WO2024064747A1 - Optimisation de remplissage de réceptacle d'ordre de tri - Google Patents

Optimisation de remplissage de réceptacle d'ordre de tri Download PDF

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Publication number
WO2024064747A1
WO2024064747A1 PCT/US2023/074683 US2023074683W WO2024064747A1 WO 2024064747 A1 WO2024064747 A1 WO 2024064747A1 US 2023074683 W US2023074683 W US 2023074683W WO 2024064747 A1 WO2024064747 A1 WO 2024064747A1
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WO
WIPO (PCT)
Prior art keywords
receptacle
articles
chamber
article
sensor
Prior art date
Application number
PCT/US2023/074683
Other languages
English (en)
Inventor
James M. Serstad
Michael C. Futch
Adam P. CLAYBROOK
Parthiban A MATHAVAN
Original Assignee
Tompkins Robotics, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tompkins Robotics, Inc. filed Critical Tompkins Robotics, Inc.
Publication of WO2024064747A1 publication Critical patent/WO2024064747A1/fr

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Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
    • B65B5/10—Filling containers or receptacles progressively or in stages by introducing successive articles, or layers of articles

Definitions

  • This invention relates generally to the field of warehouse automation, and particularly to systems and methods for automated sortation of articles into receptacles.
  • An article sorting system at a distribution center or warehouse operates to sort articles to destinations, each destination typically represented by a receptacle.
  • the receptacle may be a bin, cardboard box, bag, tote, or any other generic container.
  • an empty receptacle gets filled with articles being sorted thereinto, for e.g., by such articles being dropped or deposited into the receptacle by an automated device, one or more of the sorted articles deposited into the receptacle may protrude or overhang above the rim of the receptacle even when the receptacle may not actually be full in terms of its cubic capacity and may otherwise still have space available for accepting one or more additional articles.
  • a system for use in directing a sorting operation may have a server comprising a memory, a processor, and a receptacle assignment engine.
  • the system further may have a chamber bank comprising at least one chamber configured for receiving a receptacle therein.
  • the chamber is defined by a floor, a left wall, a right wall, and a rear wall that together define a receiving space for a receptacle, wherein at least one of the left and right wall extends above a top rim of the receptacle received therein.
  • the system may also have an automated transport device for transporting and depositing articles into the receptacles.
  • the system may be configured to: assign a first number of articles occupying a first volume to a first receptacle such that the first number of articles overfills the first receptacle when all of the first number of articles are deposited thereinto; and direct an automated transport device to transport and deposit the first count of articles into the first receptacle.
  • a chamber bank for use in directing a sorting operation.
  • the chamber bank may have at least one chamber for receiving a receptacle therein.
  • the chamber may be defined by a floor, a left wall, a right wall, and a rear wall that together define a receiving space for a receptacle. At least one of the left and right wall is taller than the corresponding abutting side wall of the receptacle received therein.
  • a first number of articles occupying a first volume are assigned for deposition into the receptacle such that the first number of articles overfills the receptacle when all of the first number of articles are deposited thereinto.
  • FIG. 1 depicts an example implementation of a chamber bank for use in directing a sorting operation, according to one or more implementations of the presently disclosed subject matter.
  • FIGS. 2-7 depict various aspects of a chamber bank for use in directing a sorting operation, according to one or more implementations of the presently disclosed subject matter.
  • FIG. 8 depicts a block diagram of an exemplary sorting system for use in directing a sorting operation such that the filling of a destination receptacle is optimized, according to one or more implementations of the presently disclosed subject matter.
  • FIG. 9 depicts an example implementation of an automated transport device for transporting an article to be sorted to a destination receptacle, according to one or more implementations of the presently disclosed subject matter.
  • FIG. 10 depicts an example implementation of a sensor such as, for e.g., an optical sensor or a photo-eye sensor, that senses that a destination receptacle has become full or is about to become full, according to one or more implementations of the presently disclosed subject matter.
  • a sensor such as, for e.g., an optical sensor or a photo-eye sensor, that senses that a destination receptacle has become full or is about to become full, according to one or more implementations of the presently disclosed subject matter.
  • FIG. 11 depicts an exemplary flowchart of an exemplary implementation of an improved sorting system for use in directing a sorting operation, according to one or more implementations of the presently disclosed subject matter.
  • FIG. 12 depicts an exemplary flowchart of an exemplary implementation of an improved sorting system for use in directing a sorting operation, according to one or more implementations of the presently disclosed subject matter.
  • FIG. 13 depicts an example implementation of a platform assembly forming part of an improved sorting system for use in directing a sorting operation, according to one or more implementations of the presently disclosed subject matter.
  • an article sorting system when a receptacle is determined to be full by a human operator or by a control system, the receptacle needs to be removed and replaced with an empty receptacle.
  • an empty receptacle gets filled by articles being sorted thereinto, for e.g., by way of such articles being dropped or deposited into the receptacle by an automated device, one or more of the sorted articles deposited into the receptacle may protrude or overhang above the rim of the receptacle even when the receptacle may not be full in terms of its cubic capacity and may otherwise still have space available for accepting one or more additional articles.
  • Embodiments disclosed herein may overcome such limitations by providing for filling up the receptacles more fully without leaving too much in terms of wasted space within the receptacles as the receptacles get filled out with sorted articles.
  • Embodiments of the presently disclosed subject matter accordingly advantageously overcome the limitations of the art by providing for apparatus, systems and methods to sort articles to destination receptacles in a manner that overcomes inherent inefficiencies and inflexibilities present in the current state of the art. Embodiments of the presently disclosed subject matter can thus help maximize the filling efficiencies of bins, totes, boxes and other collection containers during the sortation of articles thereinto.
  • Various embodiments disclosed herein provide for apparatus, systems, and methods for overfilling a destination receptacle as and when needed to thereby improve overall operational efficiencies, according to one or more implementations of the presently disclosed subject matter.
