CA2254641A1 - Article sortation system - Google Patents
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- CA2254641A1 CA2254641A1 CA 2254641 CA2254641A CA2254641A1 CA 2254641 A1 CA2254641 A1 CA 2254641A1 CA 2254641 CA2254641 CA 2254641 CA 2254641 A CA2254641 A CA 2254641A CA 2254641 A1 CA2254641 A1 CA 2254641A1
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Abstract
A warehousing system enables the simultaneously fulfilling of orders based on product type, as opposed to individual orders. Orders are filled by picking from rotary carousels into designated auto induction devices which cooperated with a continuous loop sortation conveyor for transporting the products to a predetermined sorter where all products for a given order are collected.
Description
ARTICLE SORTATION SYSTEM
The present invention relates in general to automated distribution systems for storing, retrieving and sorting articles. More particularly, the present invention relates to the retrieval of articles from a rotatable storage carousel for sortation into predetermined groups of articles.
to Many modern warehouse facilities require the storage and retrieval of thousands of individual inventoried articles. Storage systems employed in these warehouse facilities require loading of articles, typically in containers, and delivering the containers to a known location where they can later be retrieved as necessary: When an order is received, the desired articles must be picked from their respective storage locations and prepared for either shipping or use. An effective warehousing operation requires the ability to 2o both rapidly retrieve a wide variety of articles from storage and to efficiently dispose of the retrieved articles.
By way of illustration, Gallo, et al., U.S.
Patent No. 3,448,870 discloses a storage and retrieval system including a storage zone and a removal zone. The storage zone includes groups of stationary bins having aisles therebetween for access by a hand cart to the individual bins. An endless conveyor provides a path for a plurality of attached carriers which move 3o continuously to carry articles in tote boxes between the storage and removal zones. The storage zone includes a plurality of storage stations having a loader to load articles into the tote boxes and onto the moving carriers so as to be transported to the removal zone.
Each storage zone has a coding mechanism for coding the carriers loaded at that station for particular destinations, 'for example, within the removal zone. The removal zone has a plurality of removal stations, each ' including an unloader mechanism and a plurality of parallel spaced gravity conveyor tables arranged on each side of the unloader mechanism.
In operation, orders for delivery from the storage zone are sent to a dispatch station. A paper for each article within the order is prepared at the dispatch station, giving the quantity desired and the table in the removal zone at which the order is to be assembled. The attendant at the dispatch station puts to the paper for the first article, or common articles within the order, in an empty tote box, and then codes the coding mechanism at the dispatch station for the station nearest to the bin in which the articles are stored. The tote box is then placed on the conveyor at the dispatch station by the loader mechanism to the next empty carrier. The same procedure is followed for the next article or group of common articles within the same order, the tote box being coded for the storage station nearest the bin in which those articles are stored.
2o Both papers designate the same removal station and consolidation table in the removal zone.
When the tote boxes from the dispatch station are received at the respective storage stations, attendants transport the requested articles by handcart from the bins in which they are stored to the loader mechanism at the station. The coded mechanism is set to give the particular removal station and consolidation table to which the article is to be sent and the tote box is loaded onto the next empty carrier. After all of 3o the articles from a particular order arrive at the particular removal station and designated consolidation table to which they were sent from the storage zone, the attendant at the dispatch station operates a gate to release the articles onto a moving belt conveyor.
Other known storage and retrieval systems are disclosed in, for example, Kita, et al., U.S. Patent No.
5, 135, 344; Claycomb, et al. , U.S. Patent No. 5, 337, 880;
Lichti, Sr., et al., U.S. Patent No. 5,282,712; Grafe, ' et al., U.S. Patent No. 5,056,978; McElwee, U.S. Patent No. 4,519,522; Bernard, II, et al., U.S. Patent No.
5,273,392; Page, et al., U.S. Patent No. 4,307,988.
Another illustration of a warehouse distribution operation is a consumer products warehousing facility which stores and arranges such products for delivery to retail outlets. Modern consumer products warehousing facilities may require the storage of thousands of stock products which must be l0 stored in both cases and piece lots. A representative warehouse may have hundreds of customers placing orders for various products on any given day. Customer orders may require the retrieval of a widely varying number of products for shipment to each customer. It is, however, required that the ordered products be separately packaged for each customer corresponding to the particular customer order. Due to the large number of customer orders being filled at any given time, retrieving the desired product from the storage area on a customer basis is relatively inefficient and time consuming. In this regard, different customer orders may include the same product to be packaged and shipped, although of a different quantity.
The present invention discloses an article sortation system which enables the simultaneous compliance of multiple orders wherein common products may be retrieved simultaneously from the storage area for all orders being placed at a given time. The present invention further discloses an article sortation 3o system having greater increased speed and effectiveness of article handling, e.g., consumer products, while possessing the ability to coordinate order consolidating activities thereby meeting system demand in numerous warehousing applications. The present invention is therefore suitable as a modern distribution system for the storage and retrieval of thousands of inventoried articles of diverse character in a warehousing facility.
The present invention relates in general to automated distribution systems for storing, retrieving and sorting articles. More particularly, the present invention relates to the retrieval of articles from a rotatable storage carousel for sortation into predetermined groups of articles.
to Many modern warehouse facilities require the storage and retrieval of thousands of individual inventoried articles. Storage systems employed in these warehouse facilities require loading of articles, typically in containers, and delivering the containers to a known location where they can later be retrieved as necessary: When an order is received, the desired articles must be picked from their respective storage locations and prepared for either shipping or use. An effective warehousing operation requires the ability to 2o both rapidly retrieve a wide variety of articles from storage and to efficiently dispose of the retrieved articles.
By way of illustration, Gallo, et al., U.S.
Patent No. 3,448,870 discloses a storage and retrieval system including a storage zone and a removal zone. The storage zone includes groups of stationary bins having aisles therebetween for access by a hand cart to the individual bins. An endless conveyor provides a path for a plurality of attached carriers which move 3o continuously to carry articles in tote boxes between the storage and removal zones. The storage zone includes a plurality of storage stations having a loader to load articles into the tote boxes and onto the moving carriers so as to be transported to the removal zone.
Each storage zone has a coding mechanism for coding the carriers loaded at that station for particular destinations, 'for example, within the removal zone. The removal zone has a plurality of removal stations, each ' including an unloader mechanism and a plurality of parallel spaced gravity conveyor tables arranged on each side of the unloader mechanism.
In operation, orders for delivery from the storage zone are sent to a dispatch station. A paper for each article within the order is prepared at the dispatch station, giving the quantity desired and the table in the removal zone at which the order is to be assembled. The attendant at the dispatch station puts to the paper for the first article, or common articles within the order, in an empty tote box, and then codes the coding mechanism at the dispatch station for the station nearest to the bin in which the articles are stored. The tote box is then placed on the conveyor at the dispatch station by the loader mechanism to the next empty carrier. The same procedure is followed for the next article or group of common articles within the same order, the tote box being coded for the storage station nearest the bin in which those articles are stored.
2o Both papers designate the same removal station and consolidation table in the removal zone.
When the tote boxes from the dispatch station are received at the respective storage stations, attendants transport the requested articles by handcart from the bins in which they are stored to the loader mechanism at the station. The coded mechanism is set to give the particular removal station and consolidation table to which the article is to be sent and the tote box is loaded onto the next empty carrier. After all of 3o the articles from a particular order arrive at the particular removal station and designated consolidation table to which they were sent from the storage zone, the attendant at the dispatch station operates a gate to release the articles onto a moving belt conveyor.
Other known storage and retrieval systems are disclosed in, for example, Kita, et al., U.S. Patent No.
5, 135, 344; Claycomb, et al. , U.S. Patent No. 5, 337, 880;
Lichti, Sr., et al., U.S. Patent No. 5,282,712; Grafe, ' et al., U.S. Patent No. 5,056,978; McElwee, U.S. Patent No. 4,519,522; Bernard, II, et al., U.S. Patent No.
5,273,392; Page, et al., U.S. Patent No. 4,307,988.
Another illustration of a warehouse distribution operation is a consumer products warehousing facility which stores and arranges such products for delivery to retail outlets. Modern consumer products warehousing facilities may require the storage of thousands of stock products which must be l0 stored in both cases and piece lots. A representative warehouse may have hundreds of customers placing orders for various products on any given day. Customer orders may require the retrieval of a widely varying number of products for shipment to each customer. It is, however, required that the ordered products be separately packaged for each customer corresponding to the particular customer order. Due to the large number of customer orders being filled at any given time, retrieving the desired product from the storage area on a customer basis is relatively inefficient and time consuming. In this regard, different customer orders may include the same product to be packaged and shipped, although of a different quantity.
The present invention discloses an article sortation system which enables the simultaneous compliance of multiple orders wherein common products may be retrieved simultaneously from the storage area for all orders being placed at a given time. The present invention further discloses an article sortation 3o system having greater increased speed and effectiveness of article handling, e.g., consumer products, while possessing the ability to coordinate order consolidating activities thereby meeting system demand in numerous warehousing applications. The present invention is therefore suitable as a modern distribution system for the storage and retrieval of thousands of inventoried articles of diverse character in a warehousing facility.
Generally, the present invention incorporates a computer system along with various standard automated picking, display and sortation devices. The basic components of the invention may include a software scheduler, a rotary carousel, a lightree, a sortbar, a sortation conveyor, e.g., either tilt tray or cross belt type, induction device and a sorter. The system administers work requests from a host computer and directs carousel picking by order line not by total to order and thus has a virtual work order. The actual orders are automatically consolidated at remote drop points. This allows the carousels to operate as an array versus logical groups of machines, thus providing greater flexibility. The consolidation of the work order takes place remotely at a sortation area thus allowing a larger and more dynamic workload. The system accommodates either a single operator per carousel or a number of operators across the carousel array, thereby adding increased flexibility to accommodate seasonal peaks, weekly peaks or product variation.
More particularly, the system of the present inventions may perform the following functions:
I Order Scheduling and Release A customer s host computer (order entry, inventory control) receives information (purchase orders) from their customers. Orders once processed by the host computer are sent electronically to the system computer which analyzes each order and continually updates the release priority. Customer data (order file) may include a customer priority or truck route which will be used to help schedule the processing of the order in the system.
The release of orders to the system is done in a continuous stream of work versus a batch release of orders. This continuous work release guarantees a steady work flow for the pick and pack operators. This release also 'allows larger and smaller orders to be processed in the most efficient fashion. The release algorithm looks at the order priority and availability of a pack lane (drop off chute).
