U.S. patent application number 13/767905 was filed with the patent office on 2013-06-13 for matrix sorter system.
This patent application is currently assigned to SPAN TECH LLC. The applicant listed for this patent is SPAN TECH LLC. Invention is credited to JAMES L. LAYNE.
Application Number | 20130146419 13/767905 |
Document ID | / |
Family ID | 35320642 |
Filed Date | 2013-06-13 |
United States Patent
Application |
20130146419 |
Kind Code |
A1 |
LAYNE; JAMES L. |
June 13, 2013 |
MATRIX SORTER SYSTEM
Abstract
A matrix conveying system for intended use in sorting articles
and related methods of conveying and sorting articles are
disclosed. In one embodiment, the matrix system comprises a
plurality of first endless belt or chain conveyors extending in a
first direction and a plurality of second conveyors extending in a
second direction, each intersecting the plurality of first
conveyors. The system may be used to sort articles delivered from
one or more storage locations for distribution, or may instead be
used to sort articles for delivery to one or more storage
locations. In another embodiment, the system comprises a plurality
of conveyors arranged in three different layers.
Inventors: |
LAYNE; JAMES L.; (Bowling
Green, KY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SPAN TECH LLC; |
Glasgow |
KY |
US |
|
|
Assignee: |
SPAN TECH LLC
GLASGOW
KY
|
Family ID: |
35320642 |
Appl. No.: |
13/767905 |
Filed: |
February 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13299421 |
Nov 18, 2011 |
8376118 |
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13767905 |
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11568478 |
Oct 30, 2006 |
8113334 |
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PCT/US05/14790 |
Apr 28, 2005 |
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13299421 |
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60618853 |
Oct 14, 2004 |
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60567411 |
Apr 29, 2004 |
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Current U.S.
Class: |
198/367 ;
198/348; 198/369.1 |
Current CPC
Class: |
B07C 3/08 20130101; B07C
3/008 20130101; B65G 47/52 20130101 |
Class at
Publication: |
198/367 ;
198/348; 198/369.1 |
International
Class: |
B07C 3/00 20060101
B07C003/00; B65G 47/52 20060101 B65G047/52 |
Claims
1. A conveyor system for sorting articles received from an infeed
conveyor, said system comprising: a plurality of indexing conveyors
configured to receive articles from the infeed conveyor; and a
storage structure comprising a plurality of receivers, at least one
of said receivers configured to receive an article from at least
one indexing conveyor.
2. The system of claim 1, wherein the indexing conveyors are
generally coplanar.
3. The system of claim 1, wherein each of the indexing conveyors
comprise one or more individual conveyor segments.
4. The system of claim 3, wherein the total number of receivers
associated with the storage structure corresponds to the total
number of conveyor segments.
5. The system of claim 3, wherein the total number of receivers
associated with the storage structure corresponds to the total
number of conveyor segments times the total number of indexing
conveyors.
6. The system of claim 1, wherein the total number of receivers
associated with the storage structure is equal to or greater than
the total number of indexing conveyors.
7. The system of claim 1, wherein the total number of receivers
associated with the storage structure is greater than the total
number of indexing conveyors.
8. The system of claim 1, further including a motive device for
selectively moving at least one receiver to coordinate a position
of the receiver with a given indexing conveyor to receive an
article therefrom.
9. The system of claim 1, wherein the indexing conveyors each
include a conveying surface for transporting articles and the
receivers are arranged in a plane generally perpendicular to a
plane of the conveying surface of at least one indexing
conveyor.
10. The system of claim 1, wherein the indexing conveyors each
include a conveying surface for transporting articles and the
receivers are arranged in a plane generally parallel to a plane of
the conveying surface of at least one indexing conveyor.
11. The system of claim 3, wherein the conveyor segments are
configured to be driven independently from one another.
12. The system of claim 3, wherein the conveyor segments are driven
by a common electric motor.
13. The system of claim 1, further comprising a sensor associated
with an outfeed end of each indexing conveyor adjacent the storage
structure, said sensor configured to detect the presence of an
article at the outfeed end.
14. The system of claim 1, further including at least one diverter
for selectively diverting an article to at least one indexing
conveyor.
15. A conveyor system for sorting articles received from an infeed
conveyor, said system comprising: a plurality of indexing conveyors
configured to receive articles from the infeed conveyor, wherein
each of the indexing conveyors further comprises a plurality of
second conveyors, which together define the indexing conveyor; and
a storage structure comprising a plurality of receivers arranged in
a number of columns corresponding to the number of indexing
conveyors, each receiver configured to receive an article from at
least one of the plurality of indexing conveyors.
16. The system of claim 15, wherein the number of receivers within
each column corresponds to a number of indexing positions of the
indexing conveyor corresponding to each column.
17. The system of claim 15, wherein the indexing conveyors each
further include an outfeed end for delivering at least one article
to at least one receiver, and wherein the outfeed end of each
indexing conveyor includes a sensor for sensing the presence of an
article at said outfeed end.
18. The system of claim 15, further including a motive device for
selectively moving the storage structure to coordinate the position
of at least one receiver with a given outfeed end of an indexing
conveyor to receive an article therefrom.
19. The system of claim 15, further including a motive device for
selectively moving at least a portion of at least one indexing
conveyor to coordinate the position of the outfeed end of the at
least one indexing conveyor with a receiver to deliver an article
thereto.
20. A method of sorting articles from an infeed conveyor comprising
the steps of: providing a plurality of indexing conveyors;
providing a storage structure comprising a plurality of receivers;
selectively delivering at least one article to at least one of the
indexing conveyors from the infeed conveyor; and selectively
delivering the at least one article from the indexing conveyor to a
corresponding receiver.