  • Sortation systems used at distribution centers typically require a large number of collection receptacles along with their associated large physical space, large capital costs, and large operating costs.
  • businesses such as pharmacies that distribute medication, for e.g., script packages, need to sort them by store, customer, or shipping service provider before each script package (alternately referred to herein as “script”) is sent to the proper recipient.
  • This procedure is also applicable to businesses that need to sort all other articles such as generic packages, health items, beauty items, and similar other items.
  • the script packages are sorted by destination such as, for e.g., store, end customer or end shipping service, these articles are sorted into receptacles for safe shipment to the end destination. Sorted articles may be sorted to totes, mail bags, cardboard boxes, and other kinds of receptacles.
  • a script provider benefits from maximizing the number of script packages that fit into a receptacle. This is because a script provider is typically charged a certain $ amount per receptacle, e.g., $10 per tote to be shipped. Alternately, the script provider may itself own the transportation means (e.g., tractor trailers) whereby the script provider encumbers direct costs for fuel and labor associated with a sealed script receptacle being shipped including the costs associated with any unused or wasted space remaining within the receptacle. Accordingly, it is beneficial to maximize the packing density of each receptacle to thereby minimize overall transportation costs for the script packages. Increasing the script packages filled into each tote accordingly reduces the overall transportation and handling costs associated with sorting and delivering the script packages to their final destinations.
  • the script provider may itself own the transportation means (e.g., tractor trailers) whereby the script provider encumbers direct costs for fuel and labor associated with a sealed script receptacle being shipped including the costs associated with any
  • script packages were diverted to or deposited into a tote until the tote was deemed full by a sensor, e.g., in the form of a photo-eye sensor, and the corresponding script count was recorded. The packages were then “groomed” or packed down to determine the quantity of additional scripts that could diverted into the same tote until the tote was deemed full by the photo-eye sensor again.
  • Configuration 1 shown in Table 1 included casters on the chamber banks (alternately referred to as “carts”) as well as ramps provided between the platforms or tables and the totes; it was treated as a baseline. The ramps provided a transition for guiding script packages away from the photo-eye sensor.
  • Configuration 1 about 14.0 scripts were diverted into a tote on average before the first photo-eye sensor notification indicating “tote full” was triggered.
  • Configuration 2 did not include the ramp but included casters.
  • Configuration 2 with a total of 13.0 scripts on average was found to underperform as compared to Configuration 1.
  • Configuration 3 included the ramp but excluded the casters. Configuration 3 showed a 29% increase in total diverts over Configuration 1.
  • Configuration 4 excluded both the ramp and the casters. Configuration 4 showed a small improvement over Configuration 3; It was observed that one package did not divert successfully into the tote but instead fell to the side of the tote.
  • Configuration 5 the photo-eye sensor was rotated between 15 and 180 degrees or higher to allow the photo-eye sensor, for e.g., to beam towards a horizontal line a one or more inches above the top rim of the tote. Configuration 5 otherwise excluded both the ramp and the casters.
  • Configuration 5 resulted in a 1.4 script packages improvement over Configuration 3; however, configuration 5 also exhibited a few instances where script packages risked falling out of the tote, for e.g., they were half-in and half-out of the tote. This implied a high risk of tote packages falling outside of the tote when a tote is being overfilled with the ramp is absent; this also implied a high risk of an automated transport vehicle (traveling on a platform for depositing such scripts packages into the tote) dragging one such “half-in half out” script package as the vehicle drives by.
  • a mock chamber bank e.g., a tote cart for supporting receptacles such as totes was created with the spacing between a top rim of the tote and the photo-eye sensor set at different measurements including spacings of 6”, 8” and 10” apart to allow testing of performance under these 3 configurations.
  • the script packages were inducted randomly to represent a real-life sorting operation, with these script packages deposited into a tote until the tote was deemed full by the photo-eye sensor. The results of the script packages count are shown in Table 3 below: [00031] Table 3
  • FIG. 1 depicts an example implementation of chamber bank 70.
  • FIGS. 2-4 depict one or more example implementations of chamber 72 forming part of chamber bank 70.
  • FIGS. 5 and 6 depict example implementations of chamber bank 70 including a sensor such as sensor 516 having a range of vision 64.
  • FIG.7 depicts an example implementation of chamber bank 70 that includes sensor 516 having a range of vision 64 as well as a secondary sensor 518 having a secondary range of vision 65 wherein the secondary sensor 518 is positioned lower than sensor 516.
  • FIG. 8 depicts an example implementation of system 501.
  • FIG. 9 depicts an example implementation of a transport device 12 carrying thereon an article 107 for depositing into receptacle 13.
  • FIG.10 depicts an example implementation of chamber bank 70 that includes secondary sensor 518 having a secondary range of vision 65 wherein the secondary sensor 518 is positioned lower than sensor 516.
  • FIGS. 11 and 12 depict exemplary flowcharts of exemplary implementations of an improved sorting system for directing a sorting operation.
  • FIG. 13 depicts an example implementation of platform assembly 20 comprising a platform 18 with transport devices 12 carrying thereon articles 107 for depositing into a receptacle 13; the transport device 12 to the right is shown to be in the middle of the process of depositing article 107.
  • FIG. 8 accordingly depicts a block diagram of an improved article sorting system
  • system 501 for use with directing a sorting operation, for e.g., when a destination receptacle is to be overfilled to thereby improve overall operational efficiencies, according to one or more implementations of the presently disclosed subject matter.
  • system 501 comprises a control server such as server 502.
  • server 502 is a sub-component of system 501.
  • System 501 further comprises a receptacle assignment engine such as receptacle assignment engine 508, one or more receptacles 13, one or more article information acquisition devices 506, a destination information database 512, a wireless access point 514, and one or more automated transport devices such as transport devices 12.
  • Various components of system 501 are depicted in a representative manner as blocks representing a generic descriptor of the technology. Server
  • Server 502 comprises, among other components, a memory, a processor, with server 502 being in communication with or including receptacle assignment engine 508.
