U.S. patent application number 14/486570 was filed with the patent office on 2015-01-01 for adjustable speed control system, method and computer readable medium for use with a conveyor and a reader.
The applicant listed for this patent is PUROLATOR INC.. Invention is credited to Cameron James LAIRD, Kirk Edward SERJEANTSON, Adam STEVENSON, Andrew Silerio VICENCIO.
Application Number | 20150005931 14/486570 |
Document ID | / |
Family ID | 47830558 |
Filed Date | 2015-01-01 |
United States Patent
Application |
20150005931 |
Kind Code |
A1 |
SERJEANTSON; Kirk Edward ;
et al. |
January 1, 2015 |
ADJUSTABLE SPEED CONTROL SYSTEM, METHOD AND COMPUTER READABLE
MEDIUM FOR USE WITH A CONVEYOR AND A READER
Abstract
An adjustable speed control system includes a reader, databases,
processors and a conveyor controller. The databases store data
concerning conveyor stops and failed attempts by the reader to
identify conveyed items. Based on the failed attempts and the
conveyor stops, the processors calculate an optimal speed of the
conveyor. The controller adjusts the conveyor speed towards the
optimal speed to increase the conveyed items successfully
identified by the reader. Also disclosed are a corresponding method
and computer readable medium on which is stored instructions to,
upon execution, adjustably control the conveyor speed.
Inventors: |
SERJEANTSON; Kirk Edward;
(Markham, CA) ; VICENCIO; Andrew Silerio; (Barrie,
CA) ; LAIRD; Cameron James; (Milton, CA) ;
STEVENSON; Adam; (Hamilton, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PUROLATOR INC. |
Mississauga |
|
CA |
|
|
Family ID: |
47830558 |
Appl. No.: |
14/486570 |
Filed: |
September 15, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13309976 |
Dec 2, 2011 |
|
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14486570 |
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Current U.S.
Class: |
700/230 |
Current CPC
Class: |
B65G 43/00 20130101 |
Class at
Publication: |
700/230 |
International
Class: |
B65G 43/00 20060101
B65G043/00 |
Claims
1. An adjustable speed control system for use with at least one
conveyor and conveyed items carried thereby, wherein the system
comprises: (a) at least one reader adapted to automatically detect
and identify the conveyed items; (b) one or more databases
comprising, and regularly updated with, data concerning: (i) failed
attempts by the reader to identify the conveyed items, and (ii)
stops experienced by the conveyor; (c) one or more processors
adapted to automatically: (i) determine, at regular intervals, (A)
a number of the failed attempts, and (B) a duration and a number of
the stops experienced by the conveyor; and (ii) based at least in
part thereon, dynamically calculate an optimal speed of the
conveyor for reducing the number of the failed attempts, the
duration and/or the number of the stops; and (d) a controller
operatively connected to the conveyor, and adapted to automatically
and dynamically adjust an actual speed of the conveyor towards the
optimal speed; whereby the system is adapted to operatively
facilitate increasing the conveyed items which are successfully
identified by the reader.
2. A system according to claim 1, wherein said one or more of the
processors are further adapted to automatically: (iii) determine,
at regular intervals, at least one performance characteristic
associated with the conveyor; and (iv) generate a signal for
presentation of the performance characteristic to a user of the
system.
3. A system according to claim 2, wherein said one or more of the
processors are further adapted to determine the performance
characteristic by: (A) summing together the duration of each of the
stops experienced by the conveyor over a predetermined time
interval to calculate a total stop duration; and (B) multiplying
the total stop duration by a predetermined average cost associated
with the time interval and with the stops;
4. A system according to claim 2, wherein said one or more of the
processors are further adapted to determine the performance
characteristic by: (A) dynamically determining a detected item
count of the conveyed items detected by the reader over a
predetermined time interval; (B) dynamically determining an
identified item count of the conveyed items identified by the
reader over the time interval; and (C) dividing the identified item
count by the detected item count.
5. A method of adjusting an actual speed of a conveyor for use in
identifying conveyed items carried thereby, wherein the method
comprises the steps of: (a) automatically detecting and identifying
the conveyed items using a reader associated with the conveyor; (b)
regularly updating one or more databases with data concerning (i)
failed attempts by the reader to identify the conveyed items, and
(ii) stops experienced by the conveyor; (c) using one or more
processors to automatically: (i) determine, at regular intervals,
(A) a number of the failed attempts, and (B) a duration and a
number of the stops experienced by the conveyor; and (ii) based at
least in part thereon, dynamically calculate an optimal speed of
the conveyor for reducing the number of the failed attempts, the
duration and/or the number of the stops; and (d) using a
controller, operatively connected to the conveyor, to automatically
and dynamically adjust the actual speed of the conveyor towards the
optimal speed; whereby the method operatively facilitates
increasing the conveyed items which are successfully identified by
the reader.
6. A method according to claim 5, wherein in step (c), one or more
of the processors are further used to automatically: (iii)
determine, at regular intervals, at least one performance
characteristic associated with the conveyor; and (iv) generate a
signal for presentation of the performance characteristic to a
user.
7. A method according to claim 6, wherein in substep (c)(iii), one
or more of the processors determine the performance characteristic
by: (A) summing together the duration of each of the stops
experienced by the conveyor over a predetermined time interval to
calculate a total stop duration; and (B) multiplying the total stop
duration by a predetermined average cost associated with the time
interval and with the stops;
8. A method according to claim 6, wherein in substep (c)(iii), one
or more of the processors determine the performance characteristic
by: (A) dynamically determining a detected item count of the
conveyed items detected by the reader over a predetermined time
interval; (B) dynamically determining an identified item count of
the conveyed items identified by the reader over the time interval;
and (C) dividing the identified item count by the detected item
count.
9. A computer readable medium on which is physically stored
executable instructions which, upon execution, will adjustably
control an actual speed of a conveyor provided with a controller;
for use with conveyed items carried thereby, with a reader adapted
to automatically detect and identify the conveyed items, and with a
database comprising data concerning stops experienced by the
conveyor and failed attempts by the reader to identify the conveyed
items; wherein the executable instructions comprise processor
instructions for one or more processors to automatically: (a)
determine, at regular intervals, (i) a number of the failed
attempts, and (ii) a duration and a number of the stops experienced
by the conveyor; (b) based at least in part thereon, dynamically
calculate an optimal speed of the conveyor for reducing the number
of the failed attempts, the duration and/or the number of the
stops; and (c) generate a signal for transmission to the controller
for automatic and dynamic adjustment of the actual speed of the
conveyor towards the optimal speed; to thus operatively facilitate
use of the processors to increase the conveyed items which are
successfully identified by the reader.
10. A computer readable medium according to claim 9, wherein the
processor instructions are additionally for one or more of the
processors to automatically: (d) determine, at regular intervals,
at least one performance characteristic associated with the
conveyor; and (e) generate a signal for presentation of the
performance characteristic to a user.
11. A computer readable medium according to claim 10, wherein the
processor instructions are additionally for one or more of the
processors to determine the performance characteristic by: (i)
summing together the duration of each of the stops experienced by
the conveyor over a predetermined time interval to calculate a
total stop duration; and (ii) multiplying the total stop duration
by a predetermined average cost associated with the time interval
and with the stops;
12. A computer readable medium according to claim 10, wherein the
processor instructions are additionally for one or more of the
processors to determine the performance characteristic by: (i)
dynamically determining a detected item count of the conveyed items
detected by the reader over a predetermined time interval; (ii)
dynamically determining an identified item count of the conveyed
items identified by the reader over the time interval; and (iii)
dividing the identified item count by the detected item count.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a control system,
method and computer readable medium for use with a conveyor, and
more particularly to an adjustable speed control system, method and
computer readable medium for use with a conveyor and a reader.
