, the object may be pushed onto a chute 592 leading to a conveyor 594, or may be pushed onto a chute 596 leading to a mobile carrier 598. The selection of whether an object is moving to the conveyor 574, the carrier 578, or left on the conveyor 586 can be triggered by the detected weight of the object on the conveyor 586. The mobile carrier 598 may include a container or box into which received objects fall, and the mobile carrier 598 may move about a track system, as discussed in more detail below.
Fig. 69 shows a system similar to fig. 68A and 68B including a central conveyor having an in-feed conveyor section 582, an out-feed conveyor section 584, and a weight-sensing conveyor 586 as discussed above with reference to fig. 39A-43C. The system 580 also includes a pair of paddles 588, 590 located on either side of the weight sensing conveyor 586 and each paddle 588, 590 can be used to push an object on the weight sensing conveyor 586 out of the conveyor 586 in either direction or the object can remain on the conveyor 586 and be moved to an outfeed conveyor portion 584. In addition to the chute 596 leading to the automation carrier 598, the system of fig. 69 also includes a chute 593, the chute 593 having a pair of bomb bay doors 597 (as discussed above with reference to fig. 49-51B) for selectively providing objects to the conveyor 594 or dropping objects onto the conveyor 595 adjacent to the conveyor 594.
The object handling system may include multiple stations as discussed above, and the import filtering may direct different objects to different stations based on various object characteristics and end effector characteristics (e.g., knowing which end effector is better suited to manipulate which object). The ability to provide objects from an in-feed conveyor to a wide variety of processing systems provides great flexibility, and the ability to provide objects to an automated carrier provides further flexibility in object processing. For example, fig. 70 shows an object handling system 650, the object handling system 650 comprising a plurality of workstations 652, 654, 656, the plurality of workstations 652, 654, 656 receiving objects via diverters 660, 662, 670, 672, 680, 682 under the control of one or more handling systems 690. For example, workstation 652 may be well suited to move bags to destination location 666 using an articulated arm 664, and for example, workstation 654 may be better suited to move cylinders to destination location 676 using an articulated arm. Another workstation 656 may, for example, include a worker 684 for moving an object to a destination location 686 that is not easily handled by any articulated arm.
The object handling system used with the import filter system and method of various embodiments of the present invention can be any of a wide variety of object handling systems, such as sorting systems, automated storage and retrieval systems, and distribution and redistribution systems. For example, according to a further embodiment, the present invention provides a system capable of automating the outbound (outbound) processing of a processing system. The system may include one or more automated picking stations 700 (shown in fig. 71) and manual picking stations 800 (shown in fig. 72), the automated picking stations 700 and manual picking stations 800 providing a container of collections by a fleet of moving carriers traversing an intelligent floor structure formed by track segments as discussed above. The carrier may carry a container that may store objects. The system may provide a novel cargo-to-picker system that uses a fleet of small mobile carriers to carry individual stock totes and outbound receptacles to and from a pick-up station.
Embodiments in accordance with the present system include an automated pick station that picks each from a stock tote and loads each into an outbound container. The system involves machine vision, task and motion planning, control, error detection and recovery together, and sensor-enabled artificial intelligence, a hardware platform to achieve a real-time and robust solution to singulating items from cluttered containers.
Referring to fig. 71, an automated picking system 700 senses the contents of containers using a multimodal sensing unit and picks each from a homogenous inventory tote using integrated software in a robotic arm equipped with automated programmable motion grippers and handling system 720 and places them into a non-homogenous outbound container. These elements are co-located within a work cell that meets industry standard safety requirements and cooperates with the rail system to maintain a continuous supply of automated pick up systems fed with stock tote bags and outbound containers.
In particular, the system 700 includes an array 702 of track elements 704 as discussed above, and an automation carrier 706 that advances over the track elements 704 as discussed above. One or more overhead sensing units 708 (e.g., cameras or scanners) acquire sensing data about objects in the tote box or bag 710, as well as sensing data about the location of the destination box 712. A programmable motion device, such as a robotic system 714, picks objects from the tote box or bag 710 and places the objects in an adjacent box 712. One or both of the cells 710, 712 are then automatically moved back into the grid, and one or two new such cells are moved into a position adjacent to the robotic system. At the same time, the robotic system is used to handle another pair of adjacent cells (again, a tote box or bag 710 and a box 712) on the other side of the robotic system 714. Thus, the robotic system handles a pair of processing units on one side and then switches both sides when the first side is replenished. In this way, the system 700 does not need to wait for a new pair of object handling units to be presented to the robotic system. The array 702 of track elements 704 may also include a racking station 716 where the mobile unit 706 may park or pick up a container/tote 710 or cassette 712. For example, the system operates under the control of the computer processor 720.
