US 5,794,789 A · Semi-automated integrated sort system

Abstract

Inter-related devices and methods to increase sort productivity, provide for the ready integration of shipment data into a central computer system, permit centralized management and control over multiple autonomous sort operations, and integrate materials handling of the sorted shipments into the sort process. The devices and methods provide the foundation for an integrated shipment and information processing system without the complexity of automated equipment or the limitations of manual operations. The semi-automated integrated sort system has an array of chutes that flow shipments into containers or bins. The entrance to each chute is blocked by a computer-controlled gate. Detectors are placed in the chutes to detect shipments and monitor container/bin status. The chute gates, sensors, and other sort-related apparatus are connected to a computer. Automated or semi-automated data entry equipment connected to the computer provides the necessary data input. If centralized data collection or shipment management is required, the computer is connected to a central computer or computer network.

Claims49

Dependent claims

A package sort system comprising:

a sorter input work station from which packages in a package stream are supplied to a sorter person;
a plurality of manual ports adjacent the sorter input work station for the sorter person to manually insert packages from the sorter input work station for further processing;
a plurality of gates, each associated with at least a corresponding one or more of the manual ports, the gates individually movable between a closed position blocking access to corresponding manual ports and an open position allowing access to corresponding manual ports;
and
a computer holding destination information relative to intended destinations of packages in the package stream at the sorter input work station, the computer operably connected to the plurality of gates for allowing access to a particular manual port based on the destination information for a particular package being manually sorted by the sorter person at a given time such that the sorter person may manually insert that package in particular manual port.

2 more elements

A package sort system comprising:

a sorter input work station from which packages in a package stream are supplied to a sorter person;
a plurality of manual ports adjacent the sorter input work station for the sorter person to manually insert packages from the sorter input work station for further processing;
a plurality of visual indicators, each associated with at least a corresponding one of the manual ports, the visual indicators indicating to the sorter person which of plurality of manual ports a package should be inserted in;
a plurality of port sensors operable to sense which of the plurality of manual ports a package is inserted into;
and
a computer holding destination information relative to intended destinations of packages in the package stream at the sorter input work station, the computer operably connected to the plurality of port sensors such that the computer receives a signal when a package is misplaced into an incorrect port;
and
a downstream location downstream from the plurality of ports such that packages inserted into the plurality of ports proceed to the downstream location;
and
wherein the computer is operable to track the misplaced package until it reaches the downstream location such that the misplacement of the misplaced package can be corrected at the downstream location.

7 more elements

A package sort system comprising:

a sorter input work station from which packages in a package stream are supplied to a sorter person;
a plurality of manual ports adjacent the sorter input work station for the sorter to manually insert packages from the sorter input work station for further processing;
a plurality of indicators, each associated with at least a corresponding one or more of the manual ports, the indicators indicating to the sorter person which of the manual ports packages should be inserted into;
a computer holding destination information relative to intended destinations of packages in the package stream at the sorter input work station, the computer operably connected to the plurality of indicators for controlling them based on the destination information for a particular package being manually sorted by the sorter person at a given time such that the sorter person manually inserts that package in a particular manual port;
a plurality of passageways, each having a corresponding outlet and each passageway corresponding to a corresponding one of the plurality of manual ports and communicating therewith such that a package inserted into a manual port proceeds in the corresponding passageway to the corresponding outlet;
a plurality of at least partially confined holding zones at the outlets of the passageways, there being a distinct holding zone at each outlet;
and
wherein the holding zones are movable relative to the outlets such that an empty holding zone can be replaced for a full holding zone without moving the corresponding outlet and the corresponding passageway.

5 more elements

A package sort system comprising:

a computer holding destination information relative to intended destinations of packages in the package stream which are to be sorted;
an induction work station into which packages of the package stream go in an order, the computer storing information indicating the order of the packages going into the induction work station;
a sorter input work station operably connected to the induction work station such that packages from the induction work station proceed in order to the sorter input work station and from which packages in the package stream are supplied to a sorter person for sorting;
a plurality of manual ports adjacent the sorter input work station for the sorter person to insert packages from the sorter input work station for further processing;
and
a sort sensor at the sorter input work station and operably connected to provide a signal to the computer when a particular package is ready to be sorted;
and
wherein the computer is operable to direct sorting of the particular package responsive to the destination location of the package as determined from the order of packages stored by the computer.

5 more elements

A method of sorting, with the aid of a sort assisting system, said sort assisting system having:

a plurality of manual ports;
a plurality of chutes, conveyers, or other material handling devices;
input means for receiving information relative to the intended destination of an item;
directing means to alert the sort person of the appropriate manual port;
and
a data storage system to monitor and record system operating data;
said method comprising:
a. causing the item data to be input or associated with the item;
b. placing said particular item in one of said manual ports as directed by the system based on the item data;
and
wherein the sort assisting system also comprises a plurality of sensors able to detect when an item is placed in the correct (or incorrect) manual port, and wherein this data is used to record the human sort operators' overall productivity and accuracy;
and wherein the sort assisting system also comprises an interface with a separate computer system, and wherein, in the event of a mis-sort, the sort assisting system will alert the separate computer system, such that the separate computer system can direct someone to correct the mis-sort at a downstream location;
and wherein the sort assisting system also comprises an interface with a separate computer system, and wherein, the sort assisting system forwards the item information to the separate computer system, such that the data may be used for other purposes not related to sorting the package, such as billing;
and wherein the sort assisting system also receives information from the central computer system, such that the central computer system can instruct the sort operator to provide an individual item with special processing, such as in-transit forwarding, that could not be inferred from the item's own data alone;
and wherein the sort assisting system also comprises one or more holding bins equipped with directing lights and sensors, and wherein, if the item cannot be efficiently processed at that time (such as if the destination container is currently full or being replaced or if the system requires more time to determine the appropriate destination), the system will direct the operate to insert the item into the holding bin, and will stop directing the operator to do so when the system detects that the operator has inserted a package, at a later time, when the system is able to efficiently process the item in the holding bin, the system will then direct the operator to withdraw the item from the holding bin, and will then use the information associated with that item-even if data for other items has been entered in the intervening time-to direct the processing of that item;
wherein the sort assisting system also functions as an item induction station, and also comprises a computer printer and one or more data input means include both automated and non-automated/semi-automated data entry;
and the method comprising:
(a) entering item data using automated data entry
(b) reentering or using a back-up data entry method if the automated data entry is unsuccessful
(c) applying machine readable item data to the item if the item lacks such data
(d) sorting the item as described above in the first-mentioned a and b.

18 more elements

Dependencies are inferred from the claim text.

Semi-automated integrated sort system

Life of this patent

Semi-automated integrated sort system

Life of this patent

Abstract

Claims49