BACKGROUND OF THE INVENTION
[0002] In shipping systems, conveyors and other material handling
equipment ("MHE") may be used to carry packages, parcels, pieces
and other conveyed items from one location to another within a
facility before final shipment to an intended recipient. Among
shipping providers, it may also be known to provide readers--e.g.,
automated reweigh cube ("ARC") system readers--for use in
conjunction with such conveyors to ascertain information, and
capture revenue which might otherwise be lost, in connection with
the conveyed items.
[0003] As may be appreciated by persons having ordinary skill in
the art, the revenue generating capabilities associated with such
prior art conveyor and reader systems may have been limited by the
conveyor speed, by any conveyor stoppages, by the conveyor's
capacity and the utilization of the conveyed items thereon, and by
the ability and efficiency of the reader to timely identify the
conveyed items, among other things. More specifically, for example,
operating the conveyor at a speed which is less than optimal, or
carrying less than an optimal number of items thereon, may have
resulted in a lower revenue for a shipping provider than might
otherwise have been generated. Similarly, over-loading the conveyor
or running it too fast may likewise have resulted in a lower
revenue for the shipping provider, at least to the extent that
doing so may have made the conveyor prone to stoppages or may have
diminished the reader's ability to timely identify the conveyed
items.
[0004] In fields of art which are perhaps not directly
analogous--see, for example, U.S. Pat. No. 6,779,319 which was
issued on Aug. 24, 2004 to Smith et al. for "Real-time Intelligent
Packet Collation Systems and Methods"--systems may be known which
are adapted to read identification information from mail items, to
display processing efficiency information, and to provide reports
for later diagnosis and/or amelioration of problems experienced by
the systems.
[0005] In parcel delivery and/or other commercial enterprises which
utilize conveyors, it may be desirable to modify a prior art
conveyor and reader system to provide flow information to
operations and/or management. Preferably, such flow information may
find advantageous utility in modifying upstream and downstream
loading and unloading processes to increase revenue and facilitate
adequate conveyor clear times.
[0006] What may be missing from the prior art is a system, adapted
for use in conjunction with a conveyor and a reader for identifying
the conveyed items, which dynamically uses a count and precise
duration of any conveyor stoppages to calculate an optimal speed
for the conveyor, and which then automatically controls the actual
speed of the conveyor. A contemplated system of this general type
may be desirable or may afford advantageous utility for shipping
systems and shipping providers, among other possible users. Though
not essential to the working of the present invention, thus
controlling the actual speed of the conveyor may help to control,
manage, improve and/or optimize flow and loading and unloading
processes, to facilitate adequate conveyor clear times, and/or to
increase revenue.
[0007] It may be desirable for such a system to also dynamically
use other flow and/or revenue-based information (e.g., a count of
the boxes detected by the reader, pieces-per-hour information,
dimensions of the pieces which correspond to the pieces-per-hour
information) to calculate the optimal speed for the conveyor.
[0008] It may be desirable for such a system to directly interface
with a conveyor controller or another MHE controller to facilitate
automatic control of the conveyor's actual speed towards the
optimal speed calculated for the conveyor.
[0009] It may also be desirable for such a system to enable
communication to and from, and automatic control over, multiple
readers, conveyors and/or MHEs.
[0010] It may also be desirable to reduce the number or duration of
any conveyor stoppages, to otherwise increase the throughput of
conveyed items identified by the reader, and/or to alert a user of
the system when the system's performance falls outside of
acceptable parameters--any or all of which may facilitate the
generation of increased revenue.
[0011] It may be desirable to physically store, on a computer
readable medium, instructions for execution by one or more
processors to implement such a modified system.
[0012] One of the objectives of the present invention may be to
provide a system, method and/or computer readable medium to help
move items within a facility.
[0013] One of the objectives of an aspect of the present invention
may be to provide a system, method and/or computer readable medium
to help capture item attributes for additional charges and/or
recovery.
[0014] One of the objectives of an aspect of the present invention
may be to provide a system, method and/or computer readable medium
to help merge scan and recovery data for transmission to and/or
integration with tracking and billing functions within a larger
operation, for example, at the facility or across many
facilities.
[0015] One of the objectives of an aspect of the present invention
may be to provide a system, method and/or computer readable medium
adapted for use in parcel delivery or postal applications, in
transporting conveyable items to trailers, in transporting of
parcels, and/or in improving or facilitating movement of conveyable
freight.
[0016] One of the objectives of an aspect of the present invention
may be to provide a system, method and/or computer readable medium
adapted for use in airports or with airlines, and/or to improve or
facilitate re-weighing, cubing and/or movement of baggage or air
cans.
[0017] One of the objectives of an aspect of the present invention
may be to provide a system, method and/or computer readable medium
for use in supply chain management and/or movement of products.
[0018] It is an object of the present invention to obviate or
mitigate one or more of the aforementioned mentioned disadvantages
and/or shortcomings associated with the prior art, to provide one
of the aforementioned needs or advantages, and/or to achieve one or
more of the aforementioned objects of the invention.
SUMMARY OF THE INVENTION
[0019] According to the invention, there is disclosed an adjustable
speed control system for use with at least one conveyor and
conveyed items carried thereby. The system includes at least one
reader, one or more databases, one or more processors, and a
controller operatively connected to the conveyor. The reader is
adapted to automatically detect and identify the conveyed items.
The databases include, and are regularly updated with, data
concerning stops experienced by the conveyor and failed attempts by
the reader to identify the conveyed items. The processors are
adapted to automatically (i) determine, at regular intervals, a
number of the failed attempts, and a duration and a number of the
stops experienced by the conveyor. According to the invention, (ii)
based at least in part thereon, the processors are also adapted to
automatically and dynamically calculate an optimal speed of the
conveyor for reducing the number of the failed attempts, the
duration and/or the number of the stops. The controller is adapted
to automatically and dynamically adjust an actual speed of the
conveyor towards the optimal speed. Thus, according to the
invention, the system is adapted to operatively facilitate
increasing the conveyed items which are successfully identified by
the reader.
[0020] According to an aspect of one preferred embodiment of the
invention, the reader may preferably, but need not necessarily,
identify each one of the conveyed items by determining at least one
item datum associated with the aforesaid each one. The item datum
may preferably, but need not necessarily, be selected from a group
which includes of a unique identification tag, an item weight,
and/or one or more item dimensions.
[0021] According to an aspect of one preferred embodiment of the
invention, the reader may preferably, but need not necessarily,
include a scanner. The reader may preferably, but need not
necessarily, identify the conveyed items by using the scanner to
automatically read, preferably from each one of the conveyed items,
a unique identification tag associated with the aforesaid each
one.
[0022] According to another aspect of one preferred embodiment of
the invention, the reader may preferably, but need not necessarily,
include one or more weight scales associated with the conveyor. The
weight scales may preferably, but need not necessarily, be adapted
to automatically weigh the conveyed items on the conveyor.
[0023] According to yet another aspect of one preferred embodiment
of the invention, the reader may preferably, but need not
necessarily, include one or more dimensioning sensors associated
with the conveyor. The dimensioning sensors may preferably, but
need not necessarily, be adapted to automatically detect one or
more dimensions associated with each of the conveyed items.