Carousel picking control is scheduled by the scheduler. The actual carousel movement is accomplished by move commands sent from the scheduler to a star controller. The star controller manages the movement of the carousels, directs the flow of data to the lightree and sortbar display devices and sends back task complete messages to the scheduler.
to Sortation interface control is similar to the carousel picking control except the scheduler interfaces with the sortation conveyor. The scheduler tells the sortation control system of induction positions which have picked product (taken from the carousel), the I.D.
number of the induction position (where the picked product was placed) and the destination (sorter lanes) position (orders) to sort the product. Order consolidation/packing is the destination.of items picked from the carousel and taken by the sortation conveyor to the appropriate sorter lane (chute) which has other items for the same order. Once all the items for a particular order are accumulated in a sorter lane, an operator can pack the order and tell the scheduler that the order is complete. Orders can also be automatically dropped into shipping boxes if the customer s product profile accommodates this method.
Order reconciliation is accomplished by sending a message from the sortation control system back to the scheduler. This message is a divert verification 3o to a sorter lane position. The sortation conveyor may be outfitted with sensors to detect the presence of objects moving past a beam down the sorter lane. After this message is sent to the scheduler and all product has been sent to a sorter lane, the scheduler notifies the customer host computer of an order completion. If there has been any error conditions, a supervisor is notified to check and correct the error. Common errors are product out of stock, failure to divert and broken product.
Orders may be selected for picking based on the following criteria:
Priority, using a number from 1-100, is sent from the host computer along with detail order information. The priority is for the entire order not individual item lines.
Ship date/time qualified order release may be l0 used in combination with priority or as a single release standard. This information is again sent by the customer host computer to the scheduler.
Consolidation station availability is utilized after orders have been analyzed for release. Once a 15 sorter lane is assigned an order, no other order lines will be sent to that lane until the entire order is completed and packed.
Order makeup is analyzed to determine where order lines are to be picked (i.e., multiple carousels 20 and locations), how many lines are picked from each carousel; and the suggested number or pick operators needed based on volume of work. Additional parameters such as large numbers of single line orders and multiple line orders can be set to provide overall system 25 balance.
II. Carousel Picking Control Carousel functions include:
Continuous transaction picking is a method which continually injects new orders into the active 3o pick queues for the operators. This guarantees a steady state of work versus a start/stop method if batches of work are processed. The scheduler monitors the picks to ensure that when placing new work in the order queue, work already in the system is accomplished as per the 35 order release rules.
Distribution of carousels to picking is a method of looking at identical items which may be stored in multiple carousels. This helps create a more balanced system and improves overall system rate. Very high volume products can thus be picked simultaneously by multiple pick operators.
Multiple pick to locations provide further enhancement to picking common items. There are times when a popular item quantity can be picked from a single location and placed in multiple autodrop positions.
This is referred to as commonality. By way of example, three (3) customers place orders for a pencil #3 and a to quantity of one (1) each. When the carousel moves into the pick position, the lightree is told to display a total quantity to pick of three (3) pencil #3. The operator picks three (3) pencils #3 and is told by the sortbar LED~s to place one (1) pen into each induction position. The scheduler then tells the sortation conveyor that induction positions 1, 2 and 3 are ready to be picked up and taken to sorter lane, i.e., order consolidation chutes, positions associated with each customer order. This method improves overall efficiency of the system.
Configurable pick methods are utilized based on system activity, order makeup or carousel optimization. The basic algorithms employed include:
Zone, where a number of carousels are assigned to a pick operator. This zone can be dynamic but can include any number of carousels. Zone picking is done to reduce operator travel, i.e., walking, time spent looking for items.
Round robin picking is a method used in zone picking which always directs the pick operator in a sequence starting from left to right. By way of example, a three (3) carousel zone round robin pick would start at carousel #1, proceed to #2, #3, #1, #2, etc. until all picking is completed.
Next available picking differs from round robin in that operators are directed to pick from the next carousel' in position (stopped moving) versus a sequence. The operator is told which carousel to pick from via the lightree indicator associate with each carousel.
Configurable rotation algorithms employed include FIFO and closest location. First in first out (FIFO) is when order commands are taken in a strict sequence as sent from the scheduler to the controller.
The advantage of this method is that it ensures work is done exactly in the fashion needed to match the packing operation. FIFO picking will normally spin the carousel l0 in a single direction.
Closest location is when order commands are chosen based on the closest location for a product based on where the carousel is in proximity to the pick operator. The advantage of this algorithm is a reduction in wait time because pick locations are not passed as in the FIFO method. Closes location picking will tend to spin the carousel both clockwise and counterclockwise based on pick location.
III. Sortation Interface Control The scheduler interface to the sorter conveyor is generally based on electronic messages. The messages include .
Route picked product from induction device to sorter chute lane. Each induction device is given a specific number from 1 to N. Each sorter chute lane is given a number from 1 to N. After product is placed from the carousel pick position to an induction position the scheduler indicates both the from I.D. and the to I.D.
Product is classified as inducted from a pick position (induction device) when the sorter has commanded the induction device to release the product onto the moving sorter tray.
Product is classified as diverted when the sortation conveyor has moved the tray to the sorter chute lane and has discharged the product from the tray past the divest verification scanner photo eye to the sorter chute lane.
_g_ Order complete status is achieved when all line items for an order have been diverted to and packed at the sorter consolidation chute lane.
Order indexed for pack status is achieved when either the pack operator or the automated dispenser to carton indicates pack status to the scheduler. In a manual pack this could be a message from the customer host packing computer system, the packing subsystem, the conveyor sorter packing subsystem, indicating the order to has been packed and removed from the lane. If automatically dropped into a box, the sorter system would indicate this transaction in a fashion similar to the divert verification message.
Order anomaly processing is an indication of a problem with an entire order of particular lines or items of an order. Examples of problems include:
breakage, short pick, wrong item and incorrect order in lane. Typically the pack operator will request supervisor intervention to correct the problem and update the computer system. In any event, all anomaly conditions are logged for audit purposes.
IV. Order Consolidation and Packing Operations Consolidation and pack operations types indicate the method used to group orders and manage the staffing of such operations. There are a variety of methods and the method may be changed depending on type or order (single versus multiple line), complexity of pack operation, volume of work. Some basic methods include the following examples.
One operator servicing a bank of sorter consolidation chutes. It is contemplated that a single operator can service a number of pack stations. The system will turn on an LED indicator when an order is complete in a lane and the operator can then proceed to the station for final pack.
Automatic interface allows each chute to be serviced by 'a conveyor moving shipping boxes into position under each chute when an order is completed.
_g_ Once the box is filled it is moved away from the chute and sent to shipping.
Pack station operation provider can be done by the system, the customer through the software on their system, or the conveyor sortation supplier.
V. Host Interface Host interface is a computer link to the customer host system which can be established using various industry standard methods. The type of 1o interface is largely dependent on the customer host computer and network. For example, file transfer protocol provides a file based interface in which the host computer sends complete files to the scheduler.
The transactions are completed in the system and sent back as files to the customer host for accounting.
In a message based system, the interface is a more real (near time) transaction based transfer of information. The host sends messages rather than complete files and thus is more interactive than the system. This can be a TCP/IP sockets interface or other real time protocols.
The above description, as well as further objects, features and advantages of the present invention will be more fully understood with reference to the following detailed description of an article sortation system, when taken in conjunction with the accompanying drawings, wherein:
Fig. 1 is a diagrammatic perspective illustration of an article sortation system in accordance with one embodiment of the present invention;
Fig. 2 is a diagrammatic perspective view of an induction device in operative association with a plurality of carousels and a sortation conveyor;
Fig. 3 is a perspective view of an induction container for use in the induction device in accordance with one embodiment of the present invention;
Fig. 4 is a perspective view of a portion of the sortation conveyor in accordance with one embodiment of the present invention;
Fig. 5 is a .perspective view of a portion of the sortation conveyor in accordance with another embodiment of the present invention; and Fig. 6 is a diagrammatic illustration of the control system for operation of the article sortation system in accordance with one embodiment of the present invention.
Referring now to the drawings, wherein like reference numerals represent like elements, there is shown in Fig. 1 an article sortation system generally designated by reference numeral 100. The system 100 includes at least one, and preferably a plurality of rotary carousels 102 arranged opposing at least one, and preferably a plurality of induction devices 104. The induction devices 104 are arranged in operative association with a sortation conveyor 106 which, in turn, is in operative association with at least one, and preferably a plurality of sorters 108, also referred to as sort lanes or sortation devices. Visual control information is displayed by means of at least one, and preferably a plurality of lightrees 110. The system is operated by means of a computer control system 112 and associated software.
The rotary carousels 102 are of the horizontal type. In this regard, each of the carousels 102 include a plurality of storage bins 114 which are rotated around the carousel along a horizontal axis. A plurality of bins 114 may be integrally connected along a vertical axis to provide a tier of bins 114 which are rotatable in a continuous loop around the carousel 102.
Typically, multiple tiers of bins 114 are provided within a single carousel to increase storage capacity.
One suitable rotary carousel 102 for use in accordance with the system 100 of the present invention may be obtained from White Storage and Retrieval Systems, Inc.
of Kenilworth, New Jersey.
The carousels 102 have been described as being of the horizontal rotary type. However, it is to be understood that carousels of the vertical rotary type may also be employed with the system 100. In addition, conventional storage racks having non-moveable storage bins 114 may also be used with the system 100. As such, any storage system operative for storing a plurality of articles in designated locations may be employed with the system 100. For purposes of efficiency and speed, it is preferred that rotary carousels 102 be employed so as to enable the articles to be retrieved to be brought to a central designated location, preferably, adjacent the induction device 104.
A plurality of carousels 102 are generally arranged in spaced apart side-by-side relationship. The carousels 102 are positioned as shown with their narrow ends 116 aligned within a common vertical plane. The ends 116 of the carousels 102 are generally the working area of the carousels, i.e., the location where stored articles are to be removed during operation of the system 100, such as in filling orders. Fig. 1 shows, by way of example, the arrangement of eight carousels 102.
However, it is to be understood that any lesser or greater number of carousels 102 may be provided, dependent upon the size of the warehousing facility and the number of articles to be stored for satisfying orders for such articles.
Positioned generally opposing the end 116 of each carousel 102 is an induction device 104. As better shown in Figs. 2 and 3, the induction device is constructed from a frame 118 having an upper structure 120 supported off the floor. Supported by the upper structure 120 are a plurality of autodrop stations 122 each including at least one induction container 123.
