Method and apparatus for sorting randomly positioned garments minimizing serting conveyor movement

A method of sorting items in a preselected order each having an identifying marking affixed thereto, and arranged in an unordered sequence prior to sorting, the method comprising:

• (a) sequentially identifying each item in the unordered sequence from the identifying marking and outputting an identification signal with response thereto;
• (b) sequentially arranging each item in the identified sequence thereof on a sorting conveyor having a multiplicity of movable carriers each for receiving a respective item thereon;
• (c) rearranging the identification signals such that each of the identification signals is positioned between other identification signals in the preselected order;
• (d) assigning a plurality of arranged identification signals to each one of the corresponding plurality of pick-off mechanisms positioned along the sorting conveyor;
• (e) positioning the sorting conveyor such that a selected carrier on the sorting conveyor is at a selected position;
• (f) calculating bidirectional movement of the sorting conveyor to each of a plurality of potential first positions such that in each of the potential first positions an item representative of a first identification signal in each of the plurality of arranged identification signals will be positioned for pick-off by the respective pick-off mechanism thereof;
• (g) selecting one of the calculated movements which is preferred over the other calculated movements to efficiently unload the items from the sorting conveyor;
• (h) driving the sorting conveyor a fixed distance in a selected direction in response to the selected calculated movement;
• and
• (i) activating the respective pick-off mechanism to remove the item positioned for pick-off from the sorting conveyor.

Apparatus for sorting and arranging garments in a preselected order each having an identifying tag secured thereto and suspended from a garment hanger, the garments being arranged in an unordered sequence prior to sorting, the apparatus comprising:

• identifying means for sequentially generating identification signals in response to each identifying tag;
• sorting conveyor means having movable carriers thereon each for sequentially receiving a respective identified garment;
• a plurality of unloading conveyor means each for receiving a plurality of garments in a preselected order;
• a plurality of garment pick-off means each positioned along the sorting conveyor means for removing a garment from the sorting conveyor means and positioning each removed garment sequentially on a respective one of the unloading conveyor means;
• computer means for sequentially receiving the identification signals, rearranging the identification signals in a preselected order, assigning a plurality of arranged identification signals to each one of the corresponding plurality of garment pick-off means, calculating bidirectional movement of the sorting conveyor means from a current position to each of the plurality of potential pick-off positions such that the garment representative of the next identification signal in each of a plurality of arranged identification signals is positioned for removal from the sorting conveyor means by the respective garment pick-off means thereof, and selecting one of the calculated movements to minimize movement of the sorting conveyor means;
• and
• drive means responsive to the computer means for causing bidirectional movement of the conveyor means in response to the selected calculated movement.