21. The method of claim 20, wherein the step of delivering an
article to a receiver comprises selectively moving the receiver to
a position adjacent an outfeed end of the indexing conveyor.
22. The method of claim 19, further comprising the step of
selectively delivering an article to a segment of the indexing
conveyors, advancing the article to a second segment of the
indexing conveyor, prior to the step of delivering the article to
the corresponding receiver.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/568,478, filed Oct. 18, 2006, which is the
National Stage of PCT/US2005/014790, filed Apr. 28, 2005, and which
claims the benefit of U.S. Provisional Patent Application Ser. No.
60/567,411, filed Apr. 29, 2004, and Ser. No. 60/618,853, filed
Oct. 14, 2004, the disclosures of which are incorporated herein by
reference.
TECHNICAL FIELD
[0002] The present invention relates to the article conveying art
and, in particular, to a system including a matrix of conveyors for
conveying or sorting articles.
BACKGROUND OF THE INVENTION
[0003] Over the past several years, the demand from businesses a id
individuals alike for second day and even overnight deliveries of
articles, such as small to mid-sized parcels, packages and letters,
has steadily increased. This demand is due, in part, to the
prevalence of Internet and mail order shopping, which creates a
similar need for an efficient and effective distribution system to
deliver expediently the wares to a common carrier. Consequently,
the need for methods and systems for quickly transporting, sorting
and distributing this ever increasing volume of articles has
similarly increased.
[0004] In fact, it is now general practice for common carriers to
transport articles in the form of small to mid-sized packages or
the like to a central sorting terminal or hub, where they are
sorted according to selected parameters, such as having common
regional destinations, and then delivered as a group. Once these
destinations are reached, it is necessary to sort again to
distribute articles in the group to their final destinations. To
accomplish these tasks in the amount of time required to insure
overnight delivery, the central as well as the regional sorting
terminals or hubs must receive, sort and distribute hundreds of
thousands of coded packages each day. Besides on the delivery side,
a similar need exists on the distribution side, since purchasers
have become accustomed to receiving ordered items without
significant delay.
[0005] Necessarily, the sortation systems used must be capable of
processing the packages within these defined time parameters.
Indeed, in response to the continuously increasing number of
packages requiring next day or overnight delivery, the sortation
systems must operate much faster and more efficiently than just a
few years ago. It is also desirable for the systems to be more
adaptable to accommodate fluctuations in need/demand, as well as
simpler and less expensive.
[0006] Since as early as the 1960's, various package sortation
systems have relied upon primitive "induction" type systems
including an endless "loop" conveyor with mobile units that
receive, transport and deposit packages at selected distribution
stations. Specifically, U.S. Pat. No. 3,167,192 to Harrison et al.
and U.S. Pat. No. 3,327,836 to Burt each disclose package sortation
systems using tilt tray assembly units propelled by an endless
conveyor chain. Timers and somewhat unreliable magnetic readers
actuate tip solenoids to tilt the trays to one side, thus in theory
allowing gravity to pull passively the packages from atop the trays
upon reaching their destination. As should be appreciated, the
speed with which such a system can process articles leaves much to
be desired, especially since articles must potentially traverse the
entire loop before reaching the desired destination.
[0007] A more recent sortation system described in U.S. Pat. No.
4,832,204 to Handy et al. integrates these prior art tilt tray
sortation systems with more complicated scanning equipment and
computer control in an attempt to improve overall system speed and
efficiency. Despite the successful integration of these components
into a supposedly more modern and state of the art system, and at a
cost of much greater complexity and cost, the system of the '204
patent still fails to improve the basic sortation apparatus and
methods. In essence, package delivery customers are calling for a
move away from the continued reliance on the complex and expensive
tilt tray systems that rely primarily on gravity transfer, such as
in the '204 patent, and at the same time demanding significant
increases in the overall speed, efficiency and adaptability of the
sortation system.
[0008] In recent times, "tilt tray" sorters have been replaced by
allegedly more efficient "cross belt" sorters. One version of this
type of sortation system includes an endless train of driven cars
pass operator-controlled feed conveyors used to deliver a single
article for transport around the loop. When the car reaches the
desired destination for the article, an onboard conveyor actuates
to eject the article to a takeaway conveyor. An early example of
this type of system appears in U.S. Pat. No. 3,977,513 to
Rushforth, and a more modern example appears in the September 2003
issue of Modern Material Handling magazine (which is incorporated
herein by reference).
[0009] Despite the industry-wide movement toward this type of
sorting system, it still suffers from similar problems with
efficiency. Just like in the tilt tray systems, only a single
article can be loaded onto a selected car at a given instant in
time. This serves as a significant limitation on the total
throughput possible, and requires operating many such systems
simultaneously to keep up with the demand. The use of individual
cars with cross belts, which are typically complicated in
construction, also presents problems from a reliability and
maintenance standpoint.
[0010] Furthermore, past sortation systems cannot sort articles
continuously, since various events demand downtime. For example,
articles sometimes mis-introduced into the system must be retrieved
and removed. Likewise, completing the previous sorting operation
before introducing the next group of articles requires introducing
any articles accidentally left out from the previous operation,
which results in costly downtime. Running two induction-type
sortation systems in parallel alleviates the problem in part, but
this will not necessarily reduce the cost. The existing systems
also tend to occupy a great deal of floor space, which may make
this impossible to accomplish using a given facility.
[0011] Thus, an important aspect of the effort to improve this
technology involves providing a sortation system and related method
capable of transporting, sorting and distributing the increasing
volume of such articles in a more efficient manner. The desired
approach should eliminate the complexity, especially by eliminating
tilt trays for ejecting articles being conveyed at a particular
location, such as along an endless induction loop, and instead go
to a simple arrangement of endless belt or chain conveyors.