Each induction container 123 is constructed, by way of one illustration only, from a pair of spaced apart shells 124. Each shell 124, in turn, is constructed from three side walls 126, 128, 130 surrounding a bottom support 132 thereby forming an open top 133 and an open end 134.
The open ends 134 of the shells 124 are arranged facing each other such that the side walls 126, 130 and bottom supports 132 lie in respective common planes with the open top 133 facing upwardly. The shells 124 are hinged about upper pivot points 136 by to suitable means (not shown), e.g., a rod extending through the side walls 126, 130. The pivotable arrangement of the shells 124 allow the shells to rotate upwardly about the pivot points 136 in respective clockwise and counterclockwise direction as shown by the arrows. This, in turn, causes the respective bottom supports 132 to separate from their adjacent relationship as illustrated to provide a bottom opening within each autodrop station 122. It should be appreciated that any article positioned on the bottom 2o supports 132 will fall through the bottom opening as the bottom supports separate from one another upon upward rotation about the pivot points 136.
Any suitable pivoting mechanism 138 may be provided for pivoting the respective shells 124 during operation of each autodrop station 122. By way of illustration only, the mechanism 138 includes a pair of spaced apart arcuate shaped openings 140 positioned within the side walls 126 in symmetrical arrangement. A
bias spring 142 is connected between the side walls 126 to maintain the induction container 123 in closed position to maintain any articles stored therein on the bottom support 132. A pneumatic cylinder 140 having a piston rod 146 is operatively coupled between the openings 140. Specifically, the free end of the piston rod 146 is attached to a follower 148 which slides within one of the openings 140. The base of the pneumatic cylinder 140 is likewise attached to a follower 150 which rides within the other opening 140.
As the piston rod is retracted, the followers 148, 150 will ride within their respective openings 140 thereby pivoting the shells 124 about pivot points 136. The spring 142 will maintain the shells 124 in closed position until the pneumatic cylinder 144 is actuated with sufficient pressure to overcome the resistance of the spring.
The particular construction of each autodrop station 122 and the induction containers 123 is by way to of example only. Thus, other constructions for the induction device 104 having an autodrop station 122 and the induction containers 123 may be employed. It is only a requirement that the autodrop station 122 be capable of initially supporting an article therein, and subsequently, being capable of discharging the article when desired. There are known a number of manufacturers of induction devices which may be adapted for use in the system 100 in accordance with the present invention.
For example, such companies include Promech Sorting 2o Systems of The Netherlands, Diafuku of Japan, Mantissa Corporation of North Carolina and Tech Corporation of New Jersey. Accordingly, any induction device 104 which will perform the aforementioned described functions of the autodrop stations 122 may be employed with the system 100 of the present invention.
As shown in Figs. 1 and 2, an induction device 104 is positioned opposing the end 116 of each carousel 102. As such, there is a one-to-one correspondent, i.e., one induction device 104 for each carousel 102.
However, it is to be understood that each carousel 102 may be associated with more than one induction device 104, or in the alternative, a plurality of carousels may be associated with a single induction device.
Similarly, although each induction device 104 is shown having three autodrop stations 122, it is to be understood that any greater or lesser number of stations may be provided. That is, the greater the number of induction devices 104 and autodrop stations 122, the greater the number of articles which may be sorted simultaneously thereby increasing capacity of the system 100.
Turning to Figs. 1-3, the sortation conveyor 106 will now be described. The sortation conveyor 106 is in the nature of a continuous loop conveyor which is in operative association with each of the induction devices 104 and each of the sorters 108. The sortation conveyor 106 includes a frame 152, which as shown, l0 supports an upper structure 154 at varying heights above the floor. Specifically, the upper structure 154 extends through the induction devices 104 at a level underlying the autodrop stations 122. Subsequently, the sortation conveyor 106 rises to a level so as to be in operative association with each of the sorters 108.
Subsequently, the sortation conveyor 106 drops to a lower level, so as to once again, to be received within the induction devices 104. Although the sortation conveyor 106 has been described as passing through 20multiple vertical heights, it is also possible for the sortation conveyor to be level with respect to the floor. It is therefore only required that the sortation conveyor 106 be arranged in operative association with the induction devices 104 and the sorters 108.
The sortation conveyor 106 includes a plurality of movable article supports 156 arranged in spaced apart relationship along the upper structure 154.
Any suitable means, such as an endless chain or belt 158 is operative for moving the article supports 156 along the upper structure 154 in a continuous or intermittent fashion as may be desired during operation of the system 100. It is to be understood that any other mechanism operative for moving the article supports 156 along the upper structure 154 into operative relationship with the induction devices 104 and sorters 108 may be employed.
As best shown in Fig. 4, the sortation conveyor 106 in accordance with one embodiment is of the tilt tray type. In this regard, each of the article supports 156, which are in the nature of a flat shallow walled tray, are tiltably supported by the upper structure 154. In this regard, each of the article supports 156 are initially arranged in a generally horizontal plane as the support is being transported around the sortation conveyor 106 as shown in, for example, Figs. 1 and 2. However, as each article support 156 aligns with a predetermined sorter 108, the article support is tilted upwardly by a mechanism (not to shown) such that any supported article will discharge by gravity into the opposing sorter. Subsequently, the article support 156 is returned to its horizontal orientation for continued transport via the sortation conveyor 106 to the induction devices 104. An illustration of two article supports 156 being tilted for discharge of supported articles is shown in Fig. 1 at positions 160. Known manufacturers of tilt tray type sortation conveyors 106 are the same previously named manufacturers as the induction devices 104.
The sortation conveyor 106 can also be constructed as a cross belt sortation conveyor 162. In this regard, each of the article supports 156 is constructed as a conveyor belt whose direction of rotation is transverse to the direction of movement of the supports along the sortation conveyor. For example, as shown in Fig. 5, the cross belt sortation conveyor 162 includes a frame 164 having an upper structure 166 which supports a plurality of article supports 168.
Each article support 168 is in the nature of a 3o continuous belt 170 extending over a pair of spaced apart rollers 172. At least one of the rollers 172 is driven so as to cause articles supported on the article supports 168 to be discharged in the direction of the arrow. Suitable cross belt sortation conveyors 162 for use in accordance with the present invention are obtainable from H.K. Systems of Kentucky, Bematic of Germany and Diafuku of Japan.
The sorters 108 can be constructed in the nature of a belted conveyor, chute roller conveyor or slide table, or the combination of both. As shown in Fig. 1, each sorter 108 in the nature of a chute has an inlet end 174 arranged adjacent the sortation conveyor 106 and an outlet end 176. Articles discharged from the article supports 156, 168 of the sortation conveyor 106, 162 are received at the inlet end 174 of a designated sorter or chute 108. The sorters 108 are operative for to collecting articles at the outlet end 176 thereof which are discharged by the sortation conveyor 106. Any other apparatus suitable for this purpose may be used in accordance with the system 100 of the present invention.
In this regard, the sorter or chutes 108 may be large bins into which the articles fall. Sortation chutes are generally available from any of the aforementioned companies who manufacture article handling equipment as noted herein.
Each of the sorters or chutes 108 may be arranged.at the same or different elevation to the sortation conveyor 106. In this regard, articles discharged from the sortation conveyor 106 may be raised to a higher or lower elevation as may be required in collecting the articles. To provide data to the computer control system 112, a photoelectric eye 178 may be positioned at the inlet end 174 of each sorter or chute 108. The photoelectric eye 178 will send a signal to the computer control system 112 confirming that an article has been discharged from the sortation conveyor 106 to a specified sorter or chute 108. As will be described hereinafter, each sorter or chute 108 may be designated for a particular order, such as a customer order. In this regard, articles retrieved from the carousels 102 for a particular order are transported to a predetermined sorter or chute 108 by means of the sortation conveyor 106. As such, the number of sorters or chutes 108 'will govern the number of orders or other collection of articles which can be filled simultaneously in accordance with the system 100 of the present invention.
A lightree 110 is positioned in association with each of the carousels 102. Preferably, there is a one-to-one correspondence, i.e., one lightree 110 for each of the carousels 102. The lightrees 110 are generally arranged at any convenient location, and preferably, at the ends 116 of the carousels 102 approximate the induction devices 104.
to The lightrees 110 have a face 180 which can be any one of a number of known types which use an array of lightable elements or dots to form symbols such as alphanumeric characters. As is known in the art, the lightable elements can be directly lightable, such as light emitting diodes or incandescent lamps which are energized to generate light, or indirectly lightable such as liquid crystal displays, reflective disks or magnetic dots which reflect or obstruct an independent light source. As will be described hereinafter, the lightrees 110 will display information generally about the location and quantity of articles within the carousels 102 to be retrieved and possibly their destination within one of the induction devices 104.
One such suitable lightree for use in accordance with the system 100 of the present invention is available from White Storage and Retrieval Systems, Inc. of Kenilworth, New Jersey. Another lightree of the aforementioned type is disclosed in Murphree, U.S.
Patent No. 5,330,062.
3o As diagrammatically shown in Fig. 2, a sortbar 182 is positioned at each of the induction devices 104.
The sortbar 182 includes an alphanumeric display 184 which may be similarly constructed to the alphanumeric display of the lightrees 110. The sortbars 182 display information regarding the quantity and/or product number of the articles to be placed into designated autodrop stations 122 within the induction device 104.
As thus far described, the system 100 in accordance with one embodiment includes a plurality of rotatable carousels for storing a large quantity of articles to be retrieved and sorted. The carousels 102 are arranged side-by-side at a central storage location.
One common end 116 of each of the carousels 102 are positioned opposing a continuous looped sortation conveyor 106 which supports a plurality of article supports 156 in the nature of, for example, a tilt tray l0 or cross belt assembly. Overlying the sortation conveyor 106 in alignment with the carousels 102 is a plurality of induction devices 104 each provided with a plurality of induction containers 123. A plurality of sorters or chutes 108 in the nature of packing lanes are arranged along the sortation conveyor 106 at a spaced location from the induction devices 104. A plurality of lightrees 110 and sortbars 182 are used for managing operation of the system 100 with respect to the simultaneous picking of orders from the carousels 102 and placing same within an induction container 123.