  • Server 502 accordingly comprises a memory, a processor, and may further comprise receptacle assignment engine 508.
  • Transport devices 12, for example in the form of AMRs, are configured for transporting and depositing articles comprising scripts and script packages into receptacles 13.
  • Receptacle 13 includes assigned receptacles 13 and unassigned receptacles 13, filled up receptacles such as full receptacles 13, and replacement receptacles 13 that replace full receptacles 13.
  • System 501 further comprises a chamber bank such as chamber bank 70 (see FIG. 1) comprising a group or bank of chambers such as chambers 72 (see FIG.1). Each chamber 72 is configured for receiving a receptacle such as receptacle 13 therein.
  • chamber 72 is defined by a floor 74, a left wall 76, a right wall 78, and a rear wall 75 that together define a receiving space for totes or receptacles such as receptacle 13.
  • floor 74 of chamber 72 slopes downward from the rear wall 75 towards the front region of chamber 72.
  • the sloping of floor 74 can facilitate the removal of receptacle 13 either after it is full or after an order associated with the receptacle has been completed.
  • at least one of left wall 76, right wall 78, and rear wall 75 extends above a top rim 80 of receptacle 13 received within chamber 72.
  • receptacle 13 sits within chamber 72 such that each of left wall 76, right wall 78, and rear wall 75 extends one or more inches, for e.g., between 1 inch and 30 inches or more, above top rim 80 of receptacle 13; this provides for a spacing of between 1 inch and 30 inches or more between the bottom -most point or the bottom -most edge of ramp 82 of chamber bank 70 and top rim 80 of receptacle 13.
  • Transport devices 12 provide for transporting and depositing articles 107 into receptacles 13. In one embodiment, a transport device 12 travels along platform 18 (see FIG. 13) of platform assembly 20 for transporting an article 107 transporting and depositing an article 107 into a receptacle 13.
  • chamber bank 70 for use in a sorting operation such as chamber bank 70 is provided.
  • chamber bank 70 comprises one or more chambers 72.
  • Each chamber 72 is configured for receiving a receptacle 13 therein.
  • Chamber 72 is defined by a floor 74, a left wall 76, a right wall 78, and a rear wall 75 that together define a receiving space for a receptacle 13.
  • at least one of the left, right and rear walls is taller than the corresponding abutting side wall of the receptacle 13 received therein.
  • chamber 72 of system 501 further comprises a ridge 92 provided in a front portion of chamber 72 for preventing receptacle 13 from sliding out of chamber 72.
  • ridge 92 extends across a portion of the space between the left and right walls of chamber 72.
  • system 501 is configured to assign a first number of articles 107 N that occupy a first volume V to a first receptacle 13 among a plurality of receptacles 13 such that the first number of articles N overfills the first receptacle 13 when all of the first number of articles N are deposited thereinto; in at least one embodiment, the “ungroomed” volume of the first number N of articles 107 exceeds the first volume VR of a first receptacle 13.
  • System 501 is further configured to direct transport device 12 to transport and deposit the first number of articles 107 N into the first receptacle 13.
  • the first volume V occupied by the first number N of articles shall be equal to between 0% and 400% of the volume VR of first receptacle 13 such that in at least one embodiment the first number of articles N overfills the first receptacle 13 prior to the first number of articles being “groomed” by the application of pressure to compress the first of articles such that they fit with the volume VR of first receptacle 13; after one or more such groomings, the first receptacle 13 can be closed and/or otherwise sealed so that it can be transported or shipped to its destination such as a store address or a customer address.
  • receptacle assignment engine 508 is configured to compare the volume V of the first number of articles N to a volume VR of the first receptacle 13. After one or more “groomings” of the articles by the application of pressure to compress the first of articles such that they fit within the volume VR of first receptacle 13, the first volume V occupied by the first number N of articles is reduced and otherwise compressed to have a reduced total compressed volume VC such that the total compressed volume VC of all of the first number N of articles, i.e., the total compressed volume VC of the first number N of articles, is less than or equal to volume of first receptacle 13 VR.
  • the first receptacle 13 is closed and/or otherwise sealed with all of the first number N of articles present therein. Accordingly, in at least one embodiment, the first number N of articles 107 are compressed such that the total compressed volume VC of all of first number N of articles is less than the total volume VR of first receptacle 13.
  • the first number of articles N are compressed manually by a manual operator such that all of the first number N of articles fit into first receptacle 13; in other words, a person gets to the location of the first receptacle 13 and manually compresses the overfilled articles into first receptacle 13 to result in the total compressed volume VC of all of first number N of articles.
  • the first number N of articles 107 are compressed by automated means to arrive at the total compressed volume VC of all of first number N of articles such that the first number of articles can fit into the first receptacle 13 after which first receptacle 13 can be closed and/or otherwise sealed with all of the first number N of articles present therein.; in such an embodiment, a robotic arm or some other automated compressing mechanism compresses the overfilled articles into first receptacle 13 to arrive at the total compressed volume VC of all of first number N of articles after which first receptacle 13 can be closed and/or otherwise sealed with all of the first number N of articles present therein.
  • system 501 is further configured to transmit information indicating that the first receptacle 13 is ready to be compressed, at which point the first receptacle 13 can be compressed either manually or by automated means.
  • system 501 is optionally further configured to transmit information indicating that the first receptacle 13 is ready to be compressed for a second time; in such an embodiment, there may be more than one instance of compression the articles deposited into the first receptacle 13.
  • the first receptacle 13 may be compressed on 2, 3, 4 or more occasions based on the needs of the application at hand.
  • system 501 is further configured to transmit the information indicating that the first receptacle 13 is ready to be compressed in such a manner that it can be received at a hand-held computing device or smart device.
  • system 501 or receptacle assignment engine 508 is further configured to calculate or estimate an uncompressed and a compressed volume of the first number of articles to be deposited into the first receptacle.