Increased efficiency and adaptability of use, as well as lower cost
and maintenance, should advantageously result without a concomitant
increase in complexity.
SUMMARY OF THE INVENTION
[0012] In accordance with one aspect of the invention, a conveyor
system for intended use in conjunction with the sorting of articles
comprises a plurality of first substantially continuous endless
belt or chain conveyors extending in a first direction, each
providing a first conveying surface for the articles. A plurality
of second substantially continuous endless belt or chain conveyors
extending in a second direction intersect the first conveyors. Each
second conveyor provides a second conveying surface for any
articles transferred from one or more of the intersecting first
conveyors.
[0013] To automate the sortation process, the system preferably
further includes means for transferring at least one article from
at least one of the first conveyors to an intersecting one of the
second conveyors. The transferring means may be provided adjacent
each intersection for transferring one or more articles from each
first conveyor to the associated second conveyor. In one
embodiment, the first conveyors are positioned above the second
conveyors, and the means for transferring articles comprises a
portion of each first conveyor capable of assuming a drop down
position for delivering one or more of the articles to the second
conveyor. Preferably, an end of the drop down portion of each first
conveyor is staggered relative to a lateral dimension of the
associated second conveyor, which helps to avoid article
collisions.
[0014] The first conveyors are parallel to each other and generally
perpendicular to the second conveyors, and may include
interconnected modular links. Furthermore, a plurality of third
conveyors may be provided for receiving articles from the first or
second conveyors, wherein the third conveyors intersect the first
conveyors and extend generally parallel to the second conveyors.
Optionally, the third conveyors may move the corresponding articles
in a direction generally opposite that of the second conveyors.
[0015] In accordance with a second aspect of the invention, a
conveyor system for intended use in conjunction with the sorting of
articles comprises a plurality of first conveyors extending in a
first direction in a first horizontal plane. A second conveyor
extends in a second direction generally perpendicular to the first
direction and in a second horizontal plane, and further intersects
the plurality of first conveyors. Means adjacent each intersection
is provided for transferring at least one article between the first
and second conveyors to thereby effect sortation.
[0016] In one embodiment, the transferring means is an L-shaped
transfer conveyor including a first portion aligned with the first
conveyor and a second portion aligned with the second conveyor.
Preferably, the second portion is tilted relative to a horizontal
plane such that articles may slide onto the second conveyor.
Alternatively, the transferring means may be selected from the
group consisting of an active conveyor, a passive chute, and an
elevator.
[0017] The second conveyor may be positioned either below or above
the plurality of first conveyors. In either case, the system may
further include means for moving the at least one article from the
first conveyor to the transferring means. In one embodiment, the
moving means is a diverter associated with the first conveyor.
[0018] In accordance with another aspect of the invention, a
conveyor system for intended use in conjunction with the sorting of
articles comprises a plurality of first conveyors extending in a
first direction and a plurality of second conveyors extending in a
second direction. The second conveyors are positioned above and
intersect the first conveyors. At least one third conveyor extends
in either the first or second direction and is positioned below the
first conveyors.
[0019] Preferably, the first and second directions are generally
perpendicular to each other, and the system includes means for
transferring articles from one first conveyor to one second
conveyor. The system may further include means for transferring
articles from one first conveyor to the third conveyor. However, it
is preferable to provide means for transferring articles at each
intersection between the first, second, and third conveyors.
[0020] In accordance with still another aspect of the invention, a
conveyor system for intended use in conjunction with the sorting of
articles is disclosed. The system comprises a plurality of first
conveyors extending in a first direction; a plurality of second
conveyors intersecting the first conveyors; and a third conveyor
for transferring articles from a first conveyor to a second
conveyor at each intersection. Preferably, the third conveyor is
L-shaped and includes a first portion aligned with the first
conveyor and a second portion aligned with the second conveyor. The
second portion may be tilted relative to a horizontal plane such
that articles may slide onto the second conveyor.
[0021] In accordance with yet another aspect of the invention, a
conveyor system for intended use in conjunction with the sorting of
articles comprises a plurality of first conveyors extending in a
first direction, a plurality of second conveyors intersecting the
first conveyors, and at least one receiver associated with each
second conveyor for receiving articles having a particular
characteristic in common. The common characteristic may be, for
example, a delivery destination selected from the group consisting
of a country, region, state, zip code, county, city, village, town,
and street address.
[0022] Preferably, each second conveyor is associated with a
takeaway conveyor for delivering a selected article to the
receiver. The system may further include a plurality of receivers,
each associated with a takeaway conveyor for delivering a selected
article from the corresponding second conveyor. The takeaway
conveyor may be an indexing conveyor including two or more
segments, each capable of independently conveying an article to the
corresponding receiver.
[0023] In accordance with a further aspect of the invention, a
matrix sortation system comprises three different levels of
conveyors, including a first level of first conveyors, a second
level of second conveyors intersecting the first conveyors, and a
third level of third conveyors. The first conveyors may be infeed
conveyors and the second and third conveyors are takeaway
conveyors. Alternatively, the first and third conveyors may be
infeed conveyors and the second conveyors may be takeaway
conveyors
[0024] In accordance with yet a further aspect of the invention, a
method of conveying articles is disclosed. The method comprises
transporting articles along a plurality of first endless belt or
chain conveyors extending in a first direction. The method further
comprises transferring an article from at least one first conveyor
to one of a plurality of second conveyors extending in a second
direction and intersecting the plurality of first conveyors. The
method may further include the step of selecting an article for
transfer to one of the second conveyors prior to the transferring
step, which in turn may comprise identifying a common
characteristic of the article.
