U.S. patent application number 15/322392 was filed with the patent office on 2017-05-18 for parcel sorter system and method.
This patent application is currently assigned to OCADO INNOVATION LIMITED. The applicant listed for this patent is OCADO INNOVATION LIMITED. Invention is credited to Sverker LINDBO.
Application Number | 20170140327 15/322392 |
Document ID | / |
Family ID | 51410068 |
Filed Date | 2017-05-18 |
United States Patent
Application |
20170140327 |
Kind Code |
A1 |
LINDBO; Sverker |
May 18, 2017 |
PARCEL SORTER SYSTEM AND METHOD
Abstract
A system for managing shipment containers includes a storage and
retrieval system and at least one processor. The
storage-and-retrieval system includes a framework defining a
plurality of adjacent stacks capable of receiving a plurality of
stackable containers, each stackable container suitable for
containing a shipment container; and plural robotic pickers/load
handlers configured to retrieve selected stackable containers from
the framework for sortation and/or dispatch. The at least one
processor is configured to: receive or access destination address
information for each of the plurality of shipment containers
entering the system; select a subset of the plurality of shipment
containers for dispatch based on shipment container information,
and generate signals for instructing at least one robotic picker to
retrieve the selected shipment containers for dispatch.
Inventors: |
LINDBO; Sverker; (Hatfield
Hertfordshire, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
OCADO INNOVATION LIMITED |
Hatfield Hertfordshire |
|
GB |
|
|
Assignee: |
OCADO INNOVATION LIMITED
Hatfield Hertfordshire
GB
|
Family ID: |
51410068 |
Appl. No.: |
15/322392 |
Filed: |
June 24, 2015 |
PCT Filed: |
June 24, 2015 |
PCT NO: |
PCT/EP2015/064260 |
371 Date: |
December 27, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06Q 10/06315 20130101;
B65G 1/0464 20130101; B65G 1/0492 20130101; G06Q 10/08 20130101;
G06Q 10/083 20130101 |
International
Class: |
G06Q 10/08 20060101
G06Q010/08; B65G 1/04 20060101 B65G001/04; G06Q 10/06 20060101
G06Q010/06 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 25, 2014 |
GB |
1411254.4 |
Claims
1. A system for managing shipment containers, the system
comprising: a storage-and-retrieval system having: a framework
defining a plurality of adjacent stacks, each stack being
configured for receiving a plurality of stackable containers, each
stackable container being suitable for containing a shipment
container; tracks arranged above or below the framework to provide
access to stackable containers received in the framework; and a
plurality of robotic pickers/load handlers configured to move along
a direction of the tracks and to retrieve selected stackable
containers from the framework for sortation and/or dispatch; and at
least one processor configured to: receive or access destination
address information for each of the plurality of shipment
containers entering the system; select a subset of the plurality of
shipment containers for dispatch based on shipment container; and
generate signals for instructing at least one of the plurality of
robotic pickers to retrieve the selected shipment containers for
dispatch, the selection of the shipment containers being based on
at least one of: a priority of the selected shipment containers; a
capacity of a shipping vehicle on which the selected shipment
containers are to be dispatched; and the destination addresses of
the plurality of selected shipment containers; the system including
selection means for retrieving a selected shipment based on a final
destination of the selected shipment, wherein said selected
shipment will be retrieved at a given position in a retrieval
process based on a sequence required for delivery of the selected
shipment.
2. The system of claim 1, wherein the plurality of robotic pickers
are configured to transport the retrieved stackable containers for
dispatch via at least one of a plurality of transfer points at the
storage-and-retrieval system.
3. The system of claim 1, wherein the plurality of robotic pickers
or a second plurality of robotic pickers are configured for
inducting shipment containers into the storage-and-retrieval system
via at least one of a plurality of transfer points at the
storage-and-retrieval system.
4. The system of claim 1, wherein the selection of the shipment
containers is based on at least one of: a weight and at least one
dimension of at least one of the shipment containers.
5. The system of claim 1, wherein the at least one processor is
configured to select shipment containers for dispatch in the
shipping vehicle to substantially fill a delivery period associated
with the shipping vehicle based on the destination address
information of the shipping containers.
6. The system of claim 1, wherein the at least one processor is
configured to select shipment containers for dispatch by not
selecting a lower priority shipment container when a higher
priority shipment container is available.
7. The system of claim 1, wherein the at least one processor is
configured to select at least one lower priority shipment container
along with higher priority shipment containers when the capacity of
the shipping vehicle can accommodate the at least one lower
priority shipment container.