  • chamber bank 70 further comprises a ramp or transition such as ramp 82 (see FIG. 1) extending towards a top edge of the rear wall 75 of chamber 72.
  • receptacle 13 may sit within the walls of chamber 72 such that each of left wall 76, right wall 78, and rear wall 75 extends one or more inches, for e.g., anywhere between 1 inch and 30 inches or more, above top rim 80 of receptacle 13. This provides for a spacing of between 1 inch and 30 inches or more between the bottom -most point or the bottom-most edge of ramp 82 that extends towards a top edge of the rear wall 75 of the chamber 72.
  • ramp 82 comprises an article sliding path 84 defined by two or more guides 86 projecting upwards from ramp 82 (see FIG. 1).
  • chamber 72 of system 501 further comprises a gate such as gate 88 extending across an opening at a front region of chamber 72.
  • gate 88 extends across a whole of the spacing separating left wall 76 and right wall 78.
  • gate 88 extends across an opening at a front region of chamber 72.
  • an upper edge of gate 88 extends several inches (e.g., between 1 inch and 30 inches or more) above top rim 80 of receptacle 13; this feature can advantageously support articles overfilled into receptacle 13 and can otherwise advantageously prevent such overfilled articles from falling off of receptacle 13 or off of chamber 72.
  • gate 88 extending several inches above top rim 80 of receptacle 13 advantageously increases the holding capacity of receptacle 13 or of chamber 72 containing receptacle 13.
  • floor 74 of chamber 72 slopes downward from the rear wall 75 towards the front region of chamber 72, and this sloping profile of floor 74 facilitates the easy removal of an order complete receptacle or a full receptacle.
  • Chamber 72 further comprises latch 90 for detachably securing gate 88.
  • latch 90 takes the form of a magnetic latch that secures gate 88 with the gate comprising a ferrous material at least in an area that mates with latch 90.
  • chamber bank 70 accordingly further comprises a lock or latch such that latch 90 for securing gate 88.
  • latch 90 is configured for quick release or easy release such a minimal force above a low threshold value is sufficient to release the lock or latch.
  • latch 90 is a magnetic lock or a similar other locking mechanism.
  • FIG. 11 depicts an exemplary flowchart of an exemplary implementation of an improved sorting system for directing a sorting operation, according to one or more implementations of the presently disclosed subject matter.
  • FIG. 11 accordingly depicts a flowchart of an exemplary process corresponding to system 501 that may be implemented, for example, by server 502.
  • FIG. 11 illustrates a method implemented by system 501, according to one or more embodiments of the presently disclosed subject matter.
  • a system such as system 501 assigns a first number of articles to a first receptacle such as first receptacle 13.
  • system 501 directs a transport device such as transport device 12 to deposit the first number of articles at the first receptacle 13.
  • system 501 determines that the first receptacle 13 is overfilled.
  • system 501 transmits information indicating that the first receptacle 13 is ready to be compressed.
  • system 501 initiates the replacement of first receptacle 13.
  • system 501 determines that the replacement of first receptacle 13 has been accomplished.
  • FIG. 12 depicts another exemplary flowchart of an exemplary implementation of an improved sorting system for directing a sorting operation, according to one or more implementations of the presently disclosed subject matter.
  • the exemplary process shown in FIG. 12 may be implemented, for example, by server 502.
  • FIG. 12 illustrates a method implemented by system 501, according to one or more embodiments of the presently disclosed subject matter.
  • system 501 assigns a first number of articles to a first receptacle 13.
  • the system directs a transport device 12 to deposit less than the first number of articles at first receptacle 13.
  • system 501 determines that the first receptacle 13 is overfilled.
  • the system transmits information indicating that the first receptacle 13 is ready to be compressed; the articles deposited into first receptacle 13 are then compressed by manual or automated means.
  • system 501 redirects transport device 12 to deposit the remaining of the first number of articles at first receptacle 13.
  • the system initiates the replacement of the first receptacle 13.
  • the system determines that the replacement of first receptacle 13 has been accomplished.
  • system 501 further comprises a sensor such as sensor 516 (see FIG. 5) for detecting a fill level or an overfill level of first receptacle 13 or of chamber 72.
  • sensor 516 may take the form of a photo-eye sensor.
  • sensor 516 comprises one or more of: an infra-red sensor, an ultrasonic sensor, a visible light sensor, and a LIDAR (Light Detection and Ranging) sensor.
  • server 502 is in wired or wireless communication with one or more of: sensor 516 and secondary sensor 518.
  • Each of sensor 516 and secondary sensor 518 is configured to sense the filling level or an overfilling level of a receptacle 13, for e.g., to sense whether a receptacle is empty, filled, or overfilled.
  • server 502 directs a person, a robot, or an automated device to transport full receptacle 13 from its article receiving position that is proximal platform 18 or proximal platform assembly 20 to a location of further processing. In some embodiments, the full receptacle 13 is removed manually.
  • server 502 is in communication with sensor 516 configured to sense if and when a receptacle 13 has been overfilled.
  • FIGS. 5-7 illustrate some embodiments of sensor 516 that senses the filling level of receptacle 13 by employing a light plane or a light curtain set-up.
  • sensor 516 includes an emitter and a receiver, as is well understood by a person of skill in the art. Sensor 516 operates to sense that a receptacle is overfilled, filled, or is about to become full.
  • sensor 516 is in two-way communication with server 502 or with system 501.
  • sensor 516 takes the form of an optical sensor such as, for e.g., a photo-eye sensor.
  • server 502 in communication with sensor 516 receives such information about receptacle 13 from sensor 516 and optionally also from secondary sensor 518.
  • secondary sensor 518 shares the same or similar qualities as sensor 516.