[0025] Still further, the method may include the steps of: (1)
transferring the article from the second conveyor to a receiver; or
(2) simultaneously transferring articles from a first conveyor to
two different second conveyors.
[0026] In accordance with yet another aspect of the invention, a
method of conveying articles comprises transporting articles along
a plurality of first conveyors extending in a first direction;
transferring a first selected article from one first conveyor to a
second conveyor extending in a second direction and positioned
below the first conveyors; and transferring a second selected
article from one first conveyor to a third conveyor extending in
the second direction and positioned above the first conveyors. The
transferring steps may comprise actively or passively conveying the
corresponding article.
[0027] Still another aspect of the invention is a method of sorting
articles. The method comprises providing a matrix including a first
level of first conveyors extending in a first direction, a second
level of second conveyors below the first conveyors and extending
in a second direction, and a third level of third conveyors above
the first conveyors parallel to the second conveyors. The method
further comprises sorting a batch of articles delivered to the
first conveyors by selectively delivering the articles from the
corresponding first conveyor to a selected one of the second or
third conveyors. The batch of articles may include first articles
and second articles, in which case the sorting step is performed by
delivering the first article from the corresponding first conveyor
to the selected one of the second conveyors, and then delivering
the second article from the corresponding first conveyor to the
selected one of the third conveyors.
[0028] A further aspect of the invention is a method of sorting
articles. The method comprises providing a matrix comprised of a
first level of first conveyors extending in a first direction, a
second level of second conveyors below the first conveyors and
extending in a second direction, and a third level of third
conveyors above the first conveyors parallel to the second
conveyors. The method further comprises: (1) sorting a first batch
of first articles delivered to the first conveyors by selectively
delivering the first articles from the corresponding first conveyor
to a selected one of the second conveyors; and (2) sorting a second
batch of second articles delivered to the first conveyors by
selectively delivering the second articles from the corresponding
first conveyor to a selected one of the third conveyors. The
sorting of the first and second batches may be done simultaneously,
or instead, the sorting of the first batch of articles may be
completed prior to the sorting of the second batch of articles.
[0029] In accordance with one other aspect of the invention, a
method of delivering articles requiring sortation to a warehouse is
disclosed. The method comprises delivering the articles to a
plurality of infeed conveyors; transferring articles to one of a
plurality of takeaway conveyors intersecting he infeed conveyors
and associated with a particular storage location; and delivering
the articles to the storage location. The method may further
comprise the steps of: (1) delivering the articles from a storage
location to one of the plurality of infeed conveyors; and (2)
transferring articles having a common characteristic from the
infeed conveyor to one of the plurality of takeaway conveyors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a partially cutaway plan view of the sortation
system forming one aspect of the invention;
[0031] FIG. 2 is a partially cutaway side view of the system of
FIG. 1;
[0032] FIG. 3 is a partially cutaway side view of a takeaway
conveyor associated with the system of FIG. 1;
[0033] FIG. 4 is a perspective view showing another embodiment of
the sortation system;
[0034] FIG. 5 is a partially cutaway top plan view of one
embodiment of a sub-sorting station;
[0035] FIG. 6 is a partially cutaway perspective view of a
sub-sorting station;
[0036] FIG. 7 is a partially cutaway plan view of yet another
embodiment of the sortation system, including three levels of
conveyors;
[0037] FIG. 8 is an end view of two of the conveyors forming part
of the system of FIG. 7;
[0038] FIG. 9 is a partially cutaway side schematic view of one
possible means for transferring articles between two conveyors;
and
[0039] FIG. 10 is a partially cutaway top plan view of a
transferring means similar to the one shown in FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
[0040] With reference to FIG. 1, one possible embodiment of a
sorter system 10 forming one aspect of the invention is
schematically illustrated. As illustrated, the sorter system 10 may
comprise a "matrix" formed of a plurality of intersecting belt or
chain conveyors 12, 14 extending in different directions. Each
conveyor 12, 14 is of the endless belt or chain type, and thus
provides a substantially continuous conveying surface for articles
(as contrasted from tilt tray sorters, which unlike belt or chain
conveyors create a substantially interrupted conveying surface).
Although certainly not a requirement, a preference exists for the
types of endless belt or chain conveyors manufactured and sold by
Span Tech, LLC under THE DESIGNER SYSTEM.RTM. trademark, the
details of which are found in U.S. Pat. Nos. 4,953,693 and
5,031,757 (which are incorporated herein by reference).
[0041] As a result of this arrangement, each intersection
represents a possible or potential location or point T for
transferring an article between the associated conveyors 12, 14.
Consequently, two or more selected articles conveyed along
different infeed conveyors 12 extending in one direction may
undergo simultaneous sortation and delivery to one or more of the
takeaway conveyors 14 extending in a different direction and
associated with a particular destination (such as a delivery truck,
receiver, or sortation subsystem). By creating a system 10
including numerous infeed and takeaway conveyors 12, 14 extending
in both directions and selectively moving articles between them at
the desired intersections, article sortation can thus be achieved
in a highly efficient and effective manner, and one heretofore
unknown using prior types of endless loop induction systems.