[0024] According to an aspect of one preferred embodiment of the
invention, one or more of the processors may preferably, but need
not necessarily, be further adapted to automatically: (iii)
determine, preferably at regular intervals, at least one
performance characteristic which may preferably, but need not
necessarily, be associated with the conveyor; (iv) compare the
performance characteristic against target parameters therefor, with
the target parameters preferably being predetermined target
parameters; and/or (v) preferably when the performance
characteristic is outside of the target parameters, calculate the
optimal speed, preferably as further based on the performance
characteristic.
[0025] According to another aspect of one preferred embodiment of
the invention, one or more of the processors may preferably, but
need not necessarily, be further adapted to automatically: (iii)
determine, preferably at regular intervals, at least one
performance characteristic which may preferably, but need not
necessarily, be associated with the conveyor; (iv) compare the
performance characteristic against target parameters therefor, with
the target parameters preferably being predetermined target
parameters; and/or (v) preferably when the performance
characteristic is outside of the target parameters, generate an
alert, preferably for presentation to a user of the system.
[0026] According to yet another aspect of one preferred embodiment
of the invention, one or more of the processors may preferably, but
need not necessarily, be further adapted to automatically: (iii)
determine, preferably at regular intervals, at least one
performance characteristic which may preferably, but need not
necessarily, be associated with the conveyor; and/or (iv) generate
a signal, preferably for presentation of the performance
characteristic to a user of the system.
[0027] According to an aspect of one preferred embodiment of the
invention, one or more of the processors may preferably, but need
not necessarily, be further adapted to determine the performance
characteristic by dynamically determining and/or performing a
detected item count of the conveyed items, preferably as detected
by the reader over a predetermined time interval.
[0028] According to another aspect of one preferred embodiment of
the invention, the reader may preferably, but need not necessarily,
include one or more dimensioning sensors, preferably adapted to
observe the conveyor and/or automatically detect footprint
dimensions associated with the conveyed items. One or more of the
processors may preferably, but need not necessarily, be further
adapted to determine the performance characteristic by: (A)
calculating individual footprint areas occupied on the conveyor,
preferably by each of the conveyed items for which footprint
dimensions are detected by the reader over a predetermined time
interval; (B) calculating a total footprint area, preferably by
summing together the individual footprint areas; and/or (C)
dividing the total footprint area by a corresponding area of the
conveyor, preferably observed by the dimensioning sensors over the
time interval.
[0029] According to yet another aspect of one preferred embodiment
of the invention, one or more of the processors may preferably, but
need not necessarily, be further adapted to determine the
performance characteristic by: (A) calculating a total stop
duration, preferably by summing together the duration of each of
the stops experienced by the conveyor, whether over a predetermined
time interval and/or as a running total; and/or (B) multiplying the
total stop duration by an average cost, preferably a predetermined
average cost, and preferably associated with the time interval
and/or with the stops.
[0030] According to still another aspect of one preferred
embodiment of the invention, one or more of the processors may
preferably, but need not necessarily, be further adapted to
determine the performance characteristic by: (A) dynamically
determining and/or performing a detected item count of the conveyed
items, preferably as detected by the reader, whether over a
predetermined time interval and/or as a running total; (B)
dynamically determining and/or performing an identified item count
of the conveyed items, preferably as identified by the reader over
the time interval and/or as a running total; and/or (C) dividing
the identified item count by the detected item count.
[0031] According to a further aspect of one preferred embodiment of
the invention, the reader may preferably, but need not necessarily,
include one or more dimensioning sensors, preferably adapted to
automatically detect one or more dimensions associated with the
conveyed items. One or more of the processors may preferably, but
need not necessarily, be further adapted to determine the
performance characteristic by: (D) automatically determining,
preferably based on predetermined rules and/or with reference to
the dimensions and/or the failed attempts, if any of the conveyed
items is too large for the reader, and/or (E) dynamically
determining and/or performing an oversized item count, preferably
of the conveyed items which are determined to be too large for the
reader, whether over the time interval and/or as a running total.
Preferably in determining the performance characteristic, the
detected item count may preferably, but need not necessarily, be
less the oversized item count.
[0032] According to an aspect of one preferred embodiment of the
invention, the reader may preferably, but need not necessarily,
include one or more dimensioning sensors, preferably adapted to
automatically detect one or more dimensions associated with the
conveyed items. One or more of the processors may preferably, but
need not necessarily, be further adapted to determine the
performance characteristic by: (A) automatically determining,
preferably based on predetermined rules and/or with reference to
the dimensions and/or the failed attempts, if any of the conveyed
items is too large for the reader; (B) dynamically determining
and/or performing an oversized item count, preferably of the
conveyed items which are determined to be too large for the reader,
whether over a predetermined time interval and/or as a running
total; and/or (C) multiplying the oversized item count by an
average revenue, preferably a predetermined average revenue, for
each of the conveyed items.
[0033] According to an aspect of one preferred embodiment of the
invention, one or more of the processors may preferably, but need
not necessarily, be further adapted to determine the performance
characteristic, whether over a predetermined time interval and/or
as a running total, by multiplying the number of the failed
attempts by an average item revenue, preferably a predetermined
average item revenue, for the conveyed items.
[0034] According to the invention, there is also disclosed a method
of adjusting an actual speed of a conveyor for use in identifying
conveyed items carried thereby. The method includes steps (a), (b),
(c) and (d). In step (a), the conveyed items are automatically
detected and identified using a reader associated with the
conveyor. In step (b), one or more databases are regularly updated
with data concerning (i) failed attempts by the reader to identify
the conveyed items, and (ii) stops experienced by the conveyor.
According to the invention, in step (c), one or more processors are
used to automatically: (i) determine, at regular intervals, (A) a
number of the failed attempts, and (B) a duration and a number of
the stops experienced by the conveyor; and (ii) based at least in
part thereon, dynamically calculate an optimal speed of the
conveyor for reducing the number of the failed attempts, the
duration and/or the number of the stops. In step (d), a controller,
operatively connected to the conveyor, is used to automatically and
dynamically adjust the actual speed of the conveyor towards the
optimal speed. Thus, according to the invention, the method
operatively facilitates increasing the conveyed items which are
successfully identified by the reader.
[0035] According to an aspect of one preferred embodiment of the
invention, in step (a), the reader may preferably, but need not
necessarily, identify each one of the conveyed items by determining
at least one item datum, preferably associated with the aforesaid
each one. The item datum may preferably, but need not necessarily,
be selected from a group which includes a unique identification
tag, an item weight, and/or one or more item dimensions.
[0036] According to an aspect of one preferred embodiment of the
invention, preferably in step (a), the reader may preferably, but
need not necessarily, identify the conveyed items by using a
scanner to automatically read, preferably from each one of the
conveyed items, a unique identification tag associated with the
aforesaid each one.
[0037] According to an aspect of one preferred embodiment of the
invention, preferably in step (a), the reader may preferably, but
need not necessarily, automatically weigh the conveyed items,
preferably on the conveyor and/or preferably using one or more
weight scales which may preferably be associated with the
conveyor.
[0038] According to an aspect of one preferred embodiment of the
invention, preferably in step (a), the reader may preferably, but
need not necessarily, automatically detect one or more dimensions,
preferably associated with each of the conveyed items and/or
preferably using one or more dimensioning sensors which may
preferably be associated with the conveyor.
[0039] According to an aspect of one preferred embodiment of the
invention, preferably in step (c), one or more of the processors
may preferably, but need not necessarily, be further used to
automatically: (iii) determine, preferably at regular intervals, at
least one performance characteristic which may preferably, but need
not necessarily, be associated with the conveyor; and/or (iv)
compare the performance characteristic against target parameters
therefor, with the target parameters preferably having been
predetermined. Preferably when the performance characteristic is
outside of the target parameters, the calculation of the optimal
speed in substep (c)(ii) may preferably, but need not necessarily,
be further based on the performance characteristic.