  • server 502 identifies or recognizes or receives information indicating that all receptacles 13 present in a given chamber bank 70 are full; on the recognition of or on the confirmation that all receptacles 13 present in a given chamber bank 70 are full, server 502 is further configured to direct replacement of all full receptacles 13 present within the “full” chamber bank 70 with replacement receptacles 13.
  • chamber bank 70 includes casters 94 (see FIG. 1) that render chamber bank 70 mobile whereby the “full” mobile chamber bank 70 is rolled away from its position proximal to the platform 18 and replaced with an “empty” chamber bank 70 that contains one or more empty receptacles 13.
  • Server 502 is further configured to direct a transport device 12 to transport and deposit articles 107 into the empty receptacles 13 of the replaced “empty” chamber bank 70.
  • server 502 when server 502 determines that one or more receptacle 13 are full or have been overfilled thereby resulting in a full receptacle 13, server 502 is further configured to direct replacement of the full or overfilled receptacle 13 (i.e., receptacle 13 that is full or overfilled) with a replacement receptacle 13 with or without grooming of the full or overfilled receptacle 13.
  • server 502 is configured to receive confirmation of this. Server 502 is thus configured to receive confirmation of the replacement of the first receptacle with an empty receptacle.
  • system 501 further comprises an article information acquisition device 506 electronically coupled to server 502.
  • Article information acquisition device 506 is configured to determine a product type of each article by interacting with each article.
  • server 502 is further configured to calculate or receive and store information such as one or more of: first volume V of a first number N of articles deposited into first receptacle 13, volume VR of first receptacle 13, and a total compressed volume VC of the first number of articles.
  • server 502 is further configured to calculate one or more of: a total number, a total count, and a total volume of articles delivered to or deposited at the first receptacle 13 by transport device 12.
  • Server 502 can have access to information regarding the total volume of the first receptacle 13 whereby server 502 can determine, calculate, or estimate the time instant when the first receptacle is full or is about to get full.
  • transport devices 12 may traverse a surface, floor area, or a platform such as platform 18 to deposit articles into receptacles.
  • system 501 is configured to assign a second number of articles to a second receptacle 13.
  • system 501 is configured to re-assign some of the articles previously assigned to the first receptacle 13 to a second receptacle 13.
  • system 501 can further operate to coordinate the replacement of a full receptacle 13 with a replacement receptacle 13.
  • System 501 comprises, or is in communication with, a destination information database 512 with server 502 of system 501.
  • System 501 is configured to use data available at destination information database 512.
  • server 502 is further configured to optimize the total distance that needs to be traveled by one or more transport devices to fill a particular receptacle such that the total distance traveled by all transport devices 12 to fill that receptacle is minimized whenever possible.
  • a destination that is expected to receive the greatest number of articles therein is assigned to one or more receptacles that are located closest to an article induction point; this advantageously ensures that the multiple trips needed to fill a particular high demand destination involve the shortest travel durations or the shortest (one-way or two-way) travel distances.
  • server 502 is configured to determine that the first receptacle is located beyond a predetermined distance from an article induction point, and based on this determination, server 502 is further configured to re-assign the first destination to a second receptacle, wherein the second receptacle is located within the predetermined (shorter) distance from an article induction point; in other words, second receptacle is located at shorter distance from the article induction point as compared to the first receptacle.
  • server 502 re-assigns a first destination ID from the first receptacle to the second receptacle that is close to, or is closest to, an article induction point; accordingly, in some embodiments, the second receptacle is located within a predetermined distance from the article induction point.
  • Server 502 is further configured to redirect a transport device 12 to transport and deposit the first article 107 into the second receptacle, for e.g., wherein the first article 107 is associated with the first receptacle or a first destination.
  • transport device 12 can comprise an automated mobile robot (AMR), a computer-controlled vehicle, a track-arranged device, an overhead transport device, a pedestal robot, a personal AMR, a pick assist AMR, an automated conveyor system, or any similar automated transport or transfer device.
  • AMR automated mobile robot
  • transport device 12 traverses a first surface, floor area, platform, or a track arrangement.
  • transport device 12 may comprise a conveyor.
  • FIG. 9 depicts an example automated transport device such as transport device 12 for carrying, moving, or transporting an article such as first article 107 to be sorted to a receptacle.
  • system 501 carries out sortation operations using transport devices in the form of autonomous mobile robots (AMRs).
  • AMRs autonomous mobile robots
  • a given AMR has been routed to a receptacle and the system recognizes that the receptacle is full or that the receptacle has been overfilled.
  • AMRs which are enroute to a destination receptacle which is determined to be filled up or to have been overfilled after an AMR has been dispatched by the system to deliver an article to closes, the AMR is re-routed to the new receptacle.
  • the event of a destination receptacle being filled up or being overfilled can be determined by sensor 516 at the location that communicates this information to server 502, or by server 502 that calculates the total cubic volume or total weight of all of the articles sorted into that destination receptacle.
  • Server 502 re-routes any enroute vehicles from the filled or overfilled receptacle location to a new receptacle’s physical location. Any subsequent articles destined for the filled or overfilled receptacle destination are routed to the new receptacle’s physical location.
  • Server 502 initiates or directs the change-out or grooming of the filled or overfilled receptacle or the changeout of the chamber bank containing the filled or overfilled receptacle.
  • This initiation may be in the form of a message to another system that controls the change-out robots, or in the form of an indication to a human operator via lights, sounds, signals sent to a handheld computer, etc.
  • the change-out or grooming automation mechanism or human operator may send a confirmatory message to the server indicating that the location is available for another or the same assignment.
  • System 501 may further include an input article region that functions to hold articles prior to sorting.
  • the input article region includes one or more input article holders that contain unsorted articles.
  • the article holders can be placed adjacent to article information acquisition device 506 and are preferably within the reachable range of article information acquisition device 506. In this way, a worker, conveyor system, or a robotic system may move an article holder into position and optionally remove empty (or otherwise finished) article holders present at input article region.
  • Articles and/or article holders may be moved through or added to the input article region using a conveyor, a chute, an autonomous mobile robot, or using any suitable mechanism.