In operation pursuant to one illustrative example, the system 100 will be described for picking and sorting consumer goods pursuant to a plurality of customer orders. However, articles of any type and for any purpose may be stored, picked and sorted in accordance with the present invention. In this regard, the articles may be packaged for shipment or used internally as a raw material source or for any other purpose. The computer control system 112 assigns a designated article sorter or chute 108 for each order to be completed, as well as an induction container 123 for each article to be placed when removed from an opposing carousel 102. A lightree 110 designates the location of the articles to picked from the carousels 102, the quantities of such articles, as well as the particular induction container 123 where the articles are to be placed. As the articles are picked from the carousel 102, they are placed within the designated induction containers 123 where they are dropped onto an underlying article support 156 being carried by the sortation conveyor 106. The articles are delivered to the appropriately designated article sorters 108 for the specified order. Once all the articles are collected at the designated sorter, they may be collected for shipment or other purpose.
The control of the system 100 is achieved by use of the computer control system 112 as l0 diagrammatically illustrated in Fig. 5. As shown, the computer control system 112 generally includes three components, namely, a host computer 186, a scheduler 188 and a controller 190. The computer control system performs a number of system functions, for example, (1) order scheduling and release, (2) carousel picking control (3) sortation interface control, (4) order consolidation/packing, (5) order reconciliation and (6) host interface.
Articles to be retrieved and sorted pursuant to customer orders are initially stored within the carousels 102. Although the articles being stored pursuant to the present invention have not been specified, they may include a large variety of products.
For example, such articles may include cosmetics, medicine, toys, clothing items, household items, compact discs, recording tapes, books, alcoholic beverages, e.g., beer, magazines, novelty items, electronic components, telephone accessories, electrical supplies, machine parts, tools, hardware and the like. The articles may be placed into the bins 114 using any suitable means, such as an inserter/extractor device 192 positioned at, for example, the other end 194 of the carousels 102. An inserter/extractor device 192 may be provided for each of the carousels 102. However, it is contemplated that a single inserter/extractor device 192 may be operative for placing articles into more than one carousel 102.' In this regard, the inserter/extractor device 192 would be operative for movement across the end 192 of adjacent carousels. A suitable inserter/extractor device 192 for use in accordance with the system 100 of the present invention is obtainable from White Storage and Retrieval Systems, Inc. of Kenilworth, New Jersey.
Incoming orders from all customers are placed into the host computer 106. The scheduler 188 obtains data with respect to each of the orders from the host computer 186. This information may include, for to example, customer information, product identification of articles within a specified order, the quantity of such articles and priority information regarding the scheduling of retrieving the articles and sorting same for shipment or other purpose. The scheduler 188 obtains data from a large number of customer orders for prioritizing orders by, for example, the date, time of day, order number, customer, and the like. The individual articles making up the customer orders are prioritized for picking from the carousels 102. For 2o example,' all like articles for a plurality of customer orders which are to be filled within a common time frame are simultaneously picked from the carousels 102. The scheduler 188 will control operation of the sortation conveyor 106, while designating each of the sorters 108 as corresponding to a particular customer order. That is, articles retrieved from the carousels 102 for a particular customer order will be transported to the same sorter or chute 108 for assembly in completing the order. The scheduler 188 controls operation of the sortation conveyor 106 so as to transport articles in filling customer orders from the induction devices 104 to the sorters 108.
The controller 190 controls the operation of the carousels 102 and the information being displayed by the lightrees 110 and sortbars 182 with respect to the articles being retrieved in accordance with the priority defined by the scheduler 188. More specifically, the controller 190 will operate rotation of the carousels 102 so as to position the desired storage bins 114 at a location opposing one of the induction devices 104. The storage bins 114 will generally contain a plurality of articles of like type which are to be picked for filling one or more customer orders. The order of bringing the corresponding storage bins 114 to a picking location is determined by the priority set up by the scheduler 188 with respect to the customer orders analyzed in the host computer 186. The carousels 102 are preferably operated so as to minimize rotation between the location of the storage bins 114 so as to speed up the picking process.
A lightree 110 which is associated with a particular carousel 102 may display information regarding the bin location, nature of articles and number of articles to be removed from a- storage bin 114.
Any other information which may be desirable to be displayed during the picking process may be displayed by the lightrees 110. The sortbar 182 for each induction device 104 will provide displayed information identifying the specific induction container 123 within each induction device 104 the picked articles are to be deposited, including the number of such articles. In this regard, each induction container 123 will correspond to a single customer order for one or more of the designated articles which are picked from a specified storage bin 114.
Articles to be picked from the carousels 102 may be done manually by one or more operators. For example, a single operator may be stationed at the end 116 of each carousel 102 for picking articles from the storage bins 114 and placing same into an opposing induction device 104. As such, there may be a one-to-one correspondence between the number of operators and the number of carousels 102. This arrangement will provide for the high capacity of the operation of the system 100 in filling customer orders. Alternatively, it is possible for a single operator to pick from a plurality of adjacent carousels 102 or more than one operator being assigned to a single carousel. In this regard, a single operator may be stationed adjacent the ends 116 of two adjacent carousels 102 for picking articles from the storage bins 114 and placing same into one of two adjacent and opposing induction devices 104.
In a like manner, a single operator may be assigned three or more carousels 102 for picking articles and for filling customer orders. The specific number of operators will be determined by the quantity of orders l0 being fulfilled at a given time. It is also contemplated that a single operator may pick from a single carousel 102 into a plurality of induction devices 104.
The system 100 of the present invention may be further automated by incorporating a plurality of inserter/extractor devices 192 adjacent ends 116 of the carousels 102 as a replacement of the operators. In this regard, there may be a one-to-one correspondence between each carousel 102 and an inserter/extractor device.192. Alternatively, a single inserter/extractor device 192 may be operative for picking articles from a number of adjacent carousels 102. The number of inserter/extractor devices 192 employed will control the capacity of the system 100. In accordance with this embodiment, the inserter/extractor devices 192 will be controlled by the scheduler 188 for picking articles from the storage bins 114 and placing same into a designated induction container 123. It is contemplated that this arrangement will avoid the need for providing lightrees 110 and sortbars 182. However, the lightrees 110 and sortbars 182 may be provided to enable manual picking of articles if required, for example, breakdown of an inserter/extractor device 192.
An illustrative example of the operation of the system 100 will now be described. Three orders will be entered into the host computer 186. Order one will be for three articles "A" and one article "C"; order two will include two articles "A" and one article "B"; and order three will require two articles "B" and two articles "C".
The scheduler 188 will retrieve the three orders from the host computer 186. It will be noted that the priority information for the three orders designates that they should be filled at the same time.
The scheduler 188 will accordingly organize the appropriate sequence of picking articles A, B and C from the appropriate carousels 102. For example purposes l0 only, article A will be stored in the first carousel 102, articles B in a middle positioned carousel and articles C in the last carousel. The controller 190 will operate the first, middle and last carousels 102 so as to position the storage bins 114 containing the respective articles A, B and C adjacent the opposing induction devices 104. The lightrees 110 adjacent each of the first, middle and last carousels will be illuminated with displayed information. Specifically, the first lightree will display information that a total quantity of five articles A are to be removed simultaneously from a designated storage bin 114 from the first carousel 102. The middle lightree 110 will designate that a total quantity of three articles B are to be simultaneously removed from a designated storage bin 114 from the middle carousel 102. Finally, the last lightree 110 will indicate that a total quantity of three articles C are to be simultaneously removed from a designated storage bin 114 in the last carousel 102.
The articles A, B and C will be picked from the designated storage bins 114 by one or more operators pursuant to the instructions and information displayed by the lightrees 110. It is noted that of the five articles A, three pertain to customer order one and two pertain to customer order two. As to articles B, one of the articles pertain to customer order two, while two of the articles pertain to customer order three. Lastly, of the three articles C, one pertains to customer order one, while two pertain to customer order three.
However, at the time of picking the articles A, B and C
from the storage bins 114, there is no distinction that the articles are for fulfilling more than one customer order. That is, the total quantity of articles A, B or C for fulfilling all current orders are picked simultaneously from the designated storage bins 114 containing the desired article.
The operator will take the five articles A to the induction device 104 and view the information being l0 displayed by the corresponding sortbar 182. The sortbar 182 will instruct the operator at the first induction device 104 to place three articles A in one of the induction containers 123 which has been designated by the schedule 188 for receipt of articles for customer IS order one. In addition, the sortbar 182 will instruct the operator to place the remaining two articles A in another induction container 123 within the same induction device 104 which has been designated by the schedule 188 as corresponding to customer order number 20 two. In a similar manner, the sor bar 182 for the middle induction device 104 will instruct the operator to place one of the articles B into a designated induction container 123 corresponding to customer order number two, and the remaining two articles in another 25 induction container which has been designated as corresponding to customer order number three. Likewise, the final sortbar 182 will instruct the operator to place one of the articles C into a designated induction container 123 corresponding to customer order number 30 one, the remaining two articles being placed into another induction container corresponding to customer order number three. At this time, all of the articles A, B and C required for fulfilling the customer orders one through three have been placed into the induction 35 devices 104. As noted, each of the induction containers 123 receive, at any one time, like articles for a single customer order. That is, a particular induction container 123 will not contain at the same time different types of articles or articles for more than one customer order. However, it is possible for a particular induction container 123 to receive at the same time different articles from the same order.
After the operator places each of the articles into an appropriate induction container 123, the operator will press a switch which will send a signal to the scheduler 188 advising that the articles had been placed into the designated induction container. At such time, the scheduler 188 will activate the sortation conveyor 106 so as to receive the articles within predetermined article supports 156 which will be designated by the scheduler 188. The presence of articles within an induction container 123 may be detected other than by operator assistance such as the aforementioned switch. In this regard, a photoelectric eye, pressure detection device or other suitable means may be used for determining that an article has been placed within an induction container 123.
The scheduler 188 will instruct the sortation conveyor 106 to advance until a designated article support 156 which does not contain any articles is positioned underlying the respective induction container 123 containing articles A, B and C for each of the respective customer orders numbers one-three. As each of the designated article supports 156 approach underlying the corresponding induction containers 123, the scheduler 188 will activate the pivot mechanism 138 causing the overlying induction container to open and drop its contents onto the underlying article support.
The articles may be dropped onto the underlying article support 156 either on the fly or when the article support is stationary. That is, the sortation conveyor 106 may be in continuous motion with the articles being timed so as to be dropped from their respective induction containers 123 to fall into an underlying article support when the support is in approximate alignment with the induction container. In the alternative, it is possible to index the sortation conveyor 106 such that the article support 156 will momentarily stop when arranged underlying the designated induction container 123 for receipt of contained articles.