[0040] According to an aspect of one preferred embodiment of the
invention, preferably in step (c), one or more of the processors
may preferably, but need not necessarily, be further used to
automatically: (iii) determine, preferably at regular intervals, at
least one performance characteristic which may preferably, but need
not necessarily, be associated with the conveyor; (iv) compare the
performance characteristic against target parameters therefor,
preferably predetermined target parameters therefor; and/or (v)
preferably when the performance characteristic is outside of the
target parameters, generate an alert, preferably for presentation
to a user.
[0041] According to an aspect of one preferred embodiment of the
invention, in step (c), one or more of the processors may
preferably, but need not necessarily, be further used to
automatically: (iii) determine, preferably at regular intervals, at
least one performance characteristic which may preferably, but need
not necessarily, be associated with the conveyor; and/or (iv)
generate a signal, preferably for presentation of the performance
characteristic and/or preferably to a user.
[0042] According to an aspect of one preferred embodiment of the
invention, preferably in substep (c)(iii), one or more of the
processors may preferably, but need not necessarily, determine the
performance characteristic by dynamically determining and/or
performing a detected item count of the conveyed items, preferably
as detected by the reader, whether over a predetermined time
interval and/or as a running total.
[0043] According to an aspect of one preferred embodiment of the
invention, preferably in step (a), the reader may preferably, but
need not necessarily, use one or more dimensioning sensors,
preferably to observe the conveyor and/or automatically detect
footprint dimensions which may preferably, but need not
necessarily, be associated with the conveyed items. Preferably in
substep (c)(iii), one or more of the processors may preferably, but
need not necessarily, determine the performance characteristic by:
(A) calculating individual footprint areas occupied on the
conveyor, preferably by each of the conveyed items for which
footprint dimensions are detected by the reader, whether over a
predetermined time interval and/or as a running total; (B)
calculating a total footprint area, preferably by summing together
the individual footprint areas; and/or (C) dividing the total
footprint area by a corresponding area of the conveyor, preferably
as observed by the dimensioning sensors, whether over the time
interval and/or as a running total.
[0044] According to an aspect of one preferred embodiment of the
invention, preferably in substep (c)(iii), one or more of the
processors may preferably, but need not necessarily, determine the
performance characteristic by: (A) calculate a total stop duration,
preferably by summing together the duration of each of the stops
experienced by the conveyor, whether over a predetermined time
interval and/or as a running total; and/or (B) multiplying the
total stop duration by an average cost, preferably a predetermined
average cost, preferably associated with the time interval and/or
with the stops.
[0045] According to an aspect of one preferred embodiment of the
invention, preferably in substep (c)(iii), one or more of the
processors may preferably, but need not necessarily, determine the
performance characteristic by: (A) dynamically determining and/or
performing a detected item count of the conveyed items, preferably
as detected by the reader, whether over a predetermined time
interval and/or as a running total; (B) dynamically determining
and/or performing an identified item count of the conveyed items,
preferably as identified by the reader, whether over the time
interval and/or as a running total; and/or (C) dividing the
identified item count by the detected item count.
[0046] According to a further aspect of one preferred embodiment of
the invention, preferably in step (a), the reader may preferably,
but need not necessarily, use one or more dimensioning sensors,
preferably to automatically detect one or more dimensions which may
preferably, but need not necessarily, be associated with the
conveyed items. Preferably in substep (c)(iii), one or more of the
processors may preferably, but need not necessarily, further
determine the performance characteristic by (D) automatically
determining, preferably based on predetermined rules and/or with
reference to the dimensions and/or the failed attempts, if any of
the conveyed items is too large for the reader, and/or (E)
dynamically determining and/or performing an oversized item count
of the conveyed items which are determined to be too large for the
reader, whether over the time interval and/or as a running total.
Preferably in substep (c)(iii), the detected item count may
preferably, but need not necessarily, be less the oversized item
count.
[0047] According to an aspect of one preferred embodiment of the
invention, preferably in step (a), the reader may preferably, but
need not necessarily, use one or more dimensioning sensors,
preferably to automatically detect one or more dimensions
associated with the conveyed items. Preferably in substep (c)(iii),
one or more of the processors may preferably, but need not
necessarily, determine the performance characteristic by: (A)
automatically determining, preferably based on predetermined rules
and/or with reference to the dimensions and/or the failed attempts,
if any of the conveyed items is too large for the reader; (B)
dynamically determining and/or performing an oversized item count
of the conveyed items which are determined to be too large for the
reader over a predetermined time interval; and/or (C) multiplying
the oversized item count by an average revenue, preferably a
predetermined average revenue and/or preferably for each of the
conveyed items.
[0048] According to an aspect of one preferred embodiment of the
invention, preferably in substep (c)(iii), one or more of the
processors may preferably, but need not necessarily, determine the
performance characteristic, whether over a predetermined time
interval and/or as a running total, by multiplying the number of
the failed attempts by an average item revenue, preferably a
predetermined average item revenue and/or preferably for the
conveyed items.
[0049] According to the invention, there is also disclosed a
computer readable medium on which is physically stored executable
instructions. The executable instructions are such as to, upon
execution, adjustably control an actual speed of a conveyor
provided with a controller. The computer readable medium is also
for use with (1) conveyed items carried by the conveyor, (2) a
reader adapted to automatically detect and identify the conveyed
items, and (3) a database which includes data concerning stops
experienced by the conveyor and failed attempts by the reader to
identify the conveyed items. The executable instructions include
processor instructions for one or more processors to automatically
and according to the invention: (a) determine, at regular
intervals, (i) a number of the failed attempts, and (ii) a duration
and a number of the stops experienced by the conveyor; (b) based at
least in part thereon, dynamically calculate an optimal speed of
the conveyor for reducing the number of the failed attempts, the
duration and/or the number of the stops; and (c) generate a signal
for transmission to the controller for automatic and dynamic
adjustment of the actual speed of the conveyor towards the optimal
speed. Thus, according to the invention, the computer readable
medium operatively facilitates use of the processors to increase
the conveyed items which are successfully identified by the
reader.
[0050] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
automatically: (d) determine, preferably at regular intervals, at
least one performance characteristic which may preferably, but need
not necessarily, be associated with the conveyor; (e) compare the
performance characteristic against target parameters therefor,
preferably predetermined target parameters therefor; and/or (f)
preferably when the performance characteristic is outside of the
target parameters, calculate the optimal speed which may
preferably, but need not necessarily, be additionally based on the
performance characteristic.
[0051] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
automatically: (d) determine, preferably at regular intervals, at
least one performance characteristic which may preferably, but need
not necessarily, be associated with the conveyor; (e) compare the
performance characteristic against target parameters therefor,
preferably predetermined target parameters therefor; and/or (f)
preferably when the performance characteristic is outside of the
predetermined target parameters, generate an alert, preferably for
presentation to a user.
[0052] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
automatically: (d) determine, preferably at regular intervals, at
least one performance characteristic which may preferably, but need
not necessarily, be associated with the conveyor; and/or (e)
generate a signal, preferably for presentation of the performance
characteristic, and preferably to a user.
[0053] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
determine the performance characteristic by dynamically determining
and/or performing a detected item count of the conveyed items,
preferably as detected by the reader, whether over a predetermined
time interval and/or as a running total.