  • one or more articles may be supplied such that an article identifier (or property) is already known to system 501 when article information acquisition device 506 interacts with the article whereby a receptacle 13 may be associated with the article prior to placement of the article on a transport device 12.
  • the order of article selection by system 501 may factor in the capacity levels of receptacles such that an article is dispatched after server 502 determines that an associated receptacle 13 has capacity to receive the article.
  • Article information acquisition device 506 may include one or more sensors configured for article identification. This could include a sensor for scanning a barcode and/or an RFID tag reader.
  • system 501 may include 4 barcode scanners: two side scanners, one top scanner, and a bottom scanner.
  • the two side barcode scanners can capture barcodes on the sides of articles while rotating the article.
  • the top scanner can capture barcodes from up top such as after article placement in a transfer tray or the article tray.
  • the bottom scanner can capture barcodes from below as the article is removed from the article receptacle.
  • a transparent shield can be placed above the bottom scanner so that if an article is dropped it will deflect off the shield. Any suitable sensing system may be used for collecting information of an article that can be used to determine a destination output receptacle.
  • Article information acquisition device 506 may further function to collect data of the objects and the environment.
  • article information acquisition device 506 includes an imaging system, which functions to collect image data.
  • the imaging system can include at least one imaging device with a field of view of a region of interest that covers a region where the article is transferred to a transport device 12 and the input article region.
  • the imaging system may additionally include multiple imaging devices used to collect image data from multiple perspectives of a distinct region, overlapping regions, and/or distinct nonoverlapping regions.
  • the set of imaging devices (e.g., one imaging device or a plurality of imaging devices) may include a visual imaging device (e.g., a camera).
  • the set of imaging devices may additionally or alternatively include other types of imaging devices such as a depth camera.
  • Article information acquisition device 506 may collect data that is communicated to the server 502 to facilitate article placement onto a transport device.
  • image data of a collection of articles in the input article region can be processed by an analysis model that outputs one or more sortation plans (e.g., points for article selection, or motion plans for approaching, and picking up an article).
  • sortation plans e.g., points for article selection, or motion plans for approaching, and picking up an article.
  • Article information acquisition device 506 may additionally or alternatively include one or more sensors for article dimensioning.
  • Article information acquisition device 506 could include one or more dimensional camera (e.g., a depth sensor) or similar other sensor system for dimensioning the article.
  • Dimensioning can include determining spatial characteristics of the article (i.e., article dimensions).
  • the article dimensions can include defining a bounding volume of the article (e.g., a width, height, and depth of the article).
  • the article dimensions may be used at least in part in planning placement orientation during induction and sortation into a receptacle 13.
  • Other sensors such as load cells, proximity sensors, RFID tracking systems, and the like may also be used to monitor status of various aspects of system 501.
  • System 501 may additionally include other supplementary systems such as, for e.g., label printer and applicator, which function to enable labels to be produced and applied to an article prior to sortation.
  • System 501 may additionally include a receptacle capacity sensor that functions to measure the capacity level of an article receptacle and/or to detect when an article receptacle is at proximity.
  • a receptacle capacity sensor that functions to measure the capacity level of an article receptacle and/or to detect when an article receptacle is at proximity.
  • sensor 516 and secondary sensor 518 may perform this function.
  • a variety of sensing technologies may be used for these purposes.
  • a depth sensor or an imaging system can be downwardly attached to a surface such as platform 18 or ramp 82. The depth sensor can detect or collect image data used in predicting the capacity level of an article receptacle as it passes over the article receptacles. The capacity of an article receptacle may be measured each time an article is deposited into it.
  • the receptacle capacity sensor is in one- or two-way communication with server 502.
  • the output receptacle capacity sensor is coupled to platform 18 or to transport device 12 such that the output receptacle capacity sensor can be moved across an array of receptacles 13.
  • the capacity of a receptacle 13 may be measured as the capacity sensor passes over a receptacle during use of the transport device 12 such as when in transit and/or while depositing an article.
  • platform 18 or ramp 82 may be equipped with sensors or other elements that can act on an article being sorted.
  • platform 18 could include a weight sensor so that articles could be weighed prior to being transferred to a transport device.
  • the weight sensor could be a load cell (or other sort of pressure sensor, strain sensor, digital scale, or the like to estimate/measure weight) integrated into a transfer tray.
  • article information acquisition device 506 interacting with the article can include determining an identifier of the article. This may be used when information concerning the identity of the article is unknown prior to picking the article. Accordingly, the article may be scanned or imaged to determine a designated grouping. For example, for parcels, an address may be scanned and used for determining which route group to use for the parcel. Determining an identifier of the article may include scanning a barcode (or other suitable type of machine-readable code or information), reading an RFID tag, or reading another type of wireless identifier signal, visually classifying the article using computer vision analysis, and/or using some other identification or classification technique.
  • determining an identifier of the article may be used when information concerning the identity of the article is unknown prior to picking the article. Accordingly, the article may be scanned or imaged to determine a designated grouping. For example, for parcels, an address may be scanned and used for determining which route group to use for the parcel. Determining an identifier of the article may include scanning a barcode (or other
  • the system may determine a targeted article receptacle of the article based on the identifier of the article.
  • an article can be picked and scanned to determine its identity, and then based on the identity query a database to determine which one or more targeted article receptacle to associate with the article.
  • the system can then facilitate sorting the article into the targeted article receptacle such as receptacle 13.
  • server 502 operates to manage the sort destinations using at least 3 main parameters or fields: receptacles, physical locations, and logical destinations.
  • the destination associated with a receptacle 13 may represent: an order, a store, a shipping route, carrier, zip code, city, and a similar other characteristic.
  • there are multiple receptacles associated with one destination ID e.g., when a store order requires more than will fit in one receptacle.
  • server 502 uses physical locations (rather than receptacles) to sort articles and to direct transport device 12 for sorting articles into receptacles.