A manual pick-up station system is a human pick-up station for goods supplied by mobile (motion) automated mobile (motion) carriers on a rail system as discussed above. The system has the same form and function as an automated pick-up station, in that both are provided by the same carrier, both are connected to the same rail system grid, and both transport each from stock totes to an outbound container. The manual system 800 (shown in FIG. 72) relies on manual team members to perform the picking operation.
Further, the manual system lifts the carrier to an ergonomic height (e.g., via a ramp), ensures safe access to containers on the carrier, and includes a monitoring interface (HMI) to guide activities of team members. The identification of the SKU and the quantity of items to be picked up are displayed on the HMI. The team member must scan the UPC of each unit using a presentation scanner or a handheld barcode scanner to verify that the pick is complete. Once all pickups between a pair of containers are complete, the team member presses a button to mark completion.
According to this embodiment (and/or in conjunction with a system including an automated picking system as discussed above), the system 800 of fig. 72 may include an array 802 of rail elements 804, the array 802 of rail elements 804 being disposed on a plane 806 and an inclined surface 808 leading to other planes. The system 800 can also include a visual data screen 809 that provides visual data to the human sorter so as to inform the human sorter as to what goods are to be moved from the tote or container 810 to the destination box 812. The system operates under the control of, for example, a computer processor 820.
While the substantial pick-up throughput of the entire system is expected to be handled by automated pick-up systems, manual pick-up systems offer (a) the ability to scale rapidly to meet unplanned demand growth; (b) the ability to handle goods that are not yet available for automated processing; and (c) the ability to act as a QA, problem solving, or inventory integration station throughout the distribution system. Thus, the system provides significant expandability and troubleshooting capabilities, as manual sorting can be easily added to an otherwise fully automated system. Once the manual pick system is enabled (occupied by the sorter), the system will begin sending totes or containers 810 and boxes 812 to the manual pick station. The automated picking station and the manual picking station are designed to occupy the same footprint, so the manual missing station can be replaced by the automated picking station with minimal modification to the rest of the system.
Again, the carrier is a small mobile robot that can interchangeably carry inventory totes, outbound containers, or supplier boxes. These carriers can use simple linkage mechanisms to remove or replace containers from or onto the storage fixtures. Since the carrier can only carry one container at a time, it can be smaller, lighter, consume less energy, and be much faster than a larger robot. Since the carriers travel on the intelligent floor tile floor, they reduce sensing, calculation and accuracy requirements compared to mobile robots that run on bare floors. These features improve the cost of the performance index.
All carriers run on the same shared road of the track section as independent container delivery agents. The carriers can be moved forward, backward, left or right to travel around each other and to any position in the system. This flexibility allows the carrier to play multiple roles in the system by: (a) transferring the inventory totes to a pick-up station; (b) transporting the outbound container to a pickup station; (c) transferring stock totes to and from a mass storage; (d) transferring the fully loaded outbound container to a discharge aisle; (e) the empty outbound container is transported to the system. Additionally, carriers can be added incrementally as needed to scale as devices grow.
The rail floor module is a standard size, modular and connectable floor section. These tiles provide a navigation and standard driving surface for the carrier and may serve as a storage area for the containers. The modules are connected to a robotic pick unit, a docking station leading from a bulk storage and a discharge station near the load dock. The module eliminates the need for other forms of automation (e.g., conveyors) for transporting containers within the system.
As shown at 900 in fig. 73, the system may be expanded to include a much larger array of track modules 902 and a number of processing stations 904, and the number of processing stations 904, for example, may be any of an inventory infeed station, an empty outbound container infeed station, an automated and manual processing station, and an outbound station as discussed above. The system operates under the control of, for example, a computer processor 906.
Those skilled in the art will appreciate that numerous modifications and variations may be made to the above disclosed embodiments without departing from the spirit and scope of the invention.
What is claimed is.
Claims (37)
1. In an introduction system for use with an object handling system, a dispensing system for providing dissimilar objects to one of a plurality of receiving units, the dispensing system comprising an air intake system having an opening at a fixed distance from a conveyor section, the air intake system facilitating movement of objects on the conveyor section from the conveyor section to one of a plurality of adjacent conveying units.
2. The dispensing system of claim 1, wherein the conveyor portion comprises a conveyor having a plurality of openings in the conveyor.
3. The dispensing system of claim 1 or claim 2, wherein the conveyor section is formed from a mesh material.
4. The dispensing system of any of the preceding claims, wherein the air intake system is coupled to a vacuum source that is dynamically adjustable to accommodate various objects presented to the conveyor portion.