[0054] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
determine the performance characteristic by: (i) calculating
individual footprint areas occupied on the conveyor, preferably by
each of the conveyed items for which footprint dimensions are
detected by the reader, whether over a predetermined time interval
and/or as a running total; (ii) calculating a total footprint area,
preferably by summing together the individual footprint areas;
and/or (iii) dividing the total footprint area by a corresponding
area of the conveyor, preferably one which passes the reader over
the time interval and/or over the running total time period.
[0055] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
determine the performance characteristic by: (i) calculating a
total stop duration, preferably by summing together the duration of
each of the stops experienced by the conveyor, whether over a
predetermined time interval and/or as a running total; and/or (ii)
multiplying the total stop duration by an average cost, preferably
a predetermined average cost and preferably associated with the
time interval and/or with the stops.
[0056] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
determine the performance characteristic by: (i) dynamically
determining and/or performing a detected item count of the conveyed
items, preferably as detected by the reader, whether over a
predetermined time interval and/or as a running total; (ii)
dynamically performing an identified item count of the conveyed
items, preferably as identified by the reader, whether over the
time interval and/or as a running total; and/or (iii) dividing the
identified item count by the detected item count.
[0057] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
further determine the performance characteristic by: (iv)
automatically determining, preferably based on predetermined rules
and/or with reference to the failed attempts and/or dimensions of
the conveyed items, preferably as detected by the reader, if any of
the conveyed items is too large for the reader, and/or (v)
dynamically determining and/or performing an oversized item count
of the conveyed items which are determined to be too large for the
reader, whether over the time interval and/or as a running total.
The detected item count may preferably, but need not necessarily,
be less the oversized item count.
[0058] According to an aspect of one preferred embodiment of the
invention, the processor instructions may preferably, but need not
necessarily, be additionally for one or more of the processors to
determine the performance characteristic by: (i) automatically
determining, preferably based on predetermined rules and/or with
reference to the failed attempts and/or dimensions of the conveyed
items, preferably as detected by the reader, if any of the conveyed
items is too large for the reader; (ii) dynamically determining
and/or performing an oversized item count of the conveyed items
which are determined to be too large for the reader, whether over a
predetermined time interval and/or as a running total; and/or (iii)
multiplying the oversized item count by an average revenue,
preferably a predetermined average revenue and/or preferably for
each of the conveyed items.
[0059] According to an aspect of one preferred embodiment of the
invention, the processor instructions are additionally for one or
more of the processors to determine the performance characteristic,
whether over a predetermined time interval and/or as a running
total, by multiplying the number of the failed attempts by an
average item revenue, preferably a predetermined average item
revenue and/or preferably for the conveyed items.
[0060] Other advantages, features and characteristics of the
present invention, as well as methods of operation and functions of
the related elements of the system, method and computer readable
medium, and the combination of steps, parts and economies of
manufacture, will become more apparent upon consideration of the
following detailed description and the appended claims with
reference to the accompanying drawings, the latter of which are
briefly described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] The novel features which are believed to be characteristic
of the system, method and computer readable medium according to the
present invention, as to their structure, organization, use, and
method of operation, together with further objectives and
advantages thereof, will be better understood from the following
drawings in which presently preferred embodiments of the invention
will now be illustrated by way of example. It is expressly
understood, however, that the drawings are for the purpose of
illustration and description only, and are not intended as a
definition of the limits of the invention. In the accompanying
drawings:
[0062] FIG. 1 is a schematic diagram of an adjustable speed control
system according to one preferred embodiment of the invention;
[0063] FIG. 2 is a schematic diagram of selected components of the
system of FIG. 1, with the material handling equipment shown
removed therefrom;
[0064] FIG. 3a is a low pieces per hour ("PPH") alert interface
presented by a graphical user interface ("GUI") device of the
system of FIG. 1;
[0065] FIG. 3b is a non-alert interface presented by the GUI device
of FIG. 1;
[0066] FIG. 3c is a high PPH alert interface presented by the GUI
device of FIG. 1;
[0067] FIG. 4 is a process map of report generation menus
associated with the system of FIG. 1;
[0068] FIG. 5 is an on-screen report presented by the GUI device of
FIG. 1;
[0069] FIG. 6 is a flowchart of an over-arching method of adjusting
an actual speed of a conveyor according to a preferred embodiment
of the invention;
[0070] FIG. 7 is a flowchart of a pieces-per-time-interval ("PPTI")
subroutine for the method of FIG. 6;
[0071] FIG. 8 is a flowchart of a belt utilization subroutine for
the method of FIG. 6;
[0072] FIG. 9 is a flowchart of an scan quality subroutine for the
method of FIG. 6;
[0073] FIG. 10 is a flowchart of a lost revenue subroutine for the
method of FIG. 6; and
[0074] FIG. 11 is a flowchart of stop cost subroutine for the
method of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0075] Referring to FIGS. 1 to 11, there is shown an adjustable
speed control system 50 for use with at least one conveyor 62 and
conveyed items 20 carried thereby, along with steps performed
thereby, according to a related method 400, and/or under influence
of a related computer readable medium 120. The conveyor 62 may
typically convey the items 20 (as indicated generally by arrow "A"
in FIG. 1) from one location to another within a facility. It is
typically provided along with other material handling equipment
("MHE") 60, as shown in FIGS. 1 and 2.
[0076] The system 50 depicted in FIG. 1 may be used within a single
facility and/or multiple facilities. For example, some of the
components of the system 50 may be provided at a remote location
90. Each of the items (alternately, herein, "packages" or
"parcels") 20 may have the unique identification tag, preferably, a
barcode affixed thereto. The packages 20 preferably constitute
freight or other items moving within a mail system or within a
distribution system generally.
[0077] Preferably, and as best seen in FIG. 1, the system 50
includes a reader 70, databases 80, 82, processors 114, and a
controller 64 operatively connected to the conveyor 62.
[0078] In FIGS. 1 and 2, the system 50 is shown in use with one or
more communication networks 100, a networked computer 132, and
wirelessly networked 102 peripheral devices 104--i.e., a networked
laptop 104a and a networked handheld device 104b. The
communications networks 80 may include satellite networks (e.g.,
GPS networks), terrestrial wireless networks, and the Internet.
Persons having ordinary skill in the art will appreciate that the
system 50 includes hardware and software.
[0079] FIG. 2 schematically illustrates, among other things, the
processors 114, a wireless transmitter 110, a power source 140, and
at least one computer readable medium (e.g., an onboard
processor-readable memory) 120. The controller 64 is shown, in FIG.
2, in the form of a MHE controller 64 and in association with the
MHE 60. The MHE 60 is shown, in FIG. 2, in association with the
reader 70, provided in the form of an automated reweigh cube
("ARC") device 70. The ARC device 70 may be provide with an ARC
controller 74. According to the invention, the system 50 may also
use the ARC controller 74 to control the reader 70.
[0080] Reader
[0081] As best seen in FIGS. 1 and 2, the reader 70 is adapted to
automatically detect and identify the conveyed items 20. The reader
70 preferably identifies each of the conveyed items 20 by
determining the unique identification tag, an item weight, and/or
item dimensions associated therewith. More specifically, the reader
70 preferably includes a scanner 72, dimensioning sensors 78 and/or
weight scales 76 associated with the conveyor 62.