  • processing of the article to be sorted before placement on a transport device can include determining dimensional properties of the article, which functions to sense or detect one or more dimensions of the article.
  • determining dimensional properties of the article can include determining a bounding volume of the article (e.g., height, width, and depth).
  • determining dimensional properties of the article may include collecting a full or partial 3D scan of the surface of the article. Determining dimensional properties can include sensing one or more dimensional metrics of the article. This may involve moving the article in range of a dimensional camera or other sensing system. This may additionally include manipulating the article within the view of a sensor for scanning different views of the article.
  • image data may be used to predict dimensions and/or form of the object using an Al (artificial intelligence) classifier model or other technique.
  • the dimensional properties may be used for any suitable purpose, but in one particular embodiment, the dimensional properties may be used in predicting a placement orientation of the article for depositing into an article receptacle.
  • the dimensions and/or shape of the article can be used for figuring out how the article may be best placed in an article tray of an article sortation unit so that when it deposits the article into an article receptacle it has high confidence for successful depositing. This can avoid situations where articles of more irregular forms could flip over and miss an article receptacle.
  • the dimensional properties of the article can be used in determining if an article is larger in one or more axes than the container opening and then orienting the article such that when deposited the object enters an article receptacle with a side with dimensions that do fit within a defined opening of the article receptacle.
  • articles characterizes the objects subjected to sortation by a sorting system.
  • An article can be any suitable type of object such as a package, a parcel, a product, raw material good (e.g., a manufactured part), and/or any suitable type of object that needs sortation organization.
  • an article may have various properties.
  • articles could be, for example: boxed goods, bagged goods, and/or parcels.
  • An article could have destination information indicating where it should be shipped.
  • An article could have an article type information that could correspond to a stock keeping unit (SKU) identifier or an alternative product identifier.
  • SKU stock keeping unit
  • receptacles such as receptacle 13, which is used to characterize the receptacle used to hold articles once sorted.
  • the form factor and variety of the receptacles can vary greatly, and the system may be adapted to different types of receptacles such as boxes, receptacles, trays, bags, gaylords, and the like.
  • Article receptacles may use any suitable form factor and, in some cases, may use the same type of container.
  • the form factor may be customized for particular variations and implementations of system 501 as described herein.
  • one or more components such as receptacle assignment engine 508 and destination information database 512 may reside external to server 502 but nonetheless in communication with server 502.
  • System 501 further comprises or is in communication with sensor s 516, transport devices 12, and one or more receptacles 13.
  • System 501 includes additional components such as article information acquisition device 506 (e.g., a scanner, image capturing equipment, or similar other equipment), and a wireless access point 514, among others.
  • System 501 further includes one or more receptacles 13, wherein system 501 operates to sort a plurality of articles to a receptacle 13, the plurality of articles comprising a first article 107.
  • server 502 is a control server that is configured for communicating with one or more components of system 501 as described herein, and as shown, for example, in FIG. 8.
  • server 502 includes memory, a processor, and/or one or more communication interfaces communicatively coupled to each other.
  • a network may form part of system 501, wherein the network may take on any appropriate form, including a wireless network such as Wi-Fi, cellular, or other frequency bands for private use, or a hard-wired network such as LAN, WAN, internet, etc., and combinations thereof.
  • server 502 may communicate over the network with the cloud.
  • one or more components of server 502 may reside in the cloud.
  • the components such as, for example, article information acquisition device 506, wireless access point 514, computer-controlled or automated transport devices 12 and server 502 may communicate over the network with the cloud.
  • one or more components of system 501 may reside in the cloud.
  • server 502 may reside in the cloud.
  • server 502 may be in communication with one or more third-party servers, such as warehouse management system servers and automated transport device operations control servers.
  • the term “cloud” refers to several servers connected to the internet that can be leased as part of a software or application service. Cloud-based services can include web hosting, data hosting and sharing, and software or application use. The term “cloud” also refers to cloud computing, where several servers are linked together to share the load. This means that instead of using one single powerful machine, complex processes can be distributed across multiple smaller computers.
  • server 502 can be or can otherwise include a server as the term “server” is understood in its broadest sense.
  • server as used herein includes any computer that provides data to other computers. It may serve data to systems on a local area network (LAN) or a wide area network (WAN) over the Internet.
  • LAN local area network
  • WAN wide area network
  • server 502 can be or can include a cloud server.
  • cloud server includes any pooled, centralized server resource that is hosted and delivered over a network — typically the Internet — and accessed on demand by multiple users.
  • a cloud server can be remotely located (e.g., reside in a remote cloud server configuration).
  • a cloud server can be a virtual server (rather than a physical server) running in a cloud computing environment.
  • a cloud server can be built, hosted, and delivered via a cloud computing platform via the internet, and can be accessed remotely.
  • a cloud server can include all the software it requires to run and can function as an independent unit.
  • a cloud server can perform all the same functions as a traditional physical server including delivering processing power, storage, and applications.
  • cloud storage there are many distributed resources acting as one - often called federated storage clouds. This makes the cloud very tolerant of faults, due to the distribution of data. Use of the cloud can reduce the creation of different versions of files, due to shared access to documents, files, and data.
  • Each of the components of system 501 may be in communication with one or more other components through a wired and/or a wireless network.
  • the server 502 may further communicate with receptacles 13, chamber banks 70, chambers 72, receptacles 13, receptacle assignment engine 508, sensor s 516, article information acquisition devices 506, automated transport devices 12, destination information database 512, and wireless access point 514 over a network.
  • system 501 can be used for consolidating parcels for shipping.
  • a parcel processing site may use system 501 to sort parcels by destinations (e.g., zip codes or delivery routes) for subsequent shipment processing.
  • destinations e.g., zip codes or delivery routes
  • Unsorted letters and/or packages can be collected into large article receptacles and then system 501 can facilitate sorting those into smaller article receptacles for different delivery routes / destinations.