8. The system of claim 1, wherein the at least one processor is
configured to generate signals for instructing at least two of the
plurality of robotic pickers to concurrently retrieve selected
shipment containers for dispatch via a same shipping vehicle.
9. The system of claim 1, wherein the at least one processor is
configured to generate signals for instructing at least two of the
plurality of robotic pickers to concurrently retrieve selected
shipment containers for dispatch via different shipping
vehicles.
10. The system of claim 1, wherein the at least one processor is
configured to select shipment containers for dispatch in a specific
sequence.
11. The system of claim 10, wherein the sequence is selected to
decrease unfilled capacity of the shipping vehicle, or to ease
loading or unloading of the selected shipment containers into or
out of the shipping vehicle.
12. The system of claim 10, wherein the sequence is selected based
at least in part on a sequence in which the shipment containers
will be delivered.
13. The system of claim 1, wherein no more than one shipment
container is stored in a single stackable container.
14. The system of claim 1, wherein the at least one processor is
configured to select shipment containers for dispatch to a second
system for managing shipment containers.
15. The system of claim 14, wherein the at least one processor is
configured to select the shipment containers for dispatch to the
second system in a sequence or a grouping such that the shipment
containers can be dispatched from the second system for delivery
with reduced or no additional sorting at the second system.
16. The system of claim 14, wherein the system is a regional system
configured for delivering shipment containers having destination
addresses within an associated geographic region and for shipping
shipment containers having destination addresses outside the
associated geographic region to the second system.
17. The system of claim 16, wherein the second system is another
regional system.
18. The system of claim 16, wherein the second system is a central
system configured for shipping shipment containers to the regional
system and at least one other regional system.
19. The system of claim 14, wherein the system is a central system
and the second system is a regional system.
20. The system of claim 1, wherein the tracks comprise: two
substantially perpendicular sets of rails forming a grid above the
stacks of stackable containers.
21. The system of claim 20, wherein the robotic pickers/load
handlers comprise: a body mounted on wheels, a first set of the
wheels being arranged to engage with at least two rails of a first
set of the rails, the second set of the wheels being arranged to
engage with at least two rails of a second set of the rails, the
first set of wheels being independently moveable and driveable with
respect to the second set of wheels such that when in motion only
one set of wheels is engaged with the grid at any one time thereby
enabling movement of the robotic pickers/load handling devices
along the rails to any point on the grid by driving only a set of
wheels engaged with the rails.
22. A method of sorting items in a system for managing shipment
containers, the system having: a storage-and-retrieval system
having: a framework defining a plurality of adjacent stacks, each
stack being configured for receiving a plurality of stackable
containers, each stackable container being suitable for containing
a shipment container; tracks arranged above or below the framework
to provide access to stackable containers received in the
framework; and a plurality of robotic pickers/load handlers
configured to move along a direction of the tracks and to retrieve
selected stackable containers from the framework for sortation
and/or dispatch; and at least one processor, wherein the method
will: receive or access destination address information for each of
the plurality of shipment containers entering the system; select a
subset of the plurality of shipment containers for dispatch based
on shipment container; and generate signals for instructing at
least one of the plurality of robotic pickers to retrieve the
selected shipment containers for dispatch, the selection of the
shipment containers being based on at least one of: a priority of
the selected shipment containers; a capacity of a shipping vehicle
on which the selected shipment containers are to be dispatched; and
the destination addresses of the plurality of selected shipment
containers; and the method will: retrieve a selected shipment based
on a final destination of the selected shipment, wherein said
selected shipment will be retrieved at a given position in a
retrieval process based on a sequence required for delivery of the
selected shipment.
Description
FIELD OF THE INVENTION
[0001] The disclosure herein relates to systems and methods for
order fulfillment. In particular, the disclosure provides systems
and methods for managing shipment items in an order fulfillment
process.
[0002] This application claims priority from UK application number
GB1411254.4 the content of which is hereby incorporated by
reference.
BACKGROUND OF THE INVENTION
[0003] In the delivery industry, countless packages are collected
from large numbers of locations spread across large geographical
areas, and are processed before being shipped to their
destinations.
[0004] Various forms of fully- and semi-automated sorting systems
are known. They, and the various components they comprise, may take
many forms. In some systems, packages travel along a conveyor which
passes by a number of unloading stations each corresponding to a
geographic destination. When a package on the conveyor passes the
appropriate station, it is diverted by mechanisms such as
stationary or pivoting barriers, tilt trays, or live roller beds.
In some examples, these conveyor-type sorters can have a limited
number of stations, and can require multiple passes to compete the
sorting process.
[0005] There is need for improvement in the efficiency of systems
and processes for sorting and/or managing shipment items.