As previously described, the scheduler 188 will assign a specified article support 156 for the articles contained in each of the induction containers 123 corresponding to the particular customer orders being filled. Alternatively, it is possible to assign an article support 156 to more than one induction container 123 which hold articles from the same order.
Accordingly, the corresponding article supports containing three of article A and one of article C will be designated for customer order one. Similarly, the article supports 156 receiving two of article A and one of article B would be designated for customer order two.
Likewise, the article supports 156 receiving two of articles B and two of articles C would be designated for customer order number three. The scheduler 188 will operate the sortation conveyor 106 so as to align the corresponding article supports 156 for each of the customer orders with the predetermined sorters 108.
When the article supports 156 corresponding to customer order number one approach the designated sorter 108, the article supports will tilt upwardly discharging the articles. It is to be noted that the article supports 156 are tilted in the case of tilt trays, or rotation of a belt is effected if of the cross-belt type. In either event, the articles may be discharged into the corresponding sorter or chute 108 either on the fly or upon momentary stopping of the sortation conveyor 106.
In a similar manner, the article supports 156 carrying the articles for customer order number two are discharged when they aligned with the previously assigned sorter or chute 108. Finally, the articles for customer order'number three are likewise discharged into their designated sorter or chute 108. Within each sorter or chute 108, the articles corresponding to a particular order are collected from where they may be packaged or handled.
From the foregoing description of the present invention, the system 100 is capable of simultaneously processing a plurality of customer orders which, may include, common articles of varying quantity. This solves the prior problem of having to pick customer orders which do not include case lots, i.e., only one or to two articles of a particular kind. Accordingly, large numbers of customer orders containing any number of different articles, wherein the articles are of small quantities, may be filled quickly and efficiently pursuant to the system 100 of the present invention.
Although the aforementioned description was only with respect to three customer orders, it is to be understood that any number of customer orders may be simultaneously filled pursuant to the present invention.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that the embodiments are merely illustrative of the principles and application of the present invention. It is therefore to be understood that numerous modifications may be made to the embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the claims.
More particularly, the system of the present inventions may perform the following functions:
I Order Scheduling and Release A customer s host computer (order entry, inventory control) receives information (purchase orders) from their customers. Orders once processed by the host computer are sent electronically to the system computer which analyzes each order and continually updates the release priority. Customer data (order file) may include a customer priority or truck route which will be used to help schedule the processing of the order in the system.
The release of orders to the system is done in a continuous stream of work versus a batch release of orders. This continuous work release guarantees a steady work flow for the pick and pack operators. This release also 'allows larger and smaller orders to be processed in the most efficient fashion. The release algorithm looks at the order priority and availability of a pack lane (drop off chute).
Carousel picking control is scheduled by the scheduler. The actual carousel movement is accomplished by move commands sent from the scheduler to a star controller. The star controller manages the movement of the carousels, directs the flow of data to the lightree and sortbar display devices and sends back task complete messages to the scheduler.
to Sortation interface control is similar to the carousel picking control except the scheduler interfaces with the sortation conveyor. The scheduler tells the sortation control system of induction positions which have picked product (taken from the carousel), the I.D.
number of the induction position (where the picked product was placed) and the destination (sorter lanes) position (orders) to sort the product. Order consolidation/packing is the destination.of items picked from the carousel and taken by the sortation conveyor to the appropriate sorter lane (chute) which has other items for the same order. Once all the items for a particular order are accumulated in a sorter lane, an operator can pack the order and tell the scheduler that the order is complete. Orders can also be automatically dropped into shipping boxes if the customer s product profile accommodates this method.
Order reconciliation is accomplished by sending a message from the sortation control system back to the scheduler. This message is a divert verification 3o to a sorter lane position. The sortation conveyor may be outfitted with sensors to detect the presence of objects moving past a beam down the sorter lane. After this message is sent to the scheduler and all product has been sent to a sorter lane, the scheduler notifies the customer host computer of an order completion. If there has been any error conditions, a supervisor is notified to check and correct the error. Common errors are product out of stock, failure to divert and broken product.
Orders may be selected for picking based on the following criteria:
Priority, using a number from 1-100, is sent from the host computer along with detail order information. The priority is for the entire order not individual item lines.
Ship date/time qualified order release may be l0 used in combination with priority or as a single release standard. This information is again sent by the customer host computer to the scheduler.
Consolidation station availability is utilized after orders have been analyzed for release. Once a 15 sorter lane is assigned an order, no other order lines will be sent to that lane until the entire order is completed and packed.
Order makeup is analyzed to determine where order lines are to be picked (i.e., multiple carousels 20 and locations), how many lines are picked from each carousel; and the suggested number or pick operators needed based on volume of work. Additional parameters such as large numbers of single line orders and multiple line orders can be set to provide overall system 25 balance.
II. Carousel Picking Control Carousel functions include:
Continuous transaction picking is a method which continually injects new orders into the active 3o pick queues for the operators. This guarantees a steady state of work versus a start/stop method if batches of work are processed. The scheduler monitors the picks to ensure that when placing new work in the order queue, work already in the system is accomplished as per the 35 order release rules.
Distribution of carousels to picking is a method of looking at identical items which may be stored in multiple carousels. This helps create a more balanced system and improves overall system rate. Very high volume products can thus be picked simultaneously by multiple pick operators.
Multiple pick to locations provide further enhancement to picking common items. There are times when a popular item quantity can be picked from a single location and placed in multiple autodrop positions.
This is referred to as commonality. By way of example, three (3) customers place orders for a pencil #3 and a to quantity of one (1) each. When the carousel moves into the pick position, the lightree is told to display a total quantity to pick of three (3) pencil #3. The operator picks three (3) pencils #3 and is told by the sortbar LED~s to place one (1) pen into each induction position. The scheduler then tells the sortation conveyor that induction positions 1, 2 and 3 are ready to be picked up and taken to sorter lane, i.e., order consolidation chutes, positions associated with each customer order. This method improves overall efficiency of the system.
Configurable pick methods are utilized based on system activity, order makeup or carousel optimization. The basic algorithms employed include:
Zone, where a number of carousels are assigned to a pick operator. This zone can be dynamic but can include any number of carousels. Zone picking is done to reduce operator travel, i.e., walking, time spent looking for items.
Round robin picking is a method used in zone picking which always directs the pick operator in a sequence starting from left to right. By way of example, a three (3) carousel zone round robin pick would start at carousel #1, proceed to #2, #3, #1, #2, etc. until all picking is completed.
Next available picking differs from round robin in that operators are directed to pick from the next carousel' in position (stopped moving) versus a sequence. The operator is told which carousel to pick from via the lightree indicator associate with each carousel.
Configurable rotation algorithms employed include FIFO and closest location. First in first out (FIFO) is when order commands are taken in a strict sequence as sent from the scheduler to the controller.
The advantage of this method is that it ensures work is done exactly in the fashion needed to match the packing operation. FIFO picking will normally spin the carousel l0 in a single direction.
Closest location is when order commands are chosen based on the closest location for a product based on where the carousel is in proximity to the pick operator. The advantage of this algorithm is a reduction in wait time because pick locations are not passed as in the FIFO method. Closes location picking will tend to spin the carousel both clockwise and counterclockwise based on pick location.
III. Sortation Interface Control The scheduler interface to the sorter conveyor is generally based on electronic messages. The messages include .
Route picked product from induction device to sorter chute lane. Each induction device is given a specific number from 1 to N. Each sorter chute lane is given a number from 1 to N. After product is placed from the carousel pick position to an induction position the scheduler indicates both the from I.D. and the to I.D.
Product is classified as inducted from a pick position (induction device) when the sorter has commanded the induction device to release the product onto the moving sorter tray.
Product is classified as diverted when the sortation conveyor has moved the tray to the sorter chute lane and has discharged the product from the tray past the divest verification scanner photo eye to the sorter chute lane.
_g_ Order complete status is achieved when all line items for an order have been diverted to and packed at the sorter consolidation chute lane.
Order indexed for pack status is achieved when either the pack operator or the automated dispenser to carton indicates pack status to the scheduler. In a manual pack this could be a message from the customer host packing computer system, the packing subsystem, the conveyor sorter packing subsystem, indicating the order to has been packed and removed from the lane. If automatically dropped into a box, the sorter system would indicate this transaction in a fashion similar to the divert verification message.
Order anomaly processing is an indication of a problem with an entire order of particular lines or items of an order. Examples of problems include:
breakage, short pick, wrong item and incorrect order in lane. Typically the pack operator will request supervisor intervention to correct the problem and update the computer system. In any event, all anomaly conditions are logged for audit purposes.
IV. Order Consolidation and Packing Operations Consolidation and pack operations types indicate the method used to group orders and manage the staffing of such operations. There are a variety of methods and the method may be changed depending on type or order (single versus multiple line), complexity of pack operation, volume of work. Some basic methods include the following examples.
One operator servicing a bank of sorter consolidation chutes. It is contemplated that a single operator can service a number of pack stations. The system will turn on an LED indicator when an order is complete in a lane and the operator can then proceed to the station for final pack.
Automatic interface allows each chute to be serviced by 'a conveyor moving shipping boxes into position under each chute when an order is completed.
_g_ Once the box is filled it is moved away from the chute and sent to shipping.
Pack station operation provider can be done by the system, the customer through the software on their system, or the conveyor sortation supplier.
V. Host Interface Host interface is a computer link to the customer host system which can be established using various industry standard methods. The type of 1o interface is largely dependent on the customer host computer and network. For example, file transfer protocol provides a file based interface in which the host computer sends complete files to the scheduler.
The transactions are completed in the system and sent back as files to the customer host for accounting.
In a message based system, the interface is a more real (near time) transaction based transfer of information. The host sends messages rather than complete files and thus is more interactive than the system. This can be a TCP/IP sockets interface or other real time protocols.
The above description, as well as further objects, features and advantages of the present invention will be more fully understood with reference to the following detailed description of an article sortation system, when taken in conjunction with the accompanying drawings, wherein:
Fig. 1 is a diagrammatic perspective illustration of an article sortation system in accordance with one embodiment of the present invention;
Fig. 2 is a diagrammatic perspective view of an induction device in operative association with a plurality of carousels and a sortation conveyor;
Fig. 3 is a perspective view of an induction container for use in the induction device in accordance with one embodiment of the present invention;
Fig. 4 is a perspective view of a portion of the sortation conveyor in accordance with one embodiment of the present invention;
Fig. 5 is a .perspective view of a portion of the sortation conveyor in accordance with another embodiment of the present invention; and Fig. 6 is a diagrammatic illustration of the control system for operation of the article sortation system in accordance with one embodiment of the present invention.
