Classifying – separating – and assorting solids – Sorting special items – and certain methods and apparatus for... – Traveling items shifted to form line – or into end or edge...
Reexamination Certificate
2000-02-16
2003-02-18
Nguyen, Tuan N. (Department: 3653)
Classifying, separating, and assorting solids
Sorting special items, and certain methods and apparatus for...
Traveling items shifted to form line, or into end or edge...
C209S583000, C209S644000, C209S900000, C209S932000
Reexamination Certificate
active
06520342
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a product handling apparatus and, more particularly, to a product handling apparatus for labeling and sorting products.
Products, such as, for example, compact discs (CDs), cassette tapes, video cassettes and digital video discs (DVDs), are stored in vast quantities in large warehouses. The products are typically stored in warehouse locations by product type and product title.
A customer generally orders a certain number of product types and product titles. To fill a customer order, the product distributor must gather or pick the specific number of ordered product types and product titles from the various warehouse locations. If the products are not sorted during picking, the distributor will sort the products into the different customer orders and package the products for shipment to each customer. In addition, some distributors print and apply customer specific labels to the products.
In some cases, the order filling process is completed manually. The distributor manually gathers and sorts the products into different customer orders, prints and manually applies labels to the products, as necessary, and then packages the products in a customer order for shipment to that customer.
In other cases, a product handling apparatus is used to complete some steps in the order filling process. For example, after the products in a customer order are manually gathered and sorted into the customer order, a labeling apparatus is used to print and apply a label to each product and to restack the products in the same customer order.
In other product handling apparatus, the products of several customer orders may be sorted and labeled at one time. In such apparatus, the products are conveyed in a flat orientation on a conveyor belt to maintain the stability of the products on the conveyor belt during transport, labeling and sorting. To sort the products, a mechanical diverter mechanism enters the product stream and engages designated products to divert the products into an associated customer order product collection location. The mechanical diverter mechanism must then be moved out of the product stream to allow other non-designated products to pass the associated product collection location so that those products can be diverted into subsequent customer order product collection locations.
In these product handling apparatus, when products are diverted into a customer order product collection location, the products are typically jumbled and disorganized. An operator collects the products from the location and organizes and arranges the products for packaging and shipment to the customer.
SUMMARY OF THE INVENTION
One problem with the above-described manual order filling process is that this manual process is very time-consuming and labor-intensive.
One problem with the above-described product labeling apparatus is that, while the labeling apparatus improves the efficiency of one step of the order filling process, the remainder of the process must still be completed manually. Specifically, the products in a given customer order must be manually gathered and sorted into the desired customer order before being placed in the product handling apparatus for labeling.
Another problem with some product handling apparatus is that the apparatus can only handle products of one product configuration (products having, for example, the same width, height, length, weight and/or center of gravity) at any one time. To handle products of different product configurations, the apparatus must be stopped and adjusted, if such adjustment is possible, to accommodate the different product configuration, slowing the order filling process.
Yet another problem with some product handling apparatus is that the label is not firmly affixed to the product and may be removed during conveying or by the diverter mechanism when the product is diverted from the conveyor assembly. The product must then be re-labeled, either manually or by being passed through the apparatus a second time.
A further problem with some product handling apparatus is that, if the products are not conveyed in a flat orientation, products can be knocked off of the conveyor belt when a force, such as the force required to apply a label, is applied to the product, and the process will be disrupted. To reduce the likelihood of such an occurrence, the products are thus conveyed in a flat and more stable orientation on the conveyor belt.
Another problem with some product handling apparatus is that, because the products are conveyed in the flat, stable orientation, a significant diverting force must be applied to each product to divert the product from its stable position on the conveyor belt. Such a significant diverting force can normally only be achieved by using a mechanical diverter mechanism which physically engages each product to move the product from the conveyor belt.
One problem with the above-described product handling apparatus including a mechanical diverter mechanism is that, to accommodate the continuous movement of the mechanical diverter mechanism into and out of the product stream, the products can only be conveyed at a relatively slow rate to ensure proper sorting of the products and proper operation of the apparatus. If the products are conveyed at too fast a rate, the mechanical diverter mechanism may disrupt the product stream by engaging products which are not to be diverted to the associated customer order product collection location. As a result, the apparatus can become jammed, stopping the order filling process and requiring operator attention, and products can be damaged.
Another problem with some product handling apparatus is that the diverter mechanism is not controlled to vary the diverting force applied to divert different products. As a result, a product having a different product configuration may not be effectively diverted by the diverter mechanism, disrupting the sorting process.
Yet another problem with some product handling apparatus is that, in the customer order product collection locations, the products are typically jumbled and disorganized. An operator collects the products from the location and must organize and properly arrange the products for packaging and shipment to the customer.
A further problem with some product handling apparatus is that, because of the force applied by the mechanical diverting mechanisms, among other factors, it is difficult to orient the products to be stacked in an organized manner. Further, it is difficult to control movement of the stacked products to provide a consistent stacking surface for subsequent products. Mechanical movement of a product stack to accommodate the following products is awkward to control, and such control becomes increasingly awkward as additional products are loaded onto the product stack. Inconsistent and jerky movement of the product stack results, causing disruption of such a stacking process.
Another problem with some product handling apparatus is that the conveyor assembly includes several independently driven conveyor belts. To effectively transfer products from one conveyor belt to the next, the individual conveyor belts must be synchronized, or the conveying process may be disrupted. Such synchronization requires additional components for sensing and coordinating the movement of the separate and independent conveyor belts.
Yet another problem with some product handling apparatus is that the components of the product handling apparatus are arranged in a relatively straight line along the conveyor assembly. Limited work area space thus limits the number of components, such as customer order product collection locations, which can be included in the product handling apparatus. This limits the number of customer orders which may be processed by the apparatus at any one time. Also, operators of the product handling apparatus must walk the full length of the apparatus, or additional operators are required, to service the widely-spaced components of the apparatus.
The present invention provides a pro
Dumke Robert D.
Gross Mike
Horn Edward R.
Kohlman Gerald A.
Sherbinow Todd
Aladdin Engineering & Manufacturing, Inc.
Michael & Best & Friedrich LLP
Nguyen Tuan N.
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