[0082] Preferably, the reader 70 uses the scanner 72 to
automatically read the unique identification tags from the conveyed
items 20. The scanner 72 is preferably a barcode scanner. The
scanner 72 can be an imager, or a laser-based scanner. [The scanner
72 may instead be a radio-frequency identification ("RFID")
scanner. When an RFID scanner is provided, one or more of the
identification tags on the items 20 are RFID tags.] It may be wired
to communicate with, or it may wirelessly communicate--e.g., by the
Bluetooth.TM. proprietary open wireless technology standard which
is managed by the Bluetooth Special Interest Group of Kirkland,
Wash.--with the databases 80, 82 and/or with the processors 114
(e.g., via the wireless transmitter 152). The scanner 72 is adapted
to scan or read information (e.g., a barcode) from each package
60.
[0083] The weight scales 76 are shown in FIG. 2. They automatically
weigh (i.e., measures a weight of) the conveyed items 20 on the
conveyor 62. The weight scales 76 are preferably highly accurate
for weighing the packages 60 on the conveyor 62. The scales 76 are
preferably accurate to government set precision standards, and may
preferably be accurate to about one pound (1 lb.), or perhaps more
preferably to about one fifth of a pound (0.2 lbs.). They may be
adapted to measure a minimum weight of about two pounds (2
lbs.).
[0084] Preferably, the dimensioning sensors 78 automatically detect
item dimensions of each of the conveyed items 20.
[0085] Databases
[0086] The databases 80, 82 include, and are regularly updated
with, data concerning stops experienced by the conveyor 62 and
failed attempts by the reader 70 to identify the conveyed items 20.
The databases 80, 82 may include an automated flow management
("AFM") database 80 and other databases 82, such as, for example, a
mail reweigh database 84, a proof of pickup database 86, and/or one
or more ARC/MHE databases 88.
[0087] As may be best appreciated by a consideration of FIG. 1, one
or more of the databases 80, 82 (and the processors 114) preferably
may be located remotely from conveyor 62. In FIG. 1, the other
databases 82 are shown located a remote location 90.
[0088] The databases 80, 82 include information associated with the
items 20, and all or part of the databases 80, 82 may be located
behind a firewall relative to the communications networks 100.
Persons having ordinary skill in the art will appreciate that
references herein to the databases 80, 82 comprise references to
(i) a single database 80 located at a facility remote from, and/or
at the same facility as, the conveyor 62, and/or (ii) one or more
congruent and/or distributed databases 80, 82, such as, for
example, also including one or more sets of congruently
inter-related databases 80, 82--possibly distributed across
multiple facilities.
[0089] Processors
[0090] Preferably, the processors 114 are operatively encoded with
one or more algorithms 122 (shown schematically in FIG. 2 as being
stored in the memory 120) which provide them with analysis logic
122a, MHE control logic 122b, and/or report generation logic 122c.
Preferably, the algorithms 122 enable the processors 114 to assess
package and conveyor information received from the databases 80,
82. The data/information collected from the various databases 80,
82 is merged by the processors 114.
[0091] The processors 114 automatically determine, at regular
intervals, a number 166 of the failed attempts, and a duration and
a number 152 of the stops experienced by the conveyor 62. Based at
least in part thereon, the processors 114 automatically and
dynamically calculate an optimal speed of the conveyor 62 for
reducing the number 166 of the failed attempts, the duration and/or
the number 152 of the stops.
[0092] The system 50 may thus be seen to include a flow calculator
to compute and evaluate various actual and preferred flow rates,
including an optimal flow rate, based upon the flow information.
The flow calculator is also adapted to compute and provide
revenue-based information, such as opportunities to increase or
maximize revenue, based upon the flow information.
[0093] Preferably, the processors 114 automatically determine, at
regular intervals, performance characteristics associated with the
conveyor 62 (i.e., including those associated with the conveyed
items 20 thereon).
[0094] The processors 114 may merge the determined performance
characteristics with information concerning the conveyor(s) 62
and/or the packages 20 (e.g., package ID numbers, associated
services and surcharges, and origin, location and/or destination
information), and preferably transmit this data to one or more of
the databases 80, 82. In this manner, the merged data may later be
retrieved by tracking and billing functions integrated within a
larger operation, for example, at the facility or across multiple
facilities. These functions may, for example and according to some
embodiments of the invention, be "backend" functions in the sense
that they may not be performed onsite and/or local to other
functions associated with the system 50.
[0095] The performance characteristics may be determined in a
variety of ways, and a variety of performance characteristics may
be determined. In many cases, the performance characteristics may
be determined over a particular time interval. The time interval
preferably may be a predetermined one. For example, the time
interval may be related to the working hours of a particular shift
of employees. It may alternately be performed in two (2) hour
increments, five (5) minute increments, thirty (30) second
increments, or according to some other shorter or longer
incremental scale. Further, the time interval may be effectively
provided in the form of a running total, for example, if it is
predetermined to cover a period from a particular start time to a
then present time or to a predetermined end time which has just
passed.
[0096] Some of the performance characteristics which are discussed
herein include a detected item count 158, conveyor utilization,
total stop cost, scan quality 164, and potential revenue loss (1
and 2) 156.
[0097] Detected Item Count
[0098] More specifically, the processors 114 may dynamically
determine (e.g., from the ARC/MHE database 88), or may dynamically
perform, a detected item count 158 of the conveyed items 20
detected by the reader 70 over the time interval. Alternately,
herein the detected item count may be referred to as "pieces per
time interval", "packages per time interval" or, simply, "PPTI".
Perhaps notably, the count may be initially determined or performed
over a shorter period, and the PPTI over the time interval may be
determined therefrom. The time interval preferably may be one (1)
hour and, in such event, the PPTI may be alternately referred to as
"pieces per hour", "packages per hour", or "PPH".
[0099] Conveyor Utilization
[0100] The processors 114 may determine the performance
characteristic by calculating individual footprint areas occupied
on the conveyor 62 by each of the conveyed items 20 for which
footprint dimensions are detected by the reader 70 over the time
interval. The processors then calculate a total footprint area by
summing together the individual footprint areas. To determine the
conveyor utilization, the total footprint area is then divided by a
corresponding area of the conveyor 62 which is observed by the
dimensioning sensors 78 over the time interval.
[0101] Total Stop Cost
[0102] The processors 114 may calculate a total stop duration 154
by summing together the duration of each of the stops experienced
by the conveyor 62 over the time interval. To arrive at a total
stop cost, the processors may then multiply the total stop duration
154 by an average cost per unit of stopped conveyor time. This
average cost preferably may be one which is predetermined.
[0103] Scan Quality
[0104] The processors 114 may dynamically determine (e.g., from the
ARC/MHE database 88), or may dynamically perform, an identified
item count of the conveyed items 20 identified by the reader 70
over the time interval. Then, the processors may divide the
identified item count by the detected item count 158 (as discussed
hereinabove) to calculate the scan quality 164.
[0105] Preferably, in calculating the scan quality 164, the
processors 114 may automatically determine--whether from the
ARC/MHE database 88, based on predetermined rules, and/or with
reference to the item dimensions and/or the failed attempts--if any
of the conveyed items 20 is too large for the reader 70. The
processors 114 may dynamically determine (e.g., from the ARC/MHE
database 88), or may dynamically perform, an oversized item count
of the conveyed items 20 which are determined to be too large for
the reader 70 over the time interval. Then, in calculating the scan
quality, the detected item count 158 preferably may be adjusted so
as to exclude the oversized items identified by the reader 70.
[0106] Potential Revenue Loss 1
[0107] The processors 114 may multiply the oversized item count by
an average item revenue for the conveyed items 20 to determine a
first potential revenue loss. Preferably, the average item revenue
may be a predetermined one.