SUMMARY OF THE INVENTION
[0006] In various aspects, the disclosure herein provides methods,
systems, and corresponding machine-executable coded instruction
sets for sorting and/or managing shipment items.
[0007] In one aspect, there is provided a system for managing
shipment containers. The system includes: a storage-and-retrieval
system comprising: a framework defining a plurality of adjacent
stacks, each stack capable of receiving a plurality of stackable
containers, each stackable container suitable for containing a
shipment container; tracks arranged above or below the framework to
provide access to stackable containers received in the framework;
and a plurality of robotic pickers/load handlers configured to move
along a direction of the tracks and to retrieve selected stackable
containers from the framework for sortation and/or dispatch. The
system also includes at least one processor configured to: receive
or access destination address information for each of the plurality
of shipment containers entering the system; select a subset of the
plurality of shipment containers for dispatch based on shipment
container and generate signals for instructing at least one of the
plurality of robotic pickers to retrieve the selected shipment
containers for dispatch. The selection of the shipment containers
is based on at least one of: a priority of the selected shipment
containers; a capacity of a shipping vehicle on which the selected
shipment containers are to be dispatched; and the destination
addresses of the plurality of selected shipment containers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention is illustrated in the figures of the
accompanying drawings, which are meant to be exemplary and not
limiting, and in which like references are intended to refer to
like or corresponding parts.
[0009] FIGS. 1, 2, 5, 7, 9, and 11-13 are schematic block diagram
illustrating example processes and systems to which aspects of the
invention can be applied.
[0010] FIGS. 3-4 are example views of aspects of a sortation system
suitable for use in implementing aspects of the invention.
[0011] FIG. 6, 8, 10 are flowcharts showing example methods in
accordance with aspects of the invention.
DESCRIPTION OF EMBODIMENTS
[0012] Preferred embodiments of methods, systems, and apparatus
suitable for use in implementing the invention are described
through reference to the drawings.
[0013] The sortation of shipment containers, such as boxes,
envelopes, parcels, bags, crates, trays, wrapped goods, and the
like, is often part of a larger shipping network. For example, FIG.
1 shows a shipping network 10 to which aspects of the present
disclosure may be applied. In this example of a traditional tiered
shipping network, a shipment container is picked up from its source
by a person, van or other vehicle and is transported to a
distribution system 11 where the shipment container is transferred
to a truck or other vehicle to be transported to an origin regional
sorting centre 15. At the regional sorting centre 15, the shipment
container is sorted by an automated sorting system 20.
[0014] If the shipment container has a destination within the same
region, the shipment container is transported back to a destination
distribution system 11. If the shipment container has a destination
in a different region, the shipment container is transported via
plane, train, truck, or other vehicle to a destination regional
sorting centre 15.
[0015] At the destination regional sorting centre 15, the shipment
container is sorted again by an automated sorting system 20 so that
it can be transported to the proper destination distribution system
11.
[0016] FIG. 2 shows another example shipping network where a single
central regional sorting centre 15 for all distribution systems 11
in the network.
[0017] As illustrated for example in the shipping networks shown in
FIG. 1 and FIG. 2, a single regional sorting centre 15 may service
any number of distribution systems 11. In some examples, a regional
sorting centre 15 may be associated with hundreds or even thousands
of distribution systems 11. Similarly, while the example shipping
network in FIG. 1 shows two regional sorting centres 15, any number
of regional sorting centres is possible. These sorting centres may
be associated with geographic areas and/or distribution systems 11
based on geographic location, population distributions, volume of
shipment containers, or any other factors.
[0018] In other examples, a shipping network may have three or more
levels of distribution. For example, the regional sorting centres
15 in FIG. 1 could feed into a larger sorting centre which may
receive shipment containers from regional sorting centres 15 or
distribution systems 11 for sorting before being transported to the
appropriate regional sorting centre 15.
[0019] In any of the above examples or otherwise, when a shipping
container arrives at the destination distribution system 11 (e.g.
from an origin regional sorting centre or another destination
regional sorting centre), the shipment container is sorted into
vans or other vehicles for dispatch to the final destination. In
some examples, this may involve manual sortation, or an automated
sorting system 20a. Whether automated or manual, the sorted
shipment containers for one or more shipping vehicles may be
manually sequenced. In one example, shipment containers are
manually placed non-sequentially in an arrangement of pigeon holes
based on sequencing criteria and then are removed in a defined
sequence.
[0020] As illustrated by the above example, traditional sortation
of shipment containers may involve multiple steps, some of which
may be manually intensive, and may involve multi-tiered systems and
transportation between them. Such systems using conventional
conveyor-type sorters may require multiple sorting passes at a
single location, sorting passes at multiple locations, and/or
manual sequencing at one or more locations.
