Method and Apparatus for Retaining Items on Material Handling Apparatus Delivery Vehicles

A method for delivering items to a plurality of sortation locations using a plurality of vehicles displaceable along a vehicle path, comprising the steps of:

• loading an item onto a first vehicle;
• displacing a product retainer relative to a first transfer passage on the first vehicle to impede items from being displaced off the first vehicle through the first transfer passage;
• displacing the first vehicle toward a first of the sortation locations, wherein a gap is formed between the first transfer passage and the first sortation location;
• displacing the product retainer into the gap so that the product retainer operates as a bridge on which the item is displaceable;
• and
• displacing the item across the bridge and toward the first sortation location.

A delivery vehicle operable with a material handling system having a plurality of storage locations and a gate opening mechanism adjacent one of the storage locations, wherein the delivery vehicle comprises:

• a drive system for driving the vehicle to one of the destination areas;
• a motor for driving the drive system;
• a transfer mechanism for transferring items between the vehicle and the storage locations wherein the transfer mechanism comprises a surface for receiving an item to be conveyed to one of the storage locations;
• a pair of opposing walls extending upwardly relative to the surface and spaced apart from one another so that at least a portion of the surface is between the opposing walls, wherein the opposing walls are dimensioned and arranged to facilitate transfer of items off the surface at a first end of the surface and to facilitate transfer of items off the surface at a second end of the surface;
• a first gate positioned adjacent the first end of the surface and operable between an opened position and a closed position, wherein in the closed position the first gate extends across the first transfer passage and operates as a stop to impede displacement of items off the surface at the first end and in the opened position the first gate allows displacement of items off the surface at the first end;
• a first actuator connected with the first gate and operable between a first position in which the first gate is in the closed position and a second position in which the first gate is in the opened position wherein the first actuator is configured to cooperate with the gate opening mechanism so that displacement of the delivery vehicle relative to the gate opening mechanism is operable to displace the first actuator into the second position.

A material handling system, comprising

• a plurality of storage locations;
• a first actuator adjacent one of the storage locations;
• a plurality of delivery vehicles, wherein a first of the delivery vehicles comprises:
• a motor for driving the delivery first vehicle;
• a transfer mechanism for transferring items between the first vehicle and the storage locations wherein the transfer mechanism comprises a surface for receiving an item to be conveyed to one of the storage locations;
• a pair of opposing walls extending upwardly relative to the surface and spaced apart from one another so that at least a portion of the surface is between the opposing walls, wherein the opposing walls are dimensioned and arranged to facilitate transfer of items off the surface at a first end of the surface and to facilitate transfer of items off the surface at a second end of the surface;
• a first gate positioned adjacent the first end of the surface and operable between an opened position and a closed position, wherein in the closed position the first gate extends across the first transfer passage and operates as a stop to impede displacement of items off the surface at the first end and in the opened position the first gate allows displacement of items off the surface at the first end;
• a second actuator connected with the first gate and operable between a first position in which the first gate is in the closed position and a second position in which the first gate is in the opened position wherein the second actuator is configured to cooperate with the first actuator so that displacement of the delivery vehicle relative to the first actuator is operable to displace the second actuator into the second position.

A material handling system, comprising:

• a plurality of storage locations;
• an input station;
• a plurality of delivery mechanisms each being dimensioned and arranged to receive an item at the input station and each being movable along a path encompassing the input station and a corresponding target storage location of the plurality of storage locations;
• wherein each delivery mechanism includes
• a transfer mechanism defining a carrying surface dimensioned and arranged to receive an item to be delivered from the transfer station and to support the item to be delivered as the delivery mechanism moves along a respective path to a corresponding target storage location,
• a first wall extending along a first side of the carrying surface, and
• a second wall extending along a second side of the carrying surface and opposing the first wall so that a first transfer passage is formed proximate a first end of the support and a second transfer passage is formed proximate a second end of the support,
• a retention assistant comprising a displaceable wall dimensioned and arranged to extend transversely relative to the first and second walls, the displaceable wall being displaceable between a first position substantially orthogonal to an item support plane defined by the carrying service to thereby prevent an item to be delivered from moving into the first discharge opening and a second position permitting movement of an item to be delivered into and through the first discharge opening, wherein the displaceable wall is one of displaceable with or displaceable relative to the carrying surface;
• and
• a motor controllable to transfer the first item from the carrying surface of the transfer mechanism to the first storage location while the displaceable wall is in the second position.