[0108] Potential Revenue Loss 2
[0109] Preferably, when the PPTI is greater than a predetermined
target PPTI and the scan quality is lower than a predetermined
target scan quality, the processors 114 may determine a second
potential revenue loss by multiplying the number 166 of the failed
attempts (i.e., for the corresponding time interval) by the average
item revenue.
[0110] A potential revenue lost 156 may be calculated by summing
the first and second potential revenue losses.
[0111] Presentation
[0112] The processors 114 preferably generate a signal for
presentation of the various performance characteristics to a user
22 of the system 50. As shown in FIGS. 1 to 3c, the performance
characteristics may be presented by the system 50 using a graphical
user interface ("GUI") 132. Alternately, and as shown in FIGS. 1
and 5, the performance characteristics may be presented using one
or more reports 300.
[0113] FIG. 2 schematically illustrates, among other things,
various input/output devices 130 (including the GUI 132, a printer
134, speakers 136, and light emitting diodes 138).
[0114] The GUI 132 may include a touchscreen (and the two terms may
be used inter-changeably herein), a display with or without a
"point-and-click" mouse or other input device.] As may be
appreciated from a consideration of FIGS. 3a to 3c, the GUI device
132 enables (selective or automatic) display of the performance
characteristics determined by the processors 114--whether received
directly therefrom and/or retrieved from the databases 80, 82--as
well as display and input, of the certain target parameters and
other data associated with the items 20.
[0115] Each one of FIGS. 3a to 3c is a graphical representation of
an interface which may preferably be presented by the GUI 132. As
shown in FIGS. 3a to 3c, the GUI 132 preferably presents, among
other things, an alert 170, a shift indication 150, the number 153
of the stops, the total stop duration 154, the potential revenue
lost 156, the detected item count 158, a percent to bill 160,
target parameters 162, a percent good scan 164, the number 166 of
the failed attempts, and the PPH 168, as well as dashboard
representations of the percent to bill and the PPH, 172 and 174
respectively, graphical representations of the PPH and the percent
to bill over time, 176 and 178 respectively, a configure button
180, and a reset button 182.
[0116] FIG. 4 graphically represents a series of report generation
menus for display on the GUI 132 and/or in a printed report 300 or
other record. FIG. 4 shows, among other things, a location list
menu 210 (including division list 212 and terminal list 214 menu
items), a report type menu 220 (including current report 22, daily
report 224, weekly report 226 and monthly report 228 menu items),
an equipment identification menu 230 (including machine number 236
and all 234 menu items), a date menu 240 (including day 242, week
244 and month 246 menu items), and a time menu 250--which the user
22 may use to generate the reports 300.
[0117] FIG. 5 graphically represents one of the reports 300 which,
if displayed on the GUI 132, may afford some interface
capabilities. The report 300 is shown as an AFM report console. The
report 300 presents, among other things, a location field 302, a
report type field 304, a device field 306, a graphical
representation of lost time events over time 376, a graphical
representation of lost time cost over time 378, and a historical
record table 380.
[0118] The system 50 may thus be seen to include a report
generation unit for generating the reports 300. The following
reports may be generated, based upon the flow information and/or
the revenue-based information: pre-shift reports which also may be
based upon historical information, and which may enhance shift
and/or other planning; real-time reports for enhanced control
and/or monitoring; and post-shift reports for enhanced post-shift
analysis of automated reweigh and/or material handling operations.
Such reports may enable or facilitate estimation of potential
revenue lost due to a given operating condition, reaction to a
particular situation and/or issue (e.g., excessive flow, jam-up,
equipment breakdown, and/or other operational and/or customer
issues), and reduction of potential lost time, associated manpower
costs, or lost revenues.
[0119] The GUI 132 displays the flow information, revenue-based
information, and/or various alerts. Such alerts may include visual
(or audible) warning signals which may be triggered to highlight a
given condition to the user 22, for example, if a computed optimal
flow rate is not achieved.
[0120] Targets
[0121] The performance characteristics are preferably compared,
using the processors 114, against predetermined target parameters
162 for the performance characteristics.
[0122] Alerts
[0123] If the performance characteristic is outside of the target
parameters 162, when the processors 114 calculate the optimal
speed, they may preferably also do so with reference to the
performance characteristic. Additionally, the processors 114 will
generate an alert 170 for presentation to a user 22 of the system
when the performance characteristic is outside of the target
parameters 162.
[0124] Controller
[0125] The controller 64 is adapted to automatically and
dynamically adjust an actual speed of the conveyor 62 towards the
optimal speed.
[0126] The controller 64 interfaces with the material handling
equipment 60 and/or the conveyor 62. This interface is adapted to
enable automatic control of the material handling equipment 60 and
conveyor 62 in dependent relation upon the revenue-based
information. This interface, and the dynamic flow control which it
enables, may help to increase or maximize revenues in association
with automated reweigh cube systems.
[0127] According to some embodiments of the invention which may
involve the use and integration of multiple conveyors 62 and/or
MHEs 60, configurations are available where many conveyors 62 or
other MHEs 60--one or more of which may afford some functionality
for conveyor 62 and/or item 20 data capture and each of which may
afford some functionality for control by a controller
64--communicate with the processors 114 (located locally and/or
remotely) which then integrate and merge the control information
before disseminating control signals to the various conveyors 62
and MHEs 60. Conveyors 62 and MHEs 60 could each be provided with a
unique identifier to enable the processors 114 to distinguish
between and control them, as appropriate.
[0128] Method
[0129] FIGS. 6 to 11 depict selected steps and substeps of a method
400 of adjusting the actual speed of the conveyor 62 for use in
identifying conveyed items 20 carried thereby. In the description
of the method 400 which follows, the same reference numerals are
used as those which are used, above, with reference to the system
50. The method 400 is suitable for use with the system 50 described
above and shown in FIGS. 6 to 11, but it is not so limited.
[0130] As shown in FIG. 6, the method 400 includes the following
steps, among others: a target predetermination step 402, a package
identification step 404, a database updating step 406, a step 410
of determining a metric and/or performance characteristic, a step
490 of querying if the metric or performance characteristic is
outside of the appropriate target parameters. In the event that the
query is answered in the affirmative (i.e., it does not meet the
target parameters), the method 400 proceeds to an alert step 500 of
alerting the user 22 and proceeds to a step 510 of presenting it to
the user 22. If answered in the negative, the method 400 proceeds
directly from step 410 to step 510.
[0131] It will be appreciated that, according to the method 400,
the conveyed items 20 are automatically detected and identified
using the reader 70 associated with the conveyor 62. The databases
80, 82 are regularly updated with data concerning failed attempts
by the reader 70 to identify the conveyed items 20, and stops
experienced by the conveyor 62. The processors 114 are used to
automatically: determine, at regular intervals, a number 166 of the
failed attempts, and a duration and a number 152 of the stops
experienced by the conveyor 62; and based at least in part thereon,
dynamically calculate an optimal speed of the conveyor 62 for
reducing the number 166 of the failed attempts, the duration and/or
the number 152 of the stops. According to the method 400, the
controller 64 is used to automatically and dynamically adjust the
actual speed of the conveyor 62 towards the optimal speed. Thus,
according to the invention, the method 400 operatively facilitates
increasing the conveyed items 20 which are successfully identified
by the reader 70.