[0042] In the embodiment shown in FIG. 1, the infeed and takeaway
conveyors 12, 14 of the system 10 extend generally perpendicular to
each other (note first and second orthogonal directions D.sub.1 and
D.sub.2) in a spaced apart fashion and thus form a "regular" grid
(e.g., 4.times.4, although an irregular grid (2.times.3, 4.times.5,
40.times.50, etc.) could easily be used as well). In this
particular illustrated embodiment, the matrix system 10 comprises:
(1) a first set or series of infeed belt or chain conveyors 12a-12n
extending in a first longitudinal direction (four conveyors shown,
labeled 12a-12d); and (2) a second set or series of takeaway belt
or chain conveyors 14a-14n extending in a second longitudinal
direction transverse to the first direction (four shown, labeled
14a-14d). These infeed and takeaway conveyors 12, 14 preferably
each associate with a distinct starting point S and ending point E
(i.e., they are linear or straight and independent from each other,
as contrasted with known prior art induction systems using an
endless loop conveyor with a continuous train of cars to effect
sortation). Preferably, the conveyors 12, 14 in each series extend
generally parallel to each other, including in the portion
comprising the system 10, and move in the same direction (note
arrows A and B in FIG. 1) along an endless path.
[0043] As perhaps best shown in FIG. 2, the infeed conveyors
12a-12d generally lie in a first horizontal plane above the
secondary or takeaway conveyors 14a-14d, which are in a second,
different horizontal plane. This provides the system 10 with
multiple layers, levels, or tiers of conveyors 12, 14. In one
proposed embodiment, the infeed conveyors 12a-12d all lie above the
takeaway conveyors 14a-14d. However, as indicated in the
description that follows, this arrangement may be reversed or,
alternatively, more than two layers of intersecting conveyors may
be used, with some above and some below each other (see FIG. 7).
Although not shown, it should be appreciated that the conveyors 12,
14 are all preferably supported above the ground, such as in the
manner disclosed in the '693 or '757 patents.
[0044] In accordance with another aspect of the invention, means
for transferring at least one selected article between the
conveyors may be provided at or near each intersection between a
infeed conveyor 12 and a takeaway conveyor 14. In the embodiment of
FIG. 1, the means for transferring comprises a transfer conveyor
16. Preferably, the transfer conveyor 16 is a generally L-shaped,
driven, endless belt or chain conveyor, oriented such that the
articles transferred onto it move from the plane of the
corresponding infeed or first conveyor, such as conveyor 12a, to
the corresponding takeaway or second conveyor, such as conveyor
14a. The use of an L-shaped transfer conveyor 16 as illustrated is
especially preferred in situations where the articles have a
direction of elongation, since the article upon reaching the
takeaway conveyor 14 will normally assume the exact same
orientation it had on the infeed conveyor 12 (which may have been
selected by the person placing the articles to ensure that an
indicia such as a bar code was in a proper position for being
read). However, the use of a linear or passive transfer conveyor
16, such as for example, a straight endless conveyor or a passive
slide/chute, is also possible.
[0045] To move one or more of the articles selected for transfer
onto the conveyor 16, a diverter 18 may be used. The diverter 18
functions to divert or move a selected article onto the transfer
conveyor 16, and may thus comprise any structure for performing
this function. For example, the diverter 18 may comprise a
retractable arm, gate, lug, or guide for moving into the path of a
selected article on the associated infeed conveyor 12 and directing
it onto the transfer conveyor 16. Alternatively, the diverter 18
may comprise a picker, kicker, pusher, or like motive device.
[0046] As should be appreciated from the foregoing, the particular
means used to move any selected article between the conveyors 12,
14 could vary depending on the arrangement used and any special
needs (e.g., conveying delicate articles versus books). Likewise,
instead of an active transfer conveyor 16, the transferring means
for example may comprise a pusher, kicker, ejector, lifter,
elevator, actuator or combinations thereof for transferring an
article from one conveyor to another, including in possible
combination with a chute or conveyor. Although not preferred, the
possibility of using a manual "pick and place" operation at each
intersection exists (which especially helps when one or more of the
takeaway conveyors are above the infeed conveyors). In any case,
selected articles reliably make their way from the infeed conveyors
12 to at least one of the takeaway or secondary conveyors 14,
thereby effecting the desired sortation.
[0047] Turning back to FIG. 2, the portion or leg of the L-shaped
transfer conveyor 16 adjacent to and generally aligned with the
takeaway conveyor 14a may be tilted relative to a horizontal plane.
Advantageously, this tilting may cause an article being conveyed
along the transfer conveyor 16 to slide automatically onto the
associated takeaway conveyor 14 without the need for active
engagement. A passive diverter (not shown), such as a fixed gate,
may also be provided at or near the end of this leg of the transfer
conveyor 16 to help insure that any articles that do not slide off
are ultimately diverted. However, instead of a tilted arrangement
with a passive diverter, it is also possible to provide an active
diverter (not shown) for moving articles from a non-tilted section
of the conveyor 16. In order to insure that proper selection for
transfer is achieved (and thus sorting provided), articles
approaching on the infeed conveyor 12 may be identified visually by
an operator or using well-known types of "machine vision" scanning
technology (e.g., reading a bar or other code using an adjacent
(preferably overhead) reader 20)). Preferably, the article spacing
on each infeed conveyor 12 is such that only one selected article
is transferred at a time. However, unlike in prior systems
utilizing tilt trays running in endless loops in which only a
single article may be processed at a given instant in time,
articles for delivery to common destinations may simultaneously
transfer from different infeed conveyors 12a-12d to one or more of
the takeaway conveyors 14a-14d. More efficient sorting operation
and a potential multi-fold increase in throughput without a
concomitant increase in conveying speed results.