  • destinations e.g., zip codes or delivery routes
  • system 501 can be used for returned good processing and/or good restocking.
  • mixed article receptacles of returned goods could be appropriately sorted for reshelving, restocking, or other subsequent processing.
  • newly received article orders could be sorted into appropriate receptacles for replenishing article stock within a store.
  • the size and automated affordances of system 501 is such that it could be used in a variety of environments such as in a back-warehouse of a retail store or in an order fulfillment center (e.g., such as for ecommerce returns).
  • system 501 may be used for order fulfillment where a collection of articles is sorted into individual article receptacles, where each article receptacle may be associated with a particular order.
  • the orders may be, for e.g., for consumers such as ecommerce orders; in at least one example, the orders represent commercial orders for delivery to a business.
  • system 501 may also be used for dynamic or custom kitting for industrial or consumer goods.
  • the article receptacles may be attached to an automated conveyor system or other translation devices such that the article receptacles can be removed in an automated fashion. Similarly, empty (or at least not full) article receptacles may be moved into an unfilled region of the article receptacle array. In one implementation an autonomous robot, pallet jack or tug may engage with article receptacles when at capacity and remove them from the article receptacle array. Similarly, new article receptacles can be automatically inserted into a non-filled article receptacle space.
  • signaling changing of an article receptacle may include triggering an alert and indicating the article receptacle(s) to be removed.
  • the alert may similarly indicate the assigned grouping and the next task for the article receptacle. This may alert human workers that can manually or through the aid of some mechanism remove an article receptacle and/or load an article receptacle.
  • Article receptacles may be generally signaled for discharging (using an autonomous or semi -autonomous approach) when the article receptacle satisfies a capacity condition.
  • the capacity condition may be based on how full or overfilled the article receptacle is or whether an order has been completed.
  • the method can additionally model expected time and availability to exchange an article receptacle. For example, an article receptacle may be removed before it is at a capacity limit to avoid having too many article receptacles needing exchange at the same time.
  • an article receptacle may be discharged when the method determines a benefit to having a different mix of groupings allocated within the receptacle array. For example, an uncommon article receptacle may be discharged when it has few articles such that a new article receptacle placed in that position can be reassigned to a different grouping.
  • System 501 may provide a number of potential benefits as noted herein. System 501 is not limited to always providing such benefits and is presented only as exemplary representations of how system 501 may be put to use. The list of benefits is not intended to be exhaustive and other benefits may additionally or alternatively exist.
  • aspects of the present invention may be embodied as a system, method, or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment comprising software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
  • the computer readable medium may be a computer readable signal medium or a computer readable storage medium (including, but not limited to, non-transitory computer readable storage media).
  • a computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing.
  • a computer readable storage medium may be any tangible medium that can contain or store a program for use by or in connection with an instruction execution system, apparatus, or device.
  • a computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof.
  • a computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
  • Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
  • Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object-oriented programming language such as Java, Smalltalk, C++, or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages.
  • the program code may execute entirely on the user’s computer, partly on the user’s computer, as a stand-alone software package, partly on the user’s computer and partly on a remote computer or entirely on the remote computer or server.
  • the remote computer may be connected to the user’s computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
  • LAN local area network
  • WAN wide area network
  • Internet Service Provider for example, AT&T, MCI, Sprint, EarthLink, MSN, GTE, etc.
  • These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
  • the computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
  • each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s).
  • the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

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  • Warehouses Or Storage Devices (AREA)

Abstract

L'invention concerne un banc de chambres destiné à être utilisé dans une opération de tri comprenant des chambres destinées à recevoir un réceptacle à l'intérieur de celles-ci. Chaque chambre est définie par un plancher, une paroi gauche, une paroi droite et une paroi arrière qui définissent ensemble un espace de réception pour un réceptacle. Au moins l'une des parois gauche et droite est plus grande que la paroi latérale de butée correspondante du réceptacle reçu à l'intérieur de celui-ci. Un système attribue un premier nombre d'articles occupant un premier volume au réceptacle de telle sorte que le premier nombre d'articles remplit le réceptacle lorsque tous les articles du premier nombre d'articles sont déposés dans celui-ci.
PCT/US2023/074683 2022-09-20 2023-09-20 Optimisation de remplissage de réceptacle d'ordre de tri WO2024064747A1 (fr)

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US18/470,670 2022-09-20

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Citations (5)

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Publication number Priority date Publication date Assignee Title
US5987857A (en) * 1996-09-09 1999-11-23 Lipton, Division Of Conopco, Inc. Packaging apparatus
EP1970868A1 (fr) * 2007-03-16 2008-09-17 Nobab GmbH Dispositif et procédé destinés au stockage automatique de marchandises au détail
US20090064638A1 (en) * 2004-11-02 2009-03-12 Ranpak Corp. Automated flowable dunnage dispensing system and method
US20200346790A1 (en) * 2017-10-23 2020-11-05 Blueprint Holding B.V. Compactor device and conveyer system comprising such compactor device, and corresponding compacting and packing methods
US20210001489A1 (en) * 2019-07-02 2021-01-07 Intelligrated Headquarters, Llc Robotic sortation system

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5987857A (en) * 1996-09-09 1999-11-23 Lipton, Division Of Conopco, Inc. Packaging apparatus
US20090064638A1 (en) * 2004-11-02 2009-03-12 Ranpak Corp. Automated flowable dunnage dispensing system and method
EP1970868A1 (fr) * 2007-03-16 2008-09-17 Nobab GmbH Dispositif et procédé destinés au stockage automatique de marchandises au détail
US20200346790A1 (en) * 2017-10-23 2020-11-05 Blueprint Holding B.V. Compactor device and conveyer system comprising such compactor device, and corresponding compacting and packing methods
US20210001489A1 (en) * 2019-07-02 2021-01-07 Intelligrated Headquarters, Llc Robotic sortation system

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