[0132] FIGS. 7 to 11 depict certain subroutines 520, 530, 540, 570,
580 for use with the method 400 in determining the performance
characteristics, comparing them against the targets, alerting the
user if they fall outside the associated target parameters, and
displaying them to the user. More specifically, FIG. 7 depicts a
PPTI related subroutine 520, FIG. 8 depicts a conveyor utilization
related subroutine 530, FIG. 9 depicts a scan quality subroutine
540, and FIG. 11 depicts a stop cost calculation subroutine 580. It
may be appreciated that these subroutines 520, 530, 540, 580 (shown
in FIGS. 7 to 9 and 11) may be readily substituted in place of
steps 410, 490, 500 and 510 in the method 400 shown in FIG. 6.
[0133] In the PPTI related subroutine 520 shown in FIG. 7, the
processors 114 determine the performance characteristic by
dynamically determining and/or performing a detected item count 158
of the conveyed items 20 detected by the reader 70 over the time
interval. FIG. 7 shows a detected item determination step 422, a
PPTI calculation step 420, a PPTI comparison query step 490a, the
alert step 500, and a PPTI display step 510a.
[0134] In the conveyor utilization related subroutine 530 shown in
FIG. 8, the processors 114 determine the performance characteristic
by first calculating individual footprint areas occupied on the
conveyor 62 by each of the conveyed items 20 for which footprint
dimensions are detected by the reader 70 over the time interval.
They then calculate a total footprint area by summing together the
individual footprint areas. Finally, the processors 114 divide the
total footprint area by a corresponding area of the conveyor 62
observed by the dimensioning sensors 78 over the time interval.
FIG. 8 shows a belt utilization determination step 432, a first
belt utilization pre-calculation step 434, a second belt
utilization pre-calculation step 436, a belt utilization
calculation step 430, a belt utilization comparison query step
490b, the alert step 500, and a belt utilization display step
510b.
[0135] In the scan quality subroutine 540 shown in FIG. 9, the
processors 114 determine the performance characteristic by first
dynamically determining the detected item count 158 of the conveyed
items 20 detected by the reader 70 over the time interval. They
then dynamically determine an identified item count of the conveyed
items 20 identified by the reader 70 over the time interval.
Preferably, the detected item count 158 may preferably be less the
oversized item count. The processors 114 then divide the identified
item count by the detected item count 158 to arrive at the scan
quality. FIG. 9 shows the detected item determination step 422, a
first scan quality pre-calculation step 442, a second scan quality
pre-calculation step 444, a scan quality calculation step 440, a
scan quality comparison query step 490c, the alert step 500, and a
scan quality display step 510c.
[0136] In the stop cost calculation subroutine 580 shown in FIG.
11, the processors 114 calculate a total stop duration 154 by
summing together the duration of each of the stops experienced by
the conveyor 62 over the time interval. They then obtain the total
stop cost by multiplying the total stop duration 154 by an average
cost per stopped unit of time. FIG. 11 shows the stop cost
determination step 482, a stop cost pre-calculation step 484, a
stop cost calculation step 480, a stop cost comparison query step
490e, the alert step 500, and a stop cost display step 510e.
[0137] FIG. 10 depicts a potential revenue lost subroutine 570,
which includes first and second potential revenue loss subroutines,
550 and 560 respectively. In the first potential revenue loss
subroutine 550, the processors 114 automatically determine, based
on predetermined rules and with reference to the dimensions and the
failed attempts, if any of the conveyed items 20 is too large for
the reader 70. They then dynamically determine the oversized item
count. To determine the first potential revenue loss, the
processors 114 multiply the oversized item count by the average
item revenue. FIG. 10 shows the first potential revenue loss
subroutine 550 includes a first potential revenue loss
determination step 452 and a first potential revenue loss
calculation step 450.
[0138] FIG. 10 shows the second potential revenue loss subroutine
560 includes the PPTI calculation step 420, a PPTI comparison query
step 490a, the scan quality calculation step 440, the scan quality
comparison query step 490c, and the second scan quality
pre-calculation step 444. It may be appreciated that all or
portions of the PPTI related subroutine 520 (shown in FIG. 7) and
the scan quality subroutine 540 (shown in FIG. 8) may be readily
substituted in place of steps 420, 490a, 440, 490c and 444 of the
second potential revenue loss subroutine 560 shown in FIG. 10.
[0139] If either or both of the PPTI comparison query step 490a and
the scan quality comparison query step 490c are answered in the
negative, then the second potential revenue loss subroutine 560
proceeds to a set step 464 of setting the second revenue loss to
zero and from there, to a second revenue loss determination step
460. Otherwise, and as can be seen in FIG. 10, the second potential
revenue loss subroutine 560 proceeds to the second revenue loss
determination step 460 via second revenue loss calculation step
464.
[0140] To conclude, the potential revenue lost subroutine 570
proceeds to a total revenue loss step 470 of summing the first and
second revenue losses and, from there, to a revenue loss display
step 510d.
[0141] The computer readable medium 120 stores executable
instructions which, upon execution, adjustably control the actual
speed of the conveyor 62. The executable instructions include
processor instructions 122 for the processors 114 to automatically
and according to the invention perform the aforesaid method 400,
and perform steps and provide functionality as otherwise described
above and elsewhere herein. The processors 114 encoded by the
computer readable medium are such as to generate a signal for
transmission to the controller 64 for automatic and dynamic
adjustment of the actual speed of the conveyor 62 towards the
optimal speed. Thus, according to the invention, the computer
readable medium 120 facilitates use of the processors 114 to
operatively increase the conveyed items 20 which are successfully
identified by the reader 70.
[0142] Thus, the system 50, method 400 and computer readable medium
120 are adapted to operatively facilitate increasing the conveyed
items 20 which are successfully identified by the reader 70.
[0143] Notably, the system 50, method 400 and computer readable
medium 120 are used for flow management of material handling
equipment that is provided with one or more automated reweigh cube
systems. The system 50, method 400 and computer readable medium 120
are adapted to interface with the material handling equipment and
to provide flow information for use in dynamically (a) controlling,
managing, improving and/or optimizing flow and unloading processes,
(b) increasing and/or maximizing revenue through flow control,
and/or (c) ensuring clear times.
[0144] The system 50, method 400 and computer readable medium 120
are adapted to be operatively connected to at least one automated
reweigh cube system, and to provide the following flow information,
among other things: a count and the precise length of any belt
stops experienced by the material handling equipment; a count of
the boxes flowing through the automated reweigh cube system;
pieces-per-hour information, in real-time and in various
increments, during a given shift; and a profiling of the boxes,
and/or the size of the boxes, which correspond with the
pieces-per-hour information.
[0145] The system 50, method 400 and computer readable medium 120
are preferably adapted and/or adaptable for use in parcel delivery
and postal applications, in airports and with airlines, and supply
chain management. In parcel delivery and postal applications, the
system 50, method 400 and the computer readable medium 120 are
preferably adapted for transport of conveyable items to trailers,
for transport of parcels, and to improve or facilitate movement of
conveyable freight. In parcel delivery networks, the system 50,
method 400 and the computer readable medium 120 may be employed at
each of the numerous locations and terminals across North America.
In airports and with airlines, the system 50, method 400 and the
computer readable medium 120 are preferably adapted to improve or
facilitate movement of baggage and air cans.
[0146] This concludes the description of presently preferred
embodiments of the invention. The foregoing description has been
presented for the purpose of illustration and is not intended to be
exhaustive or to limit the invention to the precise form disclosed.
Other modifications, variations and alterations are possible in
light of the above teaching and will be apparent to those skilled
in the art, and may be used in the design and manufacture of other
embodiments according to the present invention without departing
from the spirit and scope of the invention. It is intended the
scope of the invention be limited not by this description but only
by the claims forming a part hereof
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