[0048] In the case where all articles divert or transfer onto
takeaway conveyors 14a-14n, then the infeed conveyors 12a-12n may
simply terminate. However, an alternative approach extends one or
more of the infeed conveyors 12a-12n such that articles not
transferred ultimately reach a downstream location for further
processing. For example, an article remaining on one infeed
conveyor 12a, such as the result of inadvertent placement, and not
actually needed to fill an order made (and thus not transferred to
any of the takeaway conveyors 14a-14n), may reach a "reject" bin
(not shown). Alternatively, such articles may collect on a single
return conveyor (not shown) extending back to an associated storage
area.
[0049] Another alternative involves delivering the articles
remaining on the infeed conveyors 12a-12n to another sorter system,
including possibly another matrix system (not shown). In the latter
case, a "single row" matrix may include a single endless belt or
chain infeed conveyor having a continuous conveying surface and a
plurality of takeaway conveyors intersecting this infeed conveyor.
This arrangement may work well in situations where the articles are
all intended for delivery to different addresses in the same city
or zip code or otherwise share a common characteristic.
[0050] Turning to FIG. 3, each takeaway conveyor 14a . . . 14n in
the system 10 may also orient at an angle, or "tilt," relative to
the horizontal plane in a direction transverse to the conveying
direction, either at the transfer point or at a downstream
location. Such tilting causes transferred articles to slide down
along the corresponding conveying surface to a known edge, which
may be defined by a side guard (not shown) adjacent to the
associated takeaway conveyor 14. As should be appreciated, this
tilting generally turns the articles to achieve a particular
orientation (e.g., short end leading, in the case of an elongate
article) for a desired operation (e.g., reading a bar code, such as
using an adjacent reader 20). Once the operation is complete, it
may also be desirable as shown in FIG. 3 to provide a portion of
the conveyor 14 with a "twist" section 22 that returns the article
to a position parallel with a horizontal plane before undergoing
further processing.
[0051] Exemplary uses of the matrix sorter system 10 described
above are myriad. One such use involves a facility for delivering
articles such as books from a storage location in a warehouse to a
particular destination (such as to a packaging area or loading dock
for shipping to retail stores). In particular, each infeed conveyor
12 associates with a grouping of books within the warehouse. A
"pick to light" system visually identifies to a "picker" the books
at the storage location in the warehouse (such as an adjacent shelf
or pallet) to place on the infeed conveyor 12. Pickers may thus
place individual books on different infeed conveyors 12 running in
parallel or alternatively on a single conveyor that ultimately
divides into several infeed conveyors associated with the system
10.
[0052] In either case, the books on each infeed conveyor 12a . . .
12n upon approaching the system 10 undergo identification, either
by an operator or a machine scan (in which case, a person
positioned upstream of the scanning location may ensure the books
are in the proper orientation and singulated (e.g., separated by a
certain minimum distance in the conveying direction)). Each
takeaway conveyor 14 may be associated with a common parameter or
characteristic shared by some books (e.g., those going to a
particular destination, company/individual, distribution center,
store, sorting location, etc.). Once identified, the corresponding
books on the various infeed conveyors 12 are identified and then
transferred to the correct takeaway conveyor 14 to effect sortation
in the desired fashion using the above-described transfer
techniques (which, again, are preferably automated, but may instead
be manual or semi-automated).
[0053] Downstream along the takeaway conveyor 14, the books may
undergo further sorting, if necessary (such as if those having
different destinations are transferred). Of course, placing persons
along this conveyor 14 to identify and move the books to packages,
bins, bags, carriers, etc. works for this purpose. Alternatively,
and as discussed further below, this "sub" sorting may instead use
an automated system, such as one that detects and routes each book
to an appropriate takeaway conveyor for delivery to a receiver
(e.g., bag, box or bin) representing an order.
[0054] An example of a particular sub-sorting arrangement useful
with a matrix sorter system 10 essentially as described above is
shown in FIGS. 4-6. FIG. 4 shows that the overall system 10
comprises a plurality (twenty) infeed conveyors 12 extending in a
first direction and a plurality (ten) of takeaway conveyors 14
extending in a second direction. The takeaway conveyors 14
generally lie in a common horizontal plane, but are positioned
below the infeed conveyors 12. Each of the ten takeaway conveyors
14 associates with one or more sortation "stations" 24. In the
illustrated embodiment, three such stations 24a, 24b, 24c lie
spaced from each other in the conveying direction and on the same
side of a common takeaway conveyor 14 (which it should be
appreciated may be a distinct conveyor from the one forming part of
the basic system 10).
[0055] Turning to FIGS. 5 and 6, it can be seen that each station
24 comprises at least one and preferably a plurality of transverse
conveyors 26 for delivering the articles from the associated
takeaway conveyor 14 to a temporary storage location corresponding
to articles sharing a common characteristic (e.g., those comprising
a particular order, or those going to a particular country, region,
state, zip code, city, town, village, address, etc.). In the
embodiment shown, six such substantially continuous conveyors
26a-26f extend in parallel. Preferably, each conveyor 26a-26f
comprises an "indexing" conveyor including a plurality of
individual conveyor segments arranged in series (with six segments
28a-28f shown for purposes of illustration only), which together
define each continuous conveyor. A common electric motor (not
shown) may drive these segments 28a-28f at the same speed and in
the same direction, or alternatively separately actuated motors may
drive them independent of each other. As indicated in FIG. 5, a
selected article may be transferred to the leading segment 28a of
each indexing conveyor 26a-26f from the takeaway conveyor 14 using
an associated diverter 18.
[0056] A sensor (not shown) associated with each conveyor segment
28a-28f may detect the presence of an article thereon. A
conventional "photoeye" arrangement or mechanical type sensor
(e.g., a weight sensor, a physical contact switch, etc.) may serve
in this role. Upon an article transferring from the takeaway
conveyor 14 to one of the indexing conveyors 26a-26f, the
corresponding segments 28a-28f run until the sensor associated with
the segment 28a closest to the storage location, or bin 30, detects
the article.