Referring now to the drawings, wherein like reference numerals represent like elements, there is shown in Fig. 1 an article sortation system generally designated by reference numeral 100. The system 100 includes at least one, and preferably a plurality of rotary carousels 102 arranged opposing at least one, and preferably a plurality of induction devices 104. The induction devices 104 are arranged in operative association with a sortation conveyor 106 which, in turn, is in operative association with at least one, and preferably a plurality of sorters 108, also referred to as sort lanes or sortation devices. Visual control information is displayed by means of at least one, and preferably a plurality of lightrees 110. The system is operated by means of a computer control system 112 and associated software.
The rotary carousels 102 are of the horizontal type. In this regard, each of the carousels 102 include a plurality of storage bins 114 which are rotated around the carousel along a horizontal axis. A plurality of bins 114 may be integrally connected along a vertical axis to provide a tier of bins 114 which are rotatable in a continuous loop around the carousel 102.
Typically, multiple tiers of bins 114 are provided within a single carousel to increase storage capacity.
One suitable rotary carousel 102 for use in accordance with the system 100 of the present invention may be obtained from White Storage and Retrieval Systems, Inc.
of Kenilworth, New Jersey.
The carousels 102 have been described as being of the horizontal rotary type. However, it is to be understood that carousels of the vertical rotary type may also be employed with the system 100. In addition, conventional storage racks having non-moveable storage bins 114 may also be used with the system 100. As such, any storage system operative for storing a plurality of articles in designated locations may be employed with the system 100. For purposes of efficiency and speed, it is preferred that rotary carousels 102 be employed so as to enable the articles to be retrieved to be brought to a central designated location, preferably, adjacent the induction device 104.
A plurality of carousels 102 are generally arranged in spaced apart side-by-side relationship. The carousels 102 are positioned as shown with their narrow ends 116 aligned within a common vertical plane. The ends 116 of the carousels 102 are generally the working area of the carousels, i.e., the location where stored articles are to be removed during operation of the system 100, such as in filling orders. Fig. 1 shows, by way of example, the arrangement of eight carousels 102.
However, it is to be understood that any lesser or greater number of carousels 102 may be provided, dependent upon the size of the warehousing facility and the number of articles to be stored for satisfying orders for such articles.
Positioned generally opposing the end 116 of each carousel 102 is an induction device 104. As better shown in Figs. 2 and 3, the induction device is constructed from a frame 118 having an upper structure 120 supported off the floor. Supported by the upper structure 120 are a plurality of autodrop stations 122 each including at least one induction container 123.
Each induction container 123 is constructed, by way of one illustration only, from a pair of spaced apart shells 124. Each shell 124, in turn, is constructed from three side walls 126, 128, 130 surrounding a bottom support 132 thereby forming an open top 133 and an open end 134.
The open ends 134 of the shells 124 are arranged facing each other such that the side walls 126, 130 and bottom supports 132 lie in respective common planes with the open top 133 facing upwardly. The shells 124 are hinged about upper pivot points 136 by to suitable means (not shown), e.g., a rod extending through the side walls 126, 130. The pivotable arrangement of the shells 124 allow the shells to rotate upwardly about the pivot points 136 in respective clockwise and counterclockwise direction as shown by the arrows. This, in turn, causes the respective bottom supports 132 to separate from their adjacent relationship as illustrated to provide a bottom opening within each autodrop station 122. It should be appreciated that any article positioned on the bottom 2o supports 132 will fall through the bottom opening as the bottom supports separate from one another upon upward rotation about the pivot points 136.
Any suitable pivoting mechanism 138 may be provided for pivoting the respective shells 124 during operation of each autodrop station 122. By way of illustration only, the mechanism 138 includes a pair of spaced apart arcuate shaped openings 140 positioned within the side walls 126 in symmetrical arrangement. A
bias spring 142 is connected between the side walls 126 to maintain the induction container 123 in closed position to maintain any articles stored therein on the bottom support 132. A pneumatic cylinder 140 having a piston rod 146 is operatively coupled between the openings 140. Specifically, the free end of the piston rod 146 is attached to a follower 148 which slides within one of the openings 140. The base of the pneumatic cylinder 140 is likewise attached to a follower 150 which rides within the other opening 140.
As the piston rod is retracted, the followers 148, 150 will ride within their respective openings 140 thereby pivoting the shells 124 about pivot points 136. The spring 142 will maintain the shells 124 in closed position until the pneumatic cylinder 144 is actuated with sufficient pressure to overcome the resistance of the spring.
The particular construction of each autodrop station 122 and the induction containers 123 is by way to of example only. Thus, other constructions for the induction device 104 having an autodrop station 122 and the induction containers 123 may be employed. It is only a requirement that the autodrop station 122 be capable of initially supporting an article therein, and subsequently, being capable of discharging the article when desired. There are known a number of manufacturers of induction devices which may be adapted for use in the system 100 in accordance with the present invention.
For example, such companies include Promech Sorting 2o Systems of The Netherlands, Diafuku of Japan, Mantissa Corporation of North Carolina and Tech Corporation of New Jersey. Accordingly, any induction device 104 which will perform the aforementioned described functions of the autodrop stations 122 may be employed with the system 100 of the present invention.
As shown in Figs. 1 and 2, an induction device 104 is positioned opposing the end 116 of each carousel 102. As such, there is a one-to-one correspondent, i.e., one induction device 104 for each carousel 102.
However, it is to be understood that each carousel 102 may be associated with more than one induction device 104, or in the alternative, a plurality of carousels may be associated with a single induction device.
Similarly, although each induction device 104 is shown having three autodrop stations 122, it is to be understood that any greater or lesser number of stations may be provided. That is, the greater the number of induction devices 104 and autodrop stations 122, the greater the number of articles which may be sorted simultaneously thereby increasing capacity of the system 100.
Turning to Figs. 1-3, the sortation conveyor 106 will now be described. The sortation conveyor 106 is in the nature of a continuous loop conveyor which is in operative association with each of the induction devices 104 and each of the sorters 108. The sortation conveyor 106 includes a frame 152, which as shown, l0 supports an upper structure 154 at varying heights above the floor. Specifically, the upper structure 154 extends through the induction devices 104 at a level underlying the autodrop stations 122. Subsequently, the sortation conveyor 106 rises to a level so as to be in operative association with each of the sorters 108.
Subsequently, the sortation conveyor 106 drops to a lower level, so as to once again, to be received within the induction devices 104. Although the sortation conveyor 106 has been described as passing through 20multiple vertical heights, it is also possible for the sortation conveyor to be level with respect to the floor. It is therefore only required that the sortation conveyor 106 be arranged in operative association with the induction devices 104 and the sorters 108.
The sortation conveyor 106 includes a plurality of movable article supports 156 arranged in spaced apart relationship along the upper structure 154.
Any suitable means, such as an endless chain or belt 158 is operative for moving the article supports 156 along the upper structure 154 in a continuous or intermittent fashion as may be desired during operation of the system 100. It is to be understood that any other mechanism operative for moving the article supports 156 along the upper structure 154 into operative relationship with the induction devices 104 and sorters 108 may be employed.
As best shown in Fig. 4, the sortation conveyor 106 in accordance with one embodiment is of the tilt tray type. In this regard, each of the article supports 156, which are in the nature of a flat shallow walled tray, are tiltably supported by the upper structure 154. In this regard, each of the article supports 156 are initially arranged in a generally horizontal plane as the support is being transported around the sortation conveyor 106 as shown in, for example, Figs. 1 and 2. However, as each article support 156 aligns with a predetermined sorter 108, the article support is tilted upwardly by a mechanism (not to shown) such that any supported article will discharge by gravity into the opposing sorter. Subsequently, the article support 156 is returned to its horizontal orientation for continued transport via the sortation conveyor 106 to the induction devices 104. An illustration of two article supports 156 being tilted for discharge of supported articles is shown in Fig. 1 at positions 160. Known manufacturers of tilt tray type sortation conveyors 106 are the same previously named manufacturers as the induction devices 104.
The sortation conveyor 106 can also be constructed as a cross belt sortation conveyor 162. In this regard, each of the article supports 156 is constructed as a conveyor belt whose direction of rotation is transverse to the direction of movement of the supports along the sortation conveyor. For example, as shown in Fig. 5, the cross belt sortation conveyor 162 includes a frame 164 having an upper structure 166 which supports a plurality of article supports 168.
Each article support 168 is in the nature of a 3o continuous belt 170 extending over a pair of spaced apart rollers 172. At least one of the rollers 172 is driven so as to cause articles supported on the article supports 168 to be discharged in the direction of the arrow. Suitable cross belt sortation conveyors 162 for use in accordance with the present invention are obtainable from H.K. Systems of Kentucky, Bematic of Germany and Diafuku of Japan.
The sorters 108 can be constructed in the nature of a belted conveyor, chute roller conveyor or slide table, or the combination of both. As shown in Fig. 1, each sorter 108 in the nature of a chute has an inlet end 174 arranged adjacent the sortation conveyor 106 and an outlet end 176. Articles discharged from the article supports 156, 168 of the sortation conveyor 106, 162 are received at the inlet end 174 of a designated sorter or chute 108. The sorters 108 are operative for to collecting articles at the outlet end 176 thereof which are discharged by the sortation conveyor 106. Any other apparatus suitable for this purpose may be used in accordance with the system 100 of the present invention.
In this regard, the sorter or chutes 108 may be large bins into which the articles fall. Sortation chutes are generally available from any of the aforementioned companies who manufacture article handling equipment as noted herein.
Each of the sorters or chutes 108 may be arranged.at the same or different elevation to the sortation conveyor 106. In this regard, articles discharged from the sortation conveyor 106 may be raised to a higher or lower elevation as may be required in collecting the articles. To provide data to the computer control system 112, a photoelectric eye 178 may be positioned at the inlet end 174 of each sorter or chute 108. The photoelectric eye 178 will send a signal to the computer control system 112 confirming that an article has been discharged from the sortation conveyor 106 to a specified sorter or chute 108. As will be described hereinafter, each sorter or chute 108 may be designated for a particular order, such as a customer order. In this regard, articles retrieved from the carousels 102 for a particular order are transported to a predetermined sorter or chute 108 by means of the sortation conveyor 106. As such, the number of sorters or chutes 108 'will govern the number of orders or other collection of articles which can be filled simultaneously in accordance with the system 100 of the present invention.