[0021] Shipping networks having parcel storage/handling hubs are
generally very dynamic in that parcels are constantly arriving and
leaving based on, for example, delivery chains and the just-in-time
nature of operation of shipping businesses. In each hub,
significant volumes of shipment containers may arrive via any
number of media (e.g. air, land, rail, water, etc.), and may be
tracked, stored and redirected for further transport. In some
industries or applications, this process may require quick
turnarounds and throughputs of storage, retrieval and dispatch of
the shipment containers. When loading vehicles, there may be
limited processing points for dispatch of shipment containers from
a warehouse to a point of transportation (e.g. shipping docks for
transfer to trucks or vans) or handling points for delivery to
airplanes, trains, ships or other large vehicles. Due to the volume
and limited number of processing points, there may be relatively
small windows of time to locate, retrieve and deliver selected
shipment containers to the required vehicles or locations.
[0022] In some instances, storage/handling hubs may be located on
expensive real estate (e.g. near docks, airports, etc.), and
therefore, there may be an interest in utilizing finite space as
efficiently as possible.
[0023] With reference to FIG. 3, an example system for managing
shipment containers may include a fully- and/or semi-automatic
storage and retrieval system 310. One manner of providing access to
shipment containers stored for fully- and/or semi-automatic
retrieval, for example, comprises placement of shipment containers,
which may be of any desired type(s), in bins or other containers
(hereinafter referred to generically as containers), and stacking
and/or otherwise disposing the containers vertically in layers, and
optionally in multiple columns and/or rows, such that individual
containers may be accessible by wholly or partially-automated
container retrieval systems. Such systems can for example comprise
various combinations of containers; container stack support
mechanisms, which may include mechanical devices such as frames
and/or free-standing, stackable, and/or otherwise specialized
container(s); and automated or semi-automated (i.e., "robotic")
retrieval devices, such as load handlers which may for example
operate on grids or other forms of rails, using wheels, and/or on
other forms of mechanical traveling devices. In some examples,
rather than being placed within containers manipulated by the
storage-and-retrieval system, the shipment containers may
configured such that they can be stored in the
storage-and-retrieval system without being placed within the
containers or bins.
[0024] For example, as shown in FIG. 3, storage and retrieval
systems may be provided in forms comprising a framework of rows and
columns of stacked containers, in combination with overhead
rail-operated load handlers 320 or other robots configured to
access the containers for both storage and removal, from above. In
another example, the storage and retrieval system may include load
handlers as part of a gantry system for storing and retrieving the
containers.
[0025] In some examples, the containers for storing and retrieving
may have a uniform or substantially uniform size. In some
embodiments, the system may be configured to handle containers of
different sizes. For example, different containers may have
different heights but similarly-sized footprints (i.e. lengths and
widths).
[0026] In another example, the system may configured to handle
containers having different sized footprints and/or heights, but
may be confined to storing different containers in specific stack
locations associated with those dimensions. These example systems
may utilize different load handlers for storing and retrieving the
differently-sized containers.
[0027] In some embodiments, the storage and retrieval system 310
may include a plurality of ports or other access points through
which containers can be inducted or dispatched from the storage and
retrieval system. These ports may include any one or combination of
ramps, conveyors, pulleys, lifting devices, or any other
mechanism(s) suitable for moving container(s) to/from the
storage-and-retrieval system, or for holding the container(s)
temporarily until they can be moved to/from the
storage-and-retrieval system. In some examples, from the ports, the
system may move the containers for positioning in/on a vehicle,
pallet and/or roll cage. In some examples, the ports may be
configured such that the load handlers transport the container(s)
retrieved from the storage and retrieval system 310 directed
into/onto a vehicle, pallet and/or roll cage.
[0028] The storage and retrieval system 310 can be configured such
that the load handlers can move, manipulate and/or transport
container(s) to and from the ports and/or between different
locations within the storage and retrieval system. In some
examples, the load handlers may be configured to handle different
sized containers. For example, in systems having containers of
different heights, the systems may include different load handlers
for each differently sized container (e.g. a taller container may
require a taller load handler) (See, for example, FIG. 4). In other
examples, the load handlers may be configured to handle any sized
container in the system.
[0029] The load handlers may be configured to receive instructions
from or to be controlled by one or more processor(s). The
processor(s) and load handlers may be configured to communicate
over a communication network capable of handling a communications
with a large number (e.g. thousands) of load handlers. In some
examples, the communication network may be a wireless network such
as Wi-Fi, OFDMA (Orthogonal Frequency-Division Multiple Access), or
any other network configuration or protocol.