[0057] In the event a second article for delivery to a second
location or bin 30 reaches that same indexing conveyor 26a-26f,
that article transfers in a similar fashion. The second article
conveys until it reaches the segment 28b upstream of the segment
28a holding the first article, which may be held stationary. This
sequence can be repeated until an article associates with each
segment 28a-28f of each indexing conveyor 26a-26f.
[0058] Once one or more of the indexing conveyors 26a-26f are
loaded, the articles transfer to the appropriate storage location.
In the illustrated embodiment, this comprises a structure 30
including a plurality of bins 32 arranged in columns corresponding
to the number of indexing conveyors 26a-26f. The number of rows may
be as few as one (in which case the indexing conveyor described
above could be replaced with a simple continuously running conveyor
for transferring selected article(s) from the takeaway conveyor 14
to the appropriate bin). However, to maximize the throughput, the
number of bins preferably corresponds at least to the number of
segments on the associated indexing conveyor, and most preferably
to the number of segments 28 times the number of conveyors 26.
Thus, in the example where six indexing conveyors comprise six
segments each, the structure 30 is six bins by six bins.
[0059] The outfeed end of each indexing conveyor 26a-26f nominally
lies adjacent only one row of bins 32. If any article on the
farthest downstream indexing conveyor 26a-26f belongs in one of
those bins (which may be known using either on the spot detection
(manual or automatic) or controls), then the corresponding indexing
conveyor actuates such that the article transfers to the desired
bin. The next-in-line article then advances as described above
until the sensor associated with the furthest downstream segment
(segment 28a in the example) detects the article. If that article
belongs in the same bin as the preceding one (such as if both are
going to a common destination or otherwise share a common
characteristic), then it too transfers.
[0060] Once all articles slated for a bin in the nominal row
transfer, the structure 30 may be moved to associate the bins of
another row with the outfeed end of the indexing conveyors 26a-26f,
and the sequence described above repeats. In the case where the
bins 32 are spaced both horizontally and vertically from each
other, this may be accomplished by using a lifter to raise and
lower the structure 30 such that an article to be transferred from
the furthest downstream segment 28a of each indexing conveyor
26a-26f is positioned adjacent the correct bin, at which e that
segment activates to effect delivery. Alternatively, the transverse
conveyors 26 may move to associate with the correct bins 32.
[0061] As illustrated, the structure 30 may be mobile, such as
through the provision of wheels 35. Once sortation ends for a given
run or shift, the structure 30 may move to a location where the
articles are further processed (such as for packaging). In the
interim, a replacement structure may be associated with the station
24 such that the sortation efficiency remains unhindered because of
the time required to check and unload the bins.
[0062] As noted above, each structure 30 in the arrangement shown
in FIGS. 4-6 thus includes thirty-six bins. In this exemplary
arrangement, three structures 30 associate with each takeaway
conveyor 14, and ten takeaway conveyors exist. The total number of
possible sort destinations equals 1,080. If the twelve rows of bins
exist instead of six, this figure doubles and thus becomes 2,160.
If six stations associate with each secondary conveyor, it doubles
again to 4,320. Then doubling the number of takeaway conveyors
(including by possibly adding a third level of conveyors; see
below) to twenty results in 8,640 possible sort addresses, a figure
unheard of using a conventional single induction loop of any
reasonable size.
[0063] An alternative to a vertical arrangement is one where the
structure 30 shown in FIG. 6 lies with its back 30a parallel to the
ground such that the bin entrances 32a are positioned below the
indexing conveyors 26a-26f. A linear motion device could then move
the structure 30 to and fro as necessary to ensure that the
articles transferred from the segments fall into the appropriate
bin. Likewise, providing fewer rows than the number of indexing
conveyors makes it necessary to move the structure 30 in two
different directions to match the next-in-line article with the
corresponding bin.
[0064] Instead of using the arrangement shown in FIGS. 5 and 6, yet
another option involves accomplishing further sorting downstream of
the matrix by separating the flow onto a plurality of "lines," such
as by using a series of parallel-running conveyors and a diverter
(not shown) to route the articles accordingly. The individual
conveyors in these lines may then form the infeed conveyors of a
second matrix system (not shown), which can further sort the
articles into even smaller sub-groups. The process may repeat as
necessary to create the desired degree or "level" of sortation for
a particular operation.
[0065] Rather than using a matrix system 10 to deliver articles
from a storage location, it may find utility in a converse
arrangement. For example, upon receiving a delivery, the articles
(boxes, packages, etc.) requiring sortation may transfer to an
infeed conveyor at the warehouse that ultimately splits into a
plurality of the infeed conveyors 12 of the matrix system 10.
Sortation of the articles may follow as described above to place
all those with a common parameter or characteristic on a particular
takeaway conveyor 14 for delivery to a particular storage location
in the warehouse (e.g., one for books on a certain topic reside,
books having a title beginning with a particular letter of the
alphabet reside, etc.). The takeaway conveyors 14 can then be
switched to infeed conveyors 12 for delivering articles for
delivery back to the matrix 10, which would then sort those
articles having the common characteristic that triggers transfer to
the takeaway conveyors (which formerly served as infeed
conveyors).
[0066] In accordance with still another aspect of the invention,
the matrix system 10 may also include three or more levels of
conveyors. For example, the third conveyors of this level may
receive selected articles from the second takeaway conveyors for
delivery to different destinations. Alternatively, these third
conveyors may serve as second infeed conveyors for delivering
articles to takeaway conveyors 14 also common to the first infeed
conveyors 12, or instead may also receive articles from the infeed
conveyors and thus function as a second set of takeaway
conveyors.