A lightree 110 is positioned in association with each of the carousels 102. Preferably, there is a one-to-one correspondence, i.e., one lightree 110 for each of the carousels 102. The lightrees 110 are generally arranged at any convenient location, and preferably, at the ends 116 of the carousels 102 approximate the induction devices 104.
to The lightrees 110 have a face 180 which can be any one of a number of known types which use an array of lightable elements or dots to form symbols such as alphanumeric characters. As is known in the art, the lightable elements can be directly lightable, such as light emitting diodes or incandescent lamps which are energized to generate light, or indirectly lightable such as liquid crystal displays, reflective disks or magnetic dots which reflect or obstruct an independent light source. As will be described hereinafter, the lightrees 110 will display information generally about the location and quantity of articles within the carousels 102 to be retrieved and possibly their destination within one of the induction devices 104.
One such suitable lightree for use in accordance with the system 100 of the present invention is available from White Storage and Retrieval Systems, Inc. of Kenilworth, New Jersey. Another lightree of the aforementioned type is disclosed in Murphree, U.S.
Patent No. 5,330,062.
3o As diagrammatically shown in Fig. 2, a sortbar 182 is positioned at each of the induction devices 104.
The sortbar 182 includes an alphanumeric display 184 which may be similarly constructed to the alphanumeric display of the lightrees 110. The sortbars 182 display information regarding the quantity and/or product number of the articles to be placed into designated autodrop stations 122 within the induction device 104.
As thus far described, the system 100 in accordance with one embodiment includes a plurality of rotatable carousels for storing a large quantity of articles to be retrieved and sorted. The carousels 102 are arranged side-by-side at a central storage location.
One common end 116 of each of the carousels 102 are positioned opposing a continuous looped sortation conveyor 106 which supports a plurality of article supports 156 in the nature of, for example, a tilt tray l0 or cross belt assembly. Overlying the sortation conveyor 106 in alignment with the carousels 102 is a plurality of induction devices 104 each provided with a plurality of induction containers 123. A plurality of sorters or chutes 108 in the nature of packing lanes are arranged along the sortation conveyor 106 at a spaced location from the induction devices 104. A plurality of lightrees 110 and sortbars 182 are used for managing operation of the system 100 with respect to the simultaneous picking of orders from the carousels 102 and placing same within an induction container 123.
In operation pursuant to one illustrative example, the system 100 will be described for picking and sorting consumer goods pursuant to a plurality of customer orders. However, articles of any type and for any purpose may be stored, picked and sorted in accordance with the present invention. In this regard, the articles may be packaged for shipment or used internally as a raw material source or for any other purpose. The computer control system 112 assigns a designated article sorter or chute 108 for each order to be completed, as well as an induction container 123 for each article to be placed when removed from an opposing carousel 102. A lightree 110 designates the location of the articles to picked from the carousels 102, the quantities of such articles, as well as the particular induction container 123 where the articles are to be placed. As the articles are picked from the carousel 102, they are placed within the designated induction containers 123 where they are dropped onto an underlying article support 156 being carried by the sortation conveyor 106. The articles are delivered to the appropriately designated article sorters 108 for the specified order. Once all the articles are collected at the designated sorter, they may be collected for shipment or other purpose.
The control of the system 100 is achieved by use of the computer control system 112 as l0 diagrammatically illustrated in Fig. 5. As shown, the computer control system 112 generally includes three components, namely, a host computer 186, a scheduler 188 and a controller 190. The computer control system performs a number of system functions, for example, (1) order scheduling and release, (2) carousel picking control (3) sortation interface control, (4) order consolidation/packing, (5) order reconciliation and (6) host interface.
Articles to be retrieved and sorted pursuant to customer orders are initially stored within the carousels 102. Although the articles being stored pursuant to the present invention have not been specified, they may include a large variety of products.
For example, such articles may include cosmetics, medicine, toys, clothing items, household items, compact discs, recording tapes, books, alcoholic beverages, e.g., beer, magazines, novelty items, electronic components, telephone accessories, electrical supplies, machine parts, tools, hardware and the like. The articles may be placed into the bins 114 using any suitable means, such as an inserter/extractor device 192 positioned at, for example, the other end 194 of the carousels 102. An inserter/extractor device 192 may be provided for each of the carousels 102. However, it is contemplated that a single inserter/extractor device 192 may be operative for placing articles into more than one carousel 102.' In this regard, the inserter/extractor device 192 would be operative for movement across the end 192 of adjacent carousels. A suitable inserter/extractor device 192 for use in accordance with the system 100 of the present invention is obtainable from White Storage and Retrieval Systems, Inc. of Kenilworth, New Jersey.
Incoming orders from all customers are placed into the host computer 106. The scheduler 188 obtains data with respect to each of the orders from the host computer 186. This information may include, for to example, customer information, product identification of articles within a specified order, the quantity of such articles and priority information regarding the scheduling of retrieving the articles and sorting same for shipment or other purpose. The scheduler 188 obtains data from a large number of customer orders for prioritizing orders by, for example, the date, time of day, order number, customer, and the like. The individual articles making up the customer orders are prioritized for picking from the carousels 102. For 2o example,' all like articles for a plurality of customer orders which are to be filled within a common time frame are simultaneously picked from the carousels 102. The scheduler 188 will control operation of the sortation conveyor 106, while designating each of the sorters 108 as corresponding to a particular customer order. That is, articles retrieved from the carousels 102 for a particular customer order will be transported to the same sorter or chute 108 for assembly in completing the order. The scheduler 188 controls operation of the sortation conveyor 106 so as to transport articles in filling customer orders from the induction devices 104 to the sorters 108.
The controller 190 controls the operation of the carousels 102 and the information being displayed by the lightrees 110 and sortbars 182 with respect to the articles being retrieved in accordance with the priority defined by the scheduler 188. More specifically, the controller 190 will operate rotation of the carousels 102 so as to position the desired storage bins 114 at a location opposing one of the induction devices 104. The storage bins 114 will generally contain a plurality of articles of like type which are to be picked for filling one or more customer orders. The order of bringing the corresponding storage bins 114 to a picking location is determined by the priority set up by the scheduler 188 with respect to the customer orders analyzed in the host computer 186. The carousels 102 are preferably operated so as to minimize rotation between the location of the storage bins 114 so as to speed up the picking process.
A lightree 110 which is associated with a particular carousel 102 may display information regarding the bin location, nature of articles and number of articles to be removed from a- storage bin 114.
Any other information which may be desirable to be displayed during the picking process may be displayed by the lightrees 110. The sortbar 182 for each induction device 104 will provide displayed information identifying the specific induction container 123 within each induction device 104 the picked articles are to be deposited, including the number of such articles. In this regard, each induction container 123 will correspond to a single customer order for one or more of the designated articles which are picked from a specified storage bin 114.
Articles to be picked from the carousels 102 may be done manually by one or more operators. For example, a single operator may be stationed at the end 116 of each carousel 102 for picking articles from the storage bins 114 and placing same into an opposing induction device 104. As such, there may be a one-to-one correspondence between the number of operators and the number of carousels 102. This arrangement will provide for the high capacity of the operation of the system 100 in filling customer orders. Alternatively, it is possible for a single operator to pick from a plurality of adjacent carousels 102 or more than one operator being assigned to a single carousel. In this regard, a single operator may be stationed adjacent the ends 116 of two adjacent carousels 102 for picking articles from the storage bins 114 and placing same into one of two adjacent and opposing induction devices 104.
In a like manner, a single operator may be assigned three or more carousels 102 for picking articles and for filling customer orders. The specific number of operators will be determined by the quantity of orders l0 being fulfilled at a given time. It is also contemplated that a single operator may pick from a single carousel 102 into a plurality of induction devices 104.
The system 100 of the present invention may be further automated by incorporating a plurality of inserter/extractor devices 192 adjacent ends 116 of the carousels 102 as a replacement of the operators. In this regard, there may be a one-to-one correspondence between each carousel 102 and an inserter/extractor device.192. Alternatively, a single inserter/extractor device 192 may be operative for picking articles from a number of adjacent carousels 102. The number of inserter/extractor devices 192 employed will control the capacity of the system 100. In accordance with this embodiment, the inserter/extractor devices 192 will be controlled by the scheduler 188 for picking articles from the storage bins 114 and placing same into a designated induction container 123. It is contemplated that this arrangement will avoid the need for providing lightrees 110 and sortbars 182. However, the lightrees 110 and sortbars 182 may be provided to enable manual picking of articles if required, for example, breakdown of an inserter/extractor device 192.
An illustrative example of the operation of the system 100 will now be described. Three orders will be entered into the host computer 186. Order one will be for three articles "A" and one article "C"; order two will include two articles "A" and one article "B"; and order three will require two articles "B" and two articles "C".
The scheduler 188 will retrieve the three orders from the host computer 186. It will be noted that the priority information for the three orders designates that they should be filled at the same time.
The scheduler 188 will accordingly organize the appropriate sequence of picking articles A, B and C from the appropriate carousels 102. For example purposes l0 only, article A will be stored in the first carousel 102, articles B in a middle positioned carousel and articles C in the last carousel. The controller 190 will operate the first, middle and last carousels 102 so as to position the storage bins 114 containing the respective articles A, B and C adjacent the opposing induction devices 104. The lightrees 110 adjacent each of the first, middle and last carousels will be illuminated with displayed information. Specifically, the first lightree will display information that a total quantity of five articles A are to be removed simultaneously from a designated storage bin 114 from the first carousel 102. The middle lightree 110 will designate that a total quantity of three articles B are to be simultaneously removed from a designated storage bin 114 from the middle carousel 102. Finally, the last lightree 110 will indicate that a total quantity of three articles C are to be simultaneously removed from a designated storage bin 114 in the last carousel 102.
The articles A, B and C will be picked from the designated storage bins 114 by one or more operators pursuant to the instructions and information displayed by the lightrees 110. It is noted that of the five articles A, three pertain to customer order one and two pertain to customer order two. As to articles B, one of the articles pertain to customer order two, while two of the articles pertain to customer order three. Lastly, of the three articles C, one pertains to customer order one, while two pertain to customer order three.
However, at the time of picking the articles A, B and C
from the storage bins 114, there is no distinction that the articles are for fulfilling more than one customer order. That is, the total quantity of articles A, B or C for fulfilling all current orders are picked simultaneously from the designated storage bins 114 containing the desired article.