[0030] The storage and retrieval system 310 may include a large
number of ports or other access points. For example, the system may
include a port for every row and/or column, or a port for every
other row and/or column. In another example, the system may include
a port every X feet (e.g. every 4 feet). The number of ports maybe
relative to the size of the storage and retrieval system 310 and/or
the number of load handlers 320. For example, in a 1000.times.600
ft or 600,000 ft.sup.2 sorter, the system may generally have
200-300 ports but could reach up to 500 ports.
[0031] In some examples, having a large number of ports may improve
the throughput and/or efficiency when inducting or dispatching
shipment container(s) to or from the storage and retrieval system
310.
[0032] In example embodiments, the shipment containers can be
placed within containers for storage in the storage and retrieval
system 310. These shipment containers may be in any form, shape,
weight and/or size suitable for placement within the storage and
retrieval system containers. For example, shipment containers can
include, but are not limited to, boxes, envelopes, parcels, bags,
crates, trays, wrapped goods, or any other container suitable for
being shipped.
[0033] As described herein, the storage and retrieval system 310
may, in some examples, be configured to provide containers for
dispatch in a sorted and/or sequenced manner.
[0034] FIG. 5 shows an example shipping network 500 which includes
or to which aspects of the present disclosure may be applied. FIG.
6 shows an example method 600 for managing shipment containers and
will be described by way of example with reference to FIG. 5. The
shipping networks described herein may include one or more servers,
control systems, and communication networks including one or more
processors configured to track and manage shipment container
information, and to schedule, sort and/or sequence shipment
containers for dispatch in accordance with any of the example
methods described herein.
[0035] In an example scenario, an incoming shipment container
arrives at the example shipping network 500 at a distribution
system 11 via a van or other vehicle. This van or other vehicle may
have picked up one or more shipment containers from a customer
location, a postal outlet, a mailbox, or any other depot or similar
location. At the distribution system 11, the shipment container may
be transferred to a truck or other vehicle to a sortation system
15, 515 including a storage and retrieval system 310. Depending on
distance or other considerations, in some examples, shipment
containers may arrive directly at the sortation system 15, 515
without first arriving at the distribution system 11.
[0036] Upon its arrival at the sortation system 15, 515, the
shipment container may optionally be weighed and/or measured to
verify size and or weight information associated with the shipment
container in a system database or other electronic storage.
Information associated with the shipment container such as the size
and weight information as well as destination information may be
entered into the system at any point before the shipment container
is retrieved for dispatch. For example, information associated with
the shipment container may be received from a customer order, from
an entry at a post office or other depot, or via a data input at
the distribution base or sortation system 15, 515.
[0037] The shipment container can, in some examples, be placed in a
storage and retrieval container for subsequent storage and/or
management within the storage and retrieval system. Generally, for
greater ease in tracking, each shipment container may be stored
within a separate storage and retrieval container. However, in some
example embodiments, two or more shipment containers may be stored
within the same storage and retrieval container. This may be
applied in scenarios for example when multiple shipment containers,
which fit in a single storage and retrieval container, are destined
for the same final or intermediate destination.
[0038] The shipment container, within a storage and retrieval
system container or otherwise, can be inducted or otherwise stored
in the storage and retrieval system 310 via one or more ports.
Induction or storage may, in some examples, involve scanning a
barcode, RFID or other identifier on the shipment container and/or
placing the shipment container within a storage-and-retrieval
system container. Induction or storage may also involve associating
the shipment container identifier with an identifier and/or
location associated with the storage-and-retrieval system container
in which the shipment container is placed.
[0039] The sortation system 15, 515 can be configured to receive
instructions to prepare one or more selected shipment containers
for dispatch. Upon receiving these instructions, one or more load
handlers can be configured to receive instructions to retrieve
containers containing the selected shipment containers. The
selected shipment containers can be dispatched from the
storage-and-retrieval system 310 via the load handler(s) and/or
port(s) in an order such that the shipment containers are grouped
into groupings associated with the last leg vehicle which will be
used to dispatch the selected containers to their final
destinations. In some examples, the shipment containers can be
sequenced based on an order for loading the last leg vehicle,
and/or a delivery order/route to be potentially followed by the
last leg vehicle.
[0040] In some examples, each grouping associated with a different
last leg vehicle may be stored separately. For example, a grouping
for a last leg delivery van may be stored in a roll cage, on a
pallet, or in a large bag or other larger container. In other
examples, the grouping(s) may be maintained simply by storing
and/or loading the shipment packages into a vehicle in a known
sequence and/or with physical (e.g. tags, stickers), or logical
(e.g. shipment container identifiers) mechanisms for separating the
groupings. In some examples, the groupings may be kept together by
storing each grouping in a separate section/division of a
vehicle.