[0067] In the latter case, the third conveyors preferably extend
parallel to the second takeaway conveyors 14 and may lie either
above or below the infeed conveyors 12 (with corresponding means,
such as chutes or powered elevators, used to transfer the articles
depending on the orientation used). However, the third conveyors
preferably run in a direction opposite that of the takeaway
conveyors 14 and are associated with downstream sub-sortation
stations (either individuals for placing the objects in bins,
automated sorters for doing so, etc.). This is shown in FIG. 7 by
opposing arrows B and C along the takeaway conveyors 14 and the
third conveyors 34, respectively (with arrows A and D also showing
that the infeed conveyors 12 may also run in different directions).
The means for transferring articles may include a transfer conveyor
16 similar to the one described above, but capable of elevating the
articles in a reliable fashion (such as by using a high-friction
surface, scoops, cleats, a "wedge" conveyor, or similar types of
arrangements that are well known in the art for reliably conveying
articles against gravity). As perhaps best understood with
reference to FIG. 8, it is also preferable for the transfer
conveyor 16 to terminate in a plane above the corresponding third
conveyor 34, such that transferred articles simply drop onto the
conveying surface.
[0068] As should be appreciated, a matrix system 10 with two or
more sets of takeaway conveyors may provide several advantages in
use. For example, in the case of two levels of takeaway conveyors
14, 34, the ability to transfer articles from the infeed conveyor
12 to either a second or third takeaway conveyor 14 or 34 during a
single run can significantly increase the potential throughput of
the system 10. This increase results without a corresponding
increase in the conveying speed, which helps to make the overall
operation more relaxed and effective than most conventional
approaches.
[0069] Another possibility involves alternating between the two
levels of takeaway conveyors 14, 34 in the matrix sorter system 10.
For example, the lower takeaway conveyors 14 used in conjunction
with the infeed conveyors 12 may sort a first batch or group of
articles introduced to the system 10. After the articles comprising
the first batch move from the infeed conveyors 12, a second group
of articles (of the same or a different type) may be introduced to
the system 10 and transferred to the upper takeaway conveyors 34
while the first group are simultaneously being conveyed and sorted
downstream on the lower takeaway conveyors 14. Using such an
arrangement may allow for continuous operation of the system 10,
despite the possible need for periodic downtime with one level of
takeaway conveyors 14 or 34 after sorting a batch of articles (such
as to address mis-sorted articles or situations where one or more
articles are incorrectly introduced into the system and need to be
replaced to fill a particular order).
[0070] Still another possible use of a matrix system involves
operating only a portion of the infeed conveyors 12 at a given
time. For example, in the arrangement shown in FIG. 4, only one of
four groups G.sub.1, G.sub.2, G.sub.3, G.sub.4 of five infeed
conveyors 12 may deliver articles to the takeaway conveyors 14 (or
deliver articles from only a certain storage location in a
warehouse) during a first shift, with other groups used during
different shifts. This maintains constant wear on the conveyors of
the various groups and also extends their service life. At times
when an increased number of articles require sortation (i.e., at
Christmas), then all corresponding infeed conveyors 12 present may
run simultaneously.
[0071] An alternative means for transferring articles between the
conveyors 12, 14 may comprise a separately actuatable drop-down
portion 36 of the associated infeed conveyor 12 (see FIGS. 9 and
10, as well as U.S. Pat. No. 4,426,074, the disclosure of which is
incorporated herein by reference). Obviously, these drop down
portions 36 would be placed at or near the intersections with the
takeaway conveyors 14, which as should be appreciated represent
possible or potential transfer points.
[0072] In the case of drop down portions 36, offsetting or
"staggering" the transfer points along the lateral extent of the
takeaway conveyors 14a-14d comprising the system 10 prevents
collisions among articles transferred from upstream infeed
conveyors (such as infeed conveyors 12a-12c in the case of four).
FIG. 9 illustrates this approach by making each second or takeaway
conveyor 14 wider than the associated first or infeed conveyor 12
(note phantom portion), and/or by selectively positioning the end
of the drop down portion 36. This allows for the easy and efficient
placement of articles at different locations along the width of the
takeaway conveyor 14, while preventing collisions with articles
delivered from an upstream transfer point associated with a
different infeed conveyor 12. In other words, the initial location
of each article upon transfer may be staggered along the lateral
dimension of the associated takeaway conveyor 14. This is
illustrated by showing packages or parcels P.sub.1 and P.sub.2 in a
side-by-side configuration in FIG. 10 (which shows the actual
transfer of the second package or parcel P.sub.2 to the takeaway is
conveyor 14 via the delivery end of a "staggered" drop down portion
36).
[0073] The foregoing descriptions of various embodiments of sorter
systems and related methods provide illustration of the inventive
concepts. The descriptions are not intended to be exhaustive or to
limit the disclosed invention to the precise form disclosed.
Modifications or variations are also possible in light of the above
teachings. For example, the conveyors 12, 14, 16, 34 if comprised
of modular links may be provided with specialized links or rollers
to facilitate article transfer (see, e.g., U.S. Pat. No. 6,874,617
to Layne, the disclosure of which is incorporated herein by
reference). Also, it should be appreciated that books are mentioned
merely to illustrate one possible type of article capable of being
conveyed or sorted using the disclosed inventions. The embodiments
described above were chosen to provide the best application to
thereby enable one of ordinary skill in the art to utilize the
inventions in various embodiments and with various modifications as
are suited to the particular use contemplated (such as, again, for
conveying or sorting articles other than books). All such
modifications and variations are within the scope of the
invention.
* * * * *