5. The dispensing system of any one of the preceding claims, further comprising a sensing unit oriented towards the object on the conveyor portion.
6. The dispensing system of any one of the preceding claims, wherein the dispensing system comprises an adjustable vacuum control system for adjusting the vacuum of the air intake system.
7. The dispensing system of any one of the preceding claims, wherein the opening of the air intake system is above the sensor portion.
8. The dispensing system in accordance with any one of the preceding claims in which the opening of the air intake system is horizontally adjacent the sensor portion.
9. The dispensing system of any one of the preceding claims, further comprising a forced air system that also assists in moving objects on the conveyor section from the conveyor section.
10. The dispensing system of claim 9, wherein the opening of the forced air system is below the conveyor section.
11. The dispensing system of claim 9, wherein the opening of the forced air system is horizontally adjacent the sensor portion.
12. The dispensing system according to any one of the preceding claims, wherein the object handling system comprises a plurality of object handling stations.
13. The dispensing system of any one of the preceding claims, wherein the air intake system is movably mounted on a rack to carry objects drawn into the air intake system toward one of the adjacent conveyors.
14. A dispensing system according to any one of the preceding claims, wherein adjacent transport units comprise any one of adjacent conveyors, chutes or moving carriers.
15. In an induction system for use with an object handling system, a dispensing system for providing dissimilar objects to one of a plurality of receiving units, the dispensing system comprising an air transport system and an air intake system, the air transport system comprising a forced air system, the air transport system and the air intake system together assisting in moving objects on the conveyor section from the conveyor section to one of a plurality of adjacent conveyors.
16. The dispensing system of claim 15, wherein the conveyor portion comprises a conveyor having a plurality of openings in the conveyor.
17. The dispensing system of claim 15 or claim 16, wherein the conveyor section is formed from a mesh material.
18. The dispensing system of any of claims 15-17, wherein the air intake system is coupled to a vacuum source that is dynamically adjustable to accommodate various objects presented to the conveyor portion.
19. The dispensing system of claim 18, further comprising a sensing unit oriented toward the object on the conveyor portion.
20. The dispensing system of claim 18, wherein the dispensing system includes an adjustable vacuum control system for adjusting the vacuum of the air intake system.
21. The dispensing system in accordance with any one of claims 15-20 in which the opening of the air intake system is above the sensor portion.
22. The dispensing system in accordance with any one of claims 15-21 in which the opening of the air intake system is horizontally adjacent the sensor portion.
23. The dispensing system of any one of claims 15-22, wherein the opening of the forced air system is below the sensor portion.
24. The dispensing system of any one of claims 15-23, wherein the opening of the forced air system is horizontally adjacent the sensor portion.
25. The dispensing system of any one of claims 15-24, wherein the air intake system is movably mounted on a rack to carry objects drawn into the air intake system toward one of the adjacent conveyors.
26. The dispensing system according to any one of claims 15-25, wherein the object handling system comprises a plurality of object handling stations.
27. The dispensing system in accordance with any one of claims 15 to 26 in which adjacent transfer units comprise any one of adjacent conveyors, chutes or moving carriers.
28. A method of distributing dissimilar objects to one of a plurality of receiving units in a pre-processing system for use with an object handling system, the method comprising:
providing an air transport system opposite the air intake system, and
engaging the air transport system and the air intake system to assist in moving objects on the conveyor section from the conveyor section to one of a plurality of adjacent conveyors.
29. The method of claim 28, wherein the air intake system is coupled to a vacuum source that is dynamically adjustable to accommodate various objects presented to the conveyor portion.
30. The method of claim 28 or claim 29, wherein the dispensing system further comprises a sensing unit oriented toward the object on the conveyor portion.
31. The method of any one of claims 28-30, wherein the dispensing system comprises an adjustable vacuum control system for adjusting the vacuum of the air intake system.
32. The method of any of claims 28-31, wherein the opening of the air intake system is above the sensor portion.
33. The method of any of claims 28-32, wherein the opening of the air induction system is horizontally adjacent to the sensor portion.
34. The method of any one of claims 28-33, wherein the opening of the forced air system is below the sensor portion.
35. The method of any one of claims 28-34, wherein the opening of the forced air system is horizontally adjacent to the sensor portion.
36. A method according to any of claims 28 to 35, wherein the air intake system is movably mounted on a gantry to carry objects drawn into the air intake system towards one of the adjacent conveyors.
37. A method according to any of claims 28-36, wherein the object handling system comprises a plurality of object handling stations.
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