[0041] Upon their selection and retrieval from the storage and
retrieval system, the grouped shipment containers having
destinations associated with the same distribution system 11 can be
transported to the distribution system 11 via a truck or other
vehicle.
[0042] Since the shipment containers are already grouped and
sequenced, at the distribution system, the shipment container
groupings can be loaded onto last leg vehicles with little or no
sorting/processing/handling at the distribution system 11. In some
examples, the distribution system 11 may perform little or no
sortation or sequencing. These processes and systems may, in some
scenarios, provide simpler, faster, lower-cost, and/or more
efficient shipment container management at the distribution system
11 and/or in the shipping network as a whole.
[0043] When the shipment containers are grouped onto pallets, roll
cages or other containers, the entire pallet(s), roll cage(s) or
other container(s) can be transferred from the vehicle arriving
from the sortation system 15, 515 to the last leg vehicle for
dispatch. This can take place at a pallet handling station or other
location which may, in some examples, include temporary storage for
the groupings until a last leg or other vehicle is available.
[0044] In some example embodiments, the placement of storage and
retrieval containers within the storage and retrieval system during
induction or during any rearrangement or shuffling of containers
can be controlled by one or more processors at the sortation system
15, 515 or elsewhere in the shipping network. These or other
processor(s) can be configured to generate signals for controlling
or instructing the load handlers.
[0045] In some scenarios, the processor(s) may be configured to
generate signals for stacking a container in a stack in the storage
and retrieval system, the stack corresponding to a vehicle load. In
some examples, one or more stacks may be associated with a single
vehicle load. In some examples, containers may be stored in a stack
in a reverse order to the order in which they need to be grouped on
a pallet, roll cage or vehicle. Once all the shipment containers
for a given vehicle are in the sortation system, the load handlers
can be instructed/controlled to transport the containers to a load
station where the shipment containers can be removed from the
storage and retrieval containers and placed onto pallets, roll
cages, or into a vehicle. The removal and placement of the shipment
containers may be done manually or with (semi-)automated robot(s)
or other equipment. In examples where every stack corresponds to a
different destination or vehicle, and each grid location requires
approximately 5 ft.sup.2, a 1000.times.600 ft grid could have
120,000 destinations. Such an example system can be used to
sort/sequence for a very large delivery fleet.
[0046] As illustrated in the above example, sorting/sequencing of
the containers can be generally performed during the induction of a
new shipment container into the system, and potential rearrangement
of proximate containers. However, in another example, the
sorting/sequencing of the containers may be performed during the
retrieval of the containers.
[0047] For example, during induction, the containers may be stored
at pseudo-random storage locations within the system, with the
processor(s) monitoring or otherwise keeping track of the container
at each storage location. Once the containers for filing or
near-filling a vehicle load (or upon another trigger), the
processor(s) can be configured to instruction/control the load
handler(s) to assemble the containers for the vehicle load. Even
though the selected containers may be dispersed at different
locations in the system, these instructions can be generated in an
order or manner such that the containers arrive at the load station
in the desired grouping and/or sequence.
[0048] In other examples, the sorting/sequencing or otherwise
arrangement of the containers in the system may be during
induction, during retrieval, or during an interim period. For
example, the processor(s) may be configured to instruct the load
handlers to sort/sequence containers in a stack associated with a
vehicle during induction when load handlers are available, and to
store containers pseudorandomly when load handlers are not readily
available. This may depend, for example on load handler congestion
or backlogs in induction, retrieval, etc. During interim periods,
the processor(s) may be configured to instruct available load
handlers to move or otherwise rearrange any (pseudonrandomly-stored
or otherwise) container not in a stack associated with a desired
vehicle to a stack (and, when possible/desired, in a sequence)
associated with the desired vehicle.
[0049] A conventional conveyor/redirection sorter as described in
the background may be able to sort 20,000 to 50,000 parcels per
hour. In contrast, a grid sorter as described herein having 10,000
load handlers, which could each perform approximately 50 moves per
hour, could potentially sort 250,000 to 500,000 parcels per
hour.
[0050] In some examples, the example embodiments described in FIGS.
5 and 6 may be well-suited for relatively dense shipment networks
such as a shipping network for the Netherlands.
[0051] FIG. 7 shows an example shipping network 700 which includes
or to which aspects of the present disclosure may be applied. FIG.
