Classifying – separating – and assorting solids – Sorting special items – and certain methods and apparatus for... – Condition responsive means controls separating means
Reexamination Certificate
1999-05-12
2001-03-13
Matecki, Katherine A. (Department: 3653)
Classifying, separating, and assorting solids
Sorting special items, and certain methods and apparatus for...
Condition responsive means controls separating means
C209S540000, C209S922000, C209S933000
Reexamination Certificate
active
06201203
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for automatically forming a plurality of packages of groups of articles. More specifically, the present invention relates to a robotic containerization system (RCS) that is configured for the efficient loading of U.S. Postal Service (USPS) mail containers such as all purpose containers (APCs) and pallets.
In a typical USPS operational facility, trays of mail are generated at various sorting operations. These trays are used to transport the mail between sorting operations, and once they have reached the level of sorting necessary for dispatch, they are placed on a conveyor that takes them to the dock area for transport to other facilities. On the dock, the trays are sorted to the destination facility, and loaded into containers. Depending on the destination the trays may be sleeved and strapped (for the air transport or long truck transport), or may be left opened for local truck transport. In most conventional facilities, the sorting and container loading process is performed manually.
There are several problems inherent in systems of the prior art for performing these sorting and loading operations. In the early portion of transit of an article passing through the system, the rate of generation of trays will be low, such that even one person located at a given run-out conveyor will be under utilized to keep pace with the rate of arriving trays. However, during heavier volume, the mail handler is faced with a demanding labor-intensive task involving repetitive heavy lifting (up to 35 pounds for trays, 70 pounds for flat tubs). Due to the demanding nature of the tasks and the varying conditions of the trays, the risk exists of dropping a tray, further reducing the efficiency of this operation. In an attempt to reduce labor costs, reduce work place injuries and improve operational efficiency, the USPS has typically deployed robotic work cells to perform the container loading functions. Currently, the USPS is deploying pedestal robot work cells that perform a 12-way sort and container loading function, and gantry robots. These cells utilize conventional material handling robots that are typically manufactured for extremely heavy-duty, high precision applications.
The gantry robot layout is more floor space efficient than the pedestal configuration, but the gantry robot requires significant head-room (approximately 13 feet) or a very specialized telescoping Z axes. Gantry robots tend to be large and expensive also. Although the gantry can be configured to meet specific operational needs of a facility once installed, it cannot easily be modified if operational requirements change.
The operation of these robotic cells has very similar characteristics. Trays arrive on an input conveyor in a random sequence. A bar-code reader at the end of the conveyor scans the tray and determines the appropriate container. The robots utilize a vacuum gripper that picks up one tray at a time. The use of a vacuum gripper requires that the tray be sleeved and strapped so there is a flat surface on top of the tray for the suction cups to grab. These grippers of the robots transporting one tray at a time result in system throughputs of approximately, only 6 to 7 trays per minute.
Accordingly, a need in the art exists for an improved automatic container loading system configured for more efficient loading of USPS mail trays into USPS containers such as all purpose containers (APCs) and pallets.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a system and method for automatically loading containers such as USPS transport letter trays in an improved manner regarding cost, functionality, floor space and performance achieved as compared to prior art robotic technology.
It is another object of the present invention to provide an automatic container loading system utilizing in-line buffering which implements continuous flow processing of product immediately adjacent to the intended container in which the product will be packaged.
It is yet another object of the present invention to provide an automatic container loading system wherein transportation, orientation, buffering and container loading operations occur in parallel thereby maximizing throughput.
It is a further object of the present invention to provide an automatic container loading system which organizes the incoming products to build up a complete layer of products so that container loading can be done in complete layers at a time to form packages of multiple articles and thereby maximize throughput.
It is another object of the present invention to provide an automatic container loading system including a central processing unit control system providing programmability and flexibility to handle different type packages, container types and stacking patterns in the all purpose containers or pallets.
It is still a further object of the present invention to provide an automatic container loading system having the ability to handle open topped trays or sleeved trays.
It is another object of the present invention to provide an automatic container loading system having a small footprint and low profile.
It is still a further object of the present invention to provide an automatic container loading system having a modular design.
The objects of the present invention may be fulfilled by providing apparatus for automatically forming a plurality of packages of groups of articles comprising:
transport conveyor means for moving a plurality of the articles along a conveying path in a substantially continuous motion;
a plurality of buffer storage assemblies disposed in spaced positions along the conveying path, each buffer storage assembly being capable of receiving groups of articles from the transport conveyor while other articles thereon sustain substantially continuous movement;
transfer means for selectively moving selected groups of articles to selected ones of the buffer storage assemblies in response to selection control signals; and
control means for generating the selection control signals according to predetermined packaging criteria for each package of the plurality of groups of articles to be formed at each of the respective buffer storage assemblies.
In a first embodiment, the transfer means comprises elevator assemblies for lifting the groups of articles from the transport conveyor into the buffer storage assemblies. The elevator assemblies include a plurality of finger-like conveyors defining shelves for engaging the bottoms of the containers. The fingers are vertically movable in selected groups between the transport conveyor and the buffer storage assemblies. The selected groups of fingers define buffer shelves. The fingers are disposed between a plurality of spaced rollers of the transport conveyor in an initial or normal position before being actuated to the extended elevated positions where a layer of articles is formed into selected patterns. Trays for other destinations can pass freely below the elevated fingers on the transport conveyor.
In a second embodiment of the present invention the in-line buffer assemblies include buffer wing assemblies mounted on a raising/lowering mechanism adjacent to a sorting conveyor. Trays are laterally transferred from the sorting conveyor to the wing assemblies instead of storing the containers in elevated positions above the transport conveyor as in the first embodiment. The buffer wing assemblies each include a plurality of rollers journaled into appropriate frame members which are freely rotatable permitting a tray to freely roll thereon in response to lateral forces applied to the trays. The rollers are disposed orthogonally to the axis of motion of the transport conveyor. The lateral force for transferring selected trays to selected buffer zones on the rollers of the buffer wing assemblies is created by the diverting action of the sorting conveyor. This sorting conveyor is a powered roller conveyor with right angle transfer. Once a complete layer of trays is assembled on the buffer
Matecki Katherine A.
Northrop Grumman Corporation
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