The operator will take the five articles A to the induction device 104 and view the information being l0 displayed by the corresponding sortbar 182. The sortbar 182 will instruct the operator at the first induction device 104 to place three articles A in one of the induction containers 123 which has been designated by the schedule 188 for receipt of articles for customer IS order one. In addition, the sortbar 182 will instruct the operator to place the remaining two articles A in another induction container 123 within the same induction device 104 which has been designated by the schedule 188 as corresponding to customer order number 20 two. In a similar manner, the sor bar 182 for the middle induction device 104 will instruct the operator to place one of the articles B into a designated induction container 123 corresponding to customer order number two, and the remaining two articles in another 25 induction container which has been designated as corresponding to customer order number three. Likewise, the final sortbar 182 will instruct the operator to place one of the articles C into a designated induction container 123 corresponding to customer order number 30 one, the remaining two articles being placed into another induction container corresponding to customer order number three. At this time, all of the articles A, B and C required for fulfilling the customer orders one through three have been placed into the induction 35 devices 104. As noted, each of the induction containers 123 receive, at any one time, like articles for a single customer order. That is, a particular induction container 123 will not contain at the same time different types of articles or articles for more than one customer order. However, it is possible for a particular induction container 123 to receive at the same time different articles from the same order.
After the operator places each of the articles into an appropriate induction container 123, the operator will press a switch which will send a signal to the scheduler 188 advising that the articles had been placed into the designated induction container. At such time, the scheduler 188 will activate the sortation conveyor 106 so as to receive the articles within predetermined article supports 156 which will be designated by the scheduler 188. The presence of articles within an induction container 123 may be detected other than by operator assistance such as the aforementioned switch. In this regard, a photoelectric eye, pressure detection device or other suitable means may be used for determining that an article has been placed within an induction container 123.
The scheduler 188 will instruct the sortation conveyor 106 to advance until a designated article support 156 which does not contain any articles is positioned underlying the respective induction container 123 containing articles A, B and C for each of the respective customer orders numbers one-three. As each of the designated article supports 156 approach underlying the corresponding induction containers 123, the scheduler 188 will activate the pivot mechanism 138 causing the overlying induction container to open and drop its contents onto the underlying article support.
The articles may be dropped onto the underlying article support 156 either on the fly or when the article support is stationary. That is, the sortation conveyor 106 may be in continuous motion with the articles being timed so as to be dropped from their respective induction containers 123 to fall into an underlying article support when the support is in approximate alignment with the induction container. In the alternative, it is possible to index the sortation conveyor 106 such that the article support 156 will momentarily stop when arranged underlying the designated induction container 123 for receipt of contained articles.
As previously described, the scheduler 188 will assign a specified article support 156 for the articles contained in each of the induction containers 123 corresponding to the particular customer orders being filled. Alternatively, it is possible to assign an article support 156 to more than one induction container 123 which hold articles from the same order.
Accordingly, the corresponding article supports containing three of article A and one of article C will be designated for customer order one. Similarly, the article supports 156 receiving two of article A and one of article B would be designated for customer order two.
Likewise, the article supports 156 receiving two of articles B and two of articles C would be designated for customer order number three. The scheduler 188 will operate the sortation conveyor 106 so as to align the corresponding article supports 156 for each of the customer orders with the predetermined sorters 108.
When the article supports 156 corresponding to customer order number one approach the designated sorter 108, the article supports will tilt upwardly discharging the articles. It is to be noted that the article supports 156 are tilted in the case of tilt trays, or rotation of a belt is effected if of the cross-belt type. In either event, the articles may be discharged into the corresponding sorter or chute 108 either on the fly or upon momentary stopping of the sortation conveyor 106.
In a similar manner, the article supports 156 carrying the articles for customer order number two are discharged when they aligned with the previously assigned sorter or chute 108. Finally, the articles for customer order'number three are likewise discharged into their designated sorter or chute 108. Within each sorter or chute 108, the articles corresponding to a particular order are collected from where they may be packaged or handled.
From the foregoing description of the present invention, the system 100 is capable of simultaneously processing a plurality of customer orders which, may include, common articles of varying quantity. This solves the prior problem of having to pick customer orders which do not include case lots, i.e., only one or to two articles of a particular kind. Accordingly, large numbers of customer orders containing any number of different articles, wherein the articles are of small quantities, may be filled quickly and efficiently pursuant to the system 100 of the present invention.
Although the aforementioned description was only with respect to three customer orders, it is to be understood that any number of customer orders may be simultaneously filled pursuant to the present invention.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that the embodiments are merely illustrative of the principles and application of the present invention. It is therefore to be understood that numerous modifications may be made to the embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the claims.
Claims (26)
1. A system for sorting articles retrieved from a storage device, said system comprising a storage device having a plurality of article storage locations, a sortation device, a conveyor having a plurality of moveable article supports positionable adjacent said storage device and said sortation device, an induction device positioned adjacent said storage device having at least one container in operative relationship with said conveyor and said article supports, and a control system for identifying the storage location of an article within said storage device for positioning said article in one of said containers for discharge to one of said article supports for transport thereby to said sortation device.
2. The system of claim 1, wherein said storage device comprises a rotary carousel.
3. The system of claim 2, wherein said storage locations comprise a plurality of bins positionable adjacent auto induction device upon rotation of said carousel.
4. The system of claim 2, further including an extractor device adjacent said carousel for removing articles from said storage locations and placing said articles within a selected one of said containers.
5. The system of claim 1, wherein said conveyor comprises a continuous loop conveyor and said moveable article supports each comprise a tiltable tray operative for receiving said article from one of said containers and delivering said article to said sortation device.
6. The system of claim 1, wherein said induction device is positioned overlying said conveyor, each of said containers having an openable support for supporting an article thereon when in a closed position and discharging said article to an underlying article support in said conveyor when in an open position.
7. The system of claim 1, further including a display capable of displaying information about the location of said articles with said storage device and the container for receiving said article.
8. The system of claim 1, wherein said control system comprises a computer.
9. A system for sorting articles from a plurality of article storage locations, said system comprising a plurality of article sortation devices, a plurality of moveable article supports positionable adjacent said article storage locations and at least one of said article sortation devices, a plurality of containers in overlying relationship with said moveable article supports, each of said containers having an openable support for supporting an article thereon when in a closed position and discharging said article to an underlying article support when in an open position, and a control system for identifying the storage location of an article for positioning said article in one of said containers for discharge to one of said article supports for transport thereby to one of said sortation device.
10. The system of claim 9, further including a rotary carousel providing said plurality of article storage locations.
11. The system of claim 9, wherein each of said article sortation devices includes an inlet communicable with each of said article supports, said inlet receiving said article being transported by said article support.
12. The system of claim 9, wherein said article supports are arranged for movement along a continuous loop.
13. The system of claim 9, wherein each of said article supports comprise a tray having a first position for receiving an article being discharged from one of said containers and a second position for discharging said article to one of said plurality of article sortation devices.
14. The system of claim 9, wherein said sortation device comprises a chute.
15. The system of claim 9, wherein each of said article sortation device includes an inlet communicable with each of said article supports, said inlet receiving said article being transported by said article supports which are arranged for movement along a continuous loop, each of said article supports comprising a tray having a first position for receiving an article being discharged from one of said containers and a second position for discharging said article to the inlet of one of said plurality of article sortation devices.
16. The system of claim 9, further including a display capable of displaying information about the location of said articles within said article storage locations and the container for receiving said article.
17. A process for sorting stored articles, said processes comprising the steps of identifying an article and its location within a storage device, retrieving said article from said storage device, placing said article in one of a plurality of containers, discharging said article from within said container onto one of a plurality of moveable article supports, and transporting said article by said article support to one of a plurality of article sortation devices.
18. The process of claim 17, further including the step of identifying a plurality of different articles and their respective locations within said storage device.
19. The process of claim 18, further including the step of placing said different articles in different ones of said plurality of containers.
20. The process of claim 19, further including the step of discharging said different articles from said different containers onto different ones of said plurality of article supports.
21. The process of claim 20, further including the step of transporting said different articles by said different article supports to different ones of said plurality of sortation devices.
22. The process of claim 20, further including the step of transporting said different articles by said different article supports to the same sortation.
23. The process of claim 18, further including the step of visually displaying information about the location of said different articles within said storage device and the corresponding containers for receiving each of said different articles.
24. A process for sorting a plurality of articles from a storage device into predetermined groups of said articles, said process comprising the steps of identifying said articles and their locations within said storage device, associating each article within said predetermined group with one of a plurality of article sortation devices, retrieving each of said articles from said storage device, place a predetermined number of said articles in a predetermined one of a plurality of containers, each said container being associated with one of said article sortation devices, discharging said articles from each of said containers onto a moveable article support, and transporting each of said article supports to said article sortation device which is associated with said article discharged from said container.
25. The process of claim 24, further including discharging said articles from said article support to its associated article sortation device for collecting said predetermined group of said articles.
26. The process of claim 24, further including the step of visually displaying information about the location of said different articles within said storage device and the corresponding containers for receiving each of said different articles.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US9008198A | 1998-06-03 | 1998-06-03 | |
| US09/090,081 | 1998-06-03 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2254641A1 true CA2254641A1 (en) | 1999-12-03 |
Family
ID=29547953
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2254641 Abandoned CA2254641A1 (en) | 1998-06-03 | 1998-11-30 | Article sortation system |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2254641A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110143395A (en) * | 2019-06-17 | 2019-08-20 | 隆链智能科技（上海）有限公司 | A kind of intelligent storage and radio frequency based on AGV trolley |
| CN111340407A (en) * | 2018-12-18 | 2020-06-26 | 菜鸟智能物流控股有限公司 | Storage object management method and device |
-
1998
- 1998-11-30 CA CA 2254641 patent/CA2254641A1/en not_active Abandoned
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111340407A (en) * | 2018-12-18 | 2020-06-26 | 菜鸟智能物流控股有限公司 | Storage object management method and device |
| CN111340407B (en) * | 2018-12-18 | 2023-10-17 | 菜鸟智能物流控股有限公司 | Storage object management method and device |
| CN110143395A (en) * | 2019-06-17 | 2019-08-20 | 隆链智能科技（上海）有限公司 | A kind of intelligent storage and radio frequency based on AGV trolley |
| CN110143395B (en) * | 2019-06-17 | 2024-05-03 | 隆链智能科技（上海）有限公司 | Intelligent storage and sorting system based on AGV trolley |
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