A method for transporting an item upon a carrying surface of a delivery mechanism, the carrying surface defining a retention zone bounded by first and second lateral walls and first and second retention assistant walls,

• wherein the first and second walls respectively define corresponding lateral wall surfaces disposed transverse to a direction of delivery mechanism travel along a path extending from an input station to a target storage location, each of the lateral wall surfaces being oriented to impede lateral movement of an item out of the retention zone,
• wherein the first retention assistant wall is disposed transverse to the first and second lateral wall surfaces and is displaceable from a first position impeding movement of an item out of the retention zone to a second position enabling movement of an item out of the retention zone and in a first transfer direction:
• and
• wherein the second retention assistant wall is disposed transverse to the first and second lateral wall surfaces, is spaced apart from the first retention assistant wall, and is one of non-manipulable out of a position impeding movement of an item out of the retention zone or displaceable from a first position impeding movement of an item out of the retention zone to a second position enabling movement of an item out of the retention zone and in a second transfer direction opposite the first transfer direction;
• the method comprising
• at the input station, positioning an item within the retention zone and onto the carrying surface of the delivery mechanism;
• while the first and second retention assistant walls are disposed in positions which impede movement of the positioned item out of the retention zone, advancing the delivery mechanism from the input station and along the path while the positioned item is free to move upon the carrying surface and within the boundaries of the retention zone despite changes in at least one of delivery mechanism direction of travel or delivery mechanism rate of travel;
• from a position proximate a target storage location along the path, displacing the second retention assistant wall from the first position to the second position and operating a transfer mechanism of the delivery mechanism to move the item in the first transfer direction, out of the retention zone, and into the target storage location.

A material handling system, comprising:

• a plurality of storage locations;
• an input station;
• a plurality of mobile delivery mechanisms each being dimensioned and arranged to receive an item at the input station and each being movable along paths encompassing the input station and a corresponding target storage location of the plurality of storage locations;
• and
• a controller for controlling movements of the mobile delivery mechanisms along paths adjacent to the plurality of storage locations;
• wherein each delivery mechanism includes
• a transfer mechanism defining a carrying surface dimensioned and arranged to receive an item to be delivered at the station and to support the item to be delivered as the delivery mechanism moves along a respective path to a corresponding target storage location,
• a first lateral wall extending along a first side of the carrying surface, and
• a second lateral wall extending along a second side of the carrying surface and opposing the first wall so that a first transfer passage is formed proximate a first end of the support and a second transfer passage is formed proximate a second end of the support,
• a retention assistant comprising a first retention assistant wall and a second retention assistant wall,
• the first retention assistant wall being dimensioned and arranged to extend transversely relative to the first and second lateral walls and displaceable between a first position substantially closing the first transfer passage to thereby prevent an item on the carrying surface from moving into and through the first transfer passage and a second position permitting movement of an item to be delivered into and through the first discharge opening, and
• the second retention assistant wall being disposed transverse to the first and second lateral wall surfaces, spaced apart from the first retention assistant wall, and being one of non-manipulable out of a position impeding movement of an item out of the retention zone or displaceable from a first position substantially closing the second transfer passage to thereby prevent an item on the carrying surface from moving into and through the second transfer passage to a second position;
• and
• a motor controllable to transfer a first item from the carrying surface of the transfer mechanism to the first storage location while the first retention assistant wall is in the second position.