8 shows an example method 800 for managing shipment containers and
will be described by way of example with reference to FIG. 7.
[0052] In the example shipping network 700, sortation system(s)
515, as described for example with reference to FIGS. 5 and 6 or
otherwise, can be located at one or more distribution system(s) 11.
Upon arrival at the distribution system(s), incoming shipment
containers can be inducted at this initial distribution system 11.
The shipment containers destined for a different distribution
system can be retrieved and sorted/grouped in a similar manner to
the other examples described herein. However, at this stage,
sequencing of the shipment containers may not be performed. The
retrieved and grouped shipment containers (in pallets, roll cages
or otherwise) can be transferred by truck or other vehicle to a
regional centre 15.
[0053] Since the shipment containers are already grouped when they
arrive at the regional centre, the shipment container groupings can
be loaded onto vehicles on which they can be transported to a
destination distribution system 11, or to a second destination
regional centre 15 and subsequently to a destination distribution
system 11 associated with the second destination regional centre.
At the regional level, no individual shipment container sorting may
be necessary, but rather the groupings/pallets/roll cages may be
handled and transferred to a vehicle destined for the proper
destination distribution system.
[0054] When the shipment containers arrive at their destination
distribution system 11, 515, if not already sequenced, the shipment
containers may be inducted into the destination distribution system
11, 515 for storage, sorting and/or sequencing (potentially with
other shipment containers from a different initial distribution
system) before being dispatched to a last leg vehicle.
[0055] In some examples, the example embodiments described in FIGS.
7 and 8 may be well-suited for geographically larger shipping
networks such as one for the United States or North America.
[0056] FIG. 9 shows an example shipping network 900 which includes
or to which aspects of the present disclosure may be applied. FIG.
10 shows an example method 1000 for managing shipment containers
and will be described by way of example with reference to FIG.
9.
[0057] In the example shipping network 900, sortation system(s)
515, as described for example with reference to FIGS. 5 and 6 or
otherwise, can be located at one or more distribution system(s) 11,
and one or more regional centre(s) 15.
[0058] Incoming shipment containers can be inducted into a
sortation system 515 at a local/distribution system 11 or can
bypass this system and be inducted into a sortation system 515 at
the regional centre 15. This decision may be performed as a
pre-sort at the local/distribution centre, or may be performed as
the incoming van or other vehicle is picking up the shipment
containers at their source.
[0059] Both the local/distribution 11 sortation system and the
regional centre 15 sortation system can be configured to group and
sequence shipment containers into vehicle groupings as described in
other examples herein.
[0060] One or more processor(s) in the network 900 may be
configured to determine where a shipment container should be stored
and/or sorted in a manner that seeks to optimize the utilization of
vehicles and sorters across the network.
[0061] In some examples, the example embodiments described in FIGS.
9 and 10 may be well-suited for relatively dense shipping networks
as may exist in Germany, France or the U.K.
[0062] FIGS. 11 and 12 show example shipping networks wherein
conventional conveyor-redirection based sorters are used in
conjunction with any of the example grid sorters described herein.
These shipping networks may be utilized during a transition from a
network with only conventional conveyor-redirection based sorters
to the grid-based sorter networks described herein.
[0063] FIG. 13 shows an example shipping network wherein
conveyor-redirection based sorters can be retained at one or more
sortation centres along with a grid-based sorter system such as any
of those described herein or otherwise. In some such example
embodiments, the conveyor-redirection based sorter(s) can be used
to sort in-coming shipment containers to the various sortation
centres, while the grid-based sorter(s) can be used to sort and
sequence out-going shipment containers for distribution vehicles in
its own region. In some examples, at the local distribution
centres, the handling of shipment containers may be reduced to
moving ready-packed pallets or roll cages from the vehicles coming
from the regional sortation centres to distribution or last leg
vehicles (cross-docking).
[0064] While in the examples above, incoming shipment containers
are described as arriving from vehicles, in some examples, incoming
shipment containers may arrive via conveyor or other transport
mechanisms from a picking station or other system as part of an
order fulfillment process. Once a shipment container for an order
has been picked, the shipment container may be directed to a
sortation system 515 at a distribution or regional centre in
accordance with any of the examples described herein or otherwise.
In some examples, the grid-based sortation system may store/manage
both inventory for picking as well as shipment containers for
storing/sorting/sequencing.
[0065] As described broadly in the above examples, and illustrated
by way of example in FIGS. 6, 8 and 10, one or more processor(s)
may be configured to collect and manage information associated with
a shipment package such as size, weight, destination address,
priority, current location, storage location within a sortation
system 515, etc. These processor(s) may be distributed and/or
located at any location or system in the shipping network.
