Automated tray handling systems and methods

An apparatus, comprising:

• a robotic system;
• and
• an end effector coupled to the robotic system, the end effector comprising a grasping element configured to engage and lift a tray via an underside of a flange of the tray;
• wherein the robotic system is configured to lift and move the tray from a tray position of a sortation system to a downstream station;
• wherein the robotic system is further configured to lift and move a second tray from an upstream station to the tray position of the sortation system.

An apparatus, comprising:

• a robotic system;
• and
• an end effector coupled to the robotic system, the end effector comprising:
• a grasping element configured to engage and lift a tray via an underside of a flange of the tray, wherein the grasping element is shaped to fit within and engage with the underside of the flange of the tray;
• a locking plate configured to engage with an upper side of the flange of the tray;
• and
• an actuator configured to move the locking plate between an open position and a closed position in which the locking plate locks the flange of the tray relative to the grasping element;
• wherein the robotic system is configured to lift and move the tray from a tray position of a sortation system to a downstream station.

An apparatus, comprising:

• a robotic system;
• and
• an end effector coupled to the robotic system, the end effector comprising:
• a grasping element configured to engage and lift a tray via an underside of a flange of the tray, wherein the grasping element comprises a lifting finger shaped to fit within and engage with the underside of the flange of the tray;
• an actuator configured to move the lifting finger between a lowered position and a raised position in which the lifting finger engages and lifts the flange of the tray;
• and
• a linear actuator configured to translate the lifting finger such that the tray is pulled or pushed relative to an interior of the end effector;
• wherein the robotic system is configured to lift and move the tray from a tray position of a sortation system to a downstream station.

A method, comprising:

• instructing, by a control system, a robotic system to move an end effector toward a tray at a tray position of a sortation system, wherein the end effector comprises a first grasping element and a second grasping element;
• instructing, by the control system, the first grasping element of the end effector to engage and lift the tray at the tray position of the sortation system via an underside of a flange of the tray;
• and
• instructing, by the control system, the robotic system to remove the tray from the tray position of the sortation system and move the tray to a downstream station using at least the first grasping element;
• wherein the first grasping element and the second grasping element are offset from each other around an axis of rotation of the end effector.

A method, comprising:

• instructing, by a control system, a robotic system to move an end effector toward a tray at a tray position of a sortation system;
• instructing, by the control system, a first grasping element of the end effector to engage and lift the tray at the tray position of the sortation system via an underside of a flange of the tray;
• and
• instructing, by the control system, the robotic system to remove the tray from the tray position of the sortation system and move the tray to a downstream station using at least the first grasping element;
• wherein the end effector comprises a passthrough end effector such that the tray is moved through an interior of the end effector.

A system, comprising:

• a sortation system comprising an array of trays associated with respective tray positions;
• a robotic system;
• and
• a passthrough end effector coupled to the robotic system and configured to manipulate individual trays of the array of trays;
• wherein the passthrough end effector is configured to move individual trays through an interior of the passthrough end effector between respective tray positions of the sortation system and at least one of an upstream station or a downstream station.