US 2026/0208972 A1 · MATERIAL HANDLING APPARATUS AND METHOD FOR SPACE EFFICIENT, HIGH SPEED TRANSPORT AND SORTATION OF ITEMS HAVING DISPARATE ITEM HANDLING CHARACTERISTICS

Abstract

A method and apparatus are provided for automating the conveyance and transfer of items and for accommodating sortation of at least some of those items into containers to form groups, the manner in which items are transferred varying according to one or more item handling attributes (e.g., size, weight, shape, fragility, resistance to impact damage, intended destination, etc) of each item. Sortable items are transferred at an induct zone onto a first type of carrier which is dimensioned and arranged to move continuously along an elevated, looped conveyance path that overlies a plurality of movable item delivery platforms. Items are dropped onto the delivery platforms as the carriers pass overhead, the timing, direction and rate of platform movements as the items descent being determined by at least one of the item handling attributes. Each platform is configured to move along a respective vertical path sufficiently close to a corresponding group of vertically spaced destination containers that a transfer mechanism of the vehicle is operable to transfer one or more items into an adjacent destination container. In an embodiment, items too large or too heavy to be dropped or transferred into one of the containers are transferred to an alternative type of carrier and, at a discharge zone along the looped conveyance path, such items are diverted away from the looped conveyance path and onto a chute, conveyor other discharge assistant by operation of a discharge mechanism.

Claims39

Dependent claims

A method for transferring items to destinations, comprising:

advancing a plurality of carriers along an elevated and looped conveyance path, the conveyance path encompassing an item induction zone and overlying a plurality of movable platforms wherein each movable platform is configured to move vertically along a respective bidirectional path adjacent to a corresponding plurality of destination areas;
at the item induction zone, transferring items of the plurality of items to carriers of the plurality of advancing carriers without interrupting carrier movement;
determining that a first item is to be delivered to a destination of a first group of destinations accessible to a first movable platform;
dropping the first item, from a carrier of the plurality of advancing carriers, so that the first item descends along a trajectory toward a support surface of the first movable platform, wherein the first item descends at a first rate of acceleration.

1 more element

A method for sorting and/or transporting items based on at least one varying item handling attribute, comprising:

advancing a plurality of carriers of multiple types along an elevated conveyance path,
wherein carriers of a first carrier type are respectively configured to transport and discharge items characterized by at least one item handling attribute of a first group of item handling attributes,
wherein carriers of a second carrier type are respectively configured to transport and discharge items characterized by at least one item handling attribute of a second group of item handling attributes,
wherein the conveyance path encompasses at least one induction zone, and
wherein at least a portion of the conveyance path overlies a plurality of item delivery platforms respectively movable vertically along one or more groups of item-receiving containers;
at the at least one induction zone, transferring items having an item handling attribute belonging to the first group to carriers of the first type;
transferring items having an item handling attribute belonging to the second group to carriers of the second type;
actuating one or more discharge mechanisms of carriers of the first type, at respective discharge locations above corresponding movable platforms, to drop one or more items onto each of the corresponding movable platforms;
and
operating a transfer mechanism of the corresponding movable platforms, each from a position adjacent a container of the one or more groups of item-receiving containers, to accumulate an associated group of one or more items in the containers.

7 more elements

A material handling system for sorting a plurality of items into groups of one or more items, comprising:

a frame defining respective interior passages and corresponding entry openings dimensioned and arranged to allow items dropped, from above an entry opening, to enter into and descend within a corresponding interior passage;
at least one induct zone for supplying items to be conveyed and/or sorted to one or more groups of item-receiving containers arranged along the interior passages;
a plurality of movable platforms, each movable platform being dimensioned and arranged for vertical movement within an interior passage defined by the frame and defining a support surface dimensioned and arranged to receive and support one or more items of the plurality of items;
and
a plurality of carriers configured for continuous movement along an elevated conveyance path,
wherein the plurality of carriers includes carriers of a first type respectively configured to transport and discharge items characterized by at least one item handling attribute of a first group of item handling attributes,
wherein the plurality of carriers includes carriers of a second type respectively configured to transfer and discharge items characterized by at least one item handling attribute of a second group of item handling attributes,
wherein the conveyance path of the carriers encompasses the at least one induction zone, and
wherein at least a portion of the conveyance path overlies the movable platforms, whereby items dropped from a carrier of the first type descend along a trajectory and onto one of the movable platforms.

6 more elements

A material handling system for sorting a plurality of items into respective groups of one or more items, comprising:

a plurality of groups of destination areas, each respective group of destination areas being arranged in a corresponding column;
a controller;
a plurality of movable platforms, each movable platform having a transfer mechanism, defining an upwardly facing support surface, and being configured
to accelerate downwardly beneath a downwardly accelerating item, during a first phase of movement, at a rate greater than zero but low enough to allow the downwardly accelerating item to approach the support surface;
to decelerate downwardly, during a second phase of movement following the first phase, wherein the controller is configured to control at least one of acceleration or deceleration during the first and second phases of movement to allow the downwardly accelerating item to contact and be supported by the support surface;
and
to stop, with a supported item, at a terminal position proximate a corresponding target destination area of a group of destination areas;
wherein the transfer mechanism of each movable platform is operable to transfer a supported item to the corresponding target destination area.

5 more elements

Dependencies are inferred from the claim text.

Material handling apparatus and method for space efficient, high speed transport and sortation of items having disparate item handling characteristics

Life of this patent

Material handling apparatus and method for space efficient, high speed transport and sortation of items having disparate item handling characteristics

Life of this patent

Abstract

Claims39