[0066] With at least some of this information, the processor(s) may
be configured to track the movement, locations and destinations of
shipment containers. The processor(s) can be configured to store,
sort, group and/or sequence the shipment containers based on any
number of factors including but not limited to the destination of
the shipping containers, the priority of the shipment containers,
and the capacity of a shipping vehicle on which selected shipment
containers are to be dispatched.
[0067] In some examples, higher priority shipment containers may be
scheduled for storage to and/or retrieval from the storage and
retrieval system 310 before lower priority shipment containers.
When a vehicle is available, in some examples, one or more priority
shipment containers can be selected for grouping, sequencing and/or
loading into the vehicle before lower priority containers. Unlike
conventional systems, the ability of a grid-based sortation system
515 to hold back or reschedule lower priority parcels may reduce
vehicle movement and/or may reduce delivery times for priority
containers. In some examples, lower priority shipment containers
maybe moved opportunistically, for example to fill a vehicle
partially-filled with higher priority containers. This can, in some
instances, be particularly beneficial for long hauls or via
expensive transport.
[0068] In some examples, the processor(s) may be configured to
select, group and/or sequence shipment containers such that as much
of the capacity of a vehicle is filled as would be efficient. In
some examples, the processor(s) may be configured to sequence
shipment containers in an order which makes it easier to load a
vehicle (e.g. an order which allows larger shipment containers to
be loaded first). In other examples, the processor(s) may be
configured to sequence shipment containers in an order similar to
the order in which the containers are to be delivered by the last
leg vehicle.
[0069] In some examples, the processor(s) may be configured to
select, group and/or sequence shipment containers such that the
total delivery time for the last leg vehicle based on the
destinations of the selected containers and the travel times
between them maximizes or utilizes the most time of a driver's
shift.
[0070] As will be further understood by those skilled in the
relevant arts, significant advantage may be realized through the
full or partial automation of any of the processes described above,
or portions thereof. Such automation may be implemented by, for
example, providing automated induction into the grid sorter by
means of industrial robots, conveyors and scanners as well as
automated exit from the grid sorter by means of industrial robots,
or other placement equipment.
[0071] Such automation may be provided in any suitable manner,
including for example the use of automatic data processors
executing suitably-configured, coded, machine-readable instructions
using a wide variety of devices, some of which are known and others
of which will doubtless be developed hereafter. Processor(s)
suitable for use in such implementations can comprise any one or
more data processor(s), computer(s), and/or other system(s) or
device(s), and necessary or desirable input/output, communications,
control, operating system, and other devices, including software,
that are suitable for accomplishing the purposes described herein.
For example, a general-purpose data processor provided on one or
more circuit boards will suffice.
[0072] In the embodiments described above, it will be appreciated
that the tracks and the robotic pickers/load handlers may be of any
suitable size and form capable of performing the invention as
described. However, it will be appreciated that the tracks may
comprise two substantially perpendicular sets of rails, together
forming tracks disposed above the stacks of stackable containers.
Furthermore, the robotic pickers/load handlers may comprise a body
mounted on wheels, the first set of wheels being arranged to engage
with at least two rails of the first set of rails, the second set
of wheels being arranged to engage with at least two rails of the
second set of rails, the first set of wheels being independently
moveable and driveable with respect to the second set of wheels
such that when in motion only one set of wheels is engaged with the
grid at any one time thereby enabling movement of the load handling
device along the rails to any point on the grid by driving only the
set of wheels engaged with the rails. Such a track system and
robotic picker/load handling device is described in UK Patent
Publication No GB2520104A1, the content of which is hereby
incorporated by reference.
[0073] In the above description it will be appreciated that a
sortation system is a system in which everything entering the
system has a predetermined destination, whereas in a storage and
retrieval system items entering the system may be allocated a
destination whilst being stored in the system. Whilst the above
description generally relates to a storage system, it will be
appreciated that it may also be relevant to a storage and retrieval
system.
[0074] While the disclosure has been provided and illustrated in
connection with specific, presently-preferred embodiments, many
variations and modifications may be made without departing from the
spirit and scope of the invention(s) disclosed herein. The
disclosure and invention(s) are therefore not to be limited to the
exact components or details of methodology or construction set
forth above. Except to the extent necessary or inherent in the
processes themselves, no particular order to steps or stages of
methods or processes described in this disclosure, including the
Figures, is intended or implied. In many cases the order of process
steps may be varied without changing the purpose, effect, or import
of the methods described. The scope of the invention is to be
defined solely by the appended claims, giving due consideration to
the doctrine of equivalents and related doctrines.
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