Automated case order sequencing method and system
Assignee3584925 Canada Inc. (Drl Systems)
InventorDaniel R. Lafontaine
Life of this patent
Estimating the term…
Abstract
A system and method for automatically preparing client orders in a distribution facility, where the inputs to the system are complete pallets of cases of individual products and the outputs of the system are client order pallets of mixed products. Specifically, the methods and systems are for conveying, storing, and dispensing cases using automated case order sequencing typically using non-product-dedicated and non-accumulating buffer conveyors.
Claims30
A system of non-accumulating case conveyors and guides for storing and selectively dispensing cases of products according to predetermined order sequences, the system comprising:
- a plurality of non-accumulating buffer conveyors being substantially parallel to one another for accumulating at least one case of a respective said products;
- an output sequencing transport conveyor being locally substantially perpendicular to a respective downstream end of the non-accumulating buffer conveyors for sequentially transferring cases of the products therefrom;
- for each said plurality of non-accumulating buffer conveyors, a case transfer device connecting to the downstream end of respective said non-accumulating buffer conveyor for selectively transferring a case of the products therefrom, each said case transfer device having a respective downstream end thereof connecting to the output sequencing transport conveyor for selectively transferring the corresponding case of products thereon;
- a controller unit connecting to the plurality of non-accumulating buffer conveyors, the plurality of case transfer devices and the output sequencing transport conveyor to control respective operation thereof so as to allow the forming of the predetermined order sequences of cases of products on the output sequencing transport conveyor from the cases of respective products from the plurality of the non-accumulating buffer conveyors;
- wherein each said conveyor is a powered conveyor for respective selective activation thereof by the controller unit, and each said non-accumulating buffer conveyor includes a clutch mechanism for selective activation thereof by the controller unit, each said clutch mechanism connecting to a common drive shaft controlled by the controller unit;
- and
- wherein said controller unit further stopping rotation of the common drive shaft;
- disengaging corresponding one said clutch mechanism from a currently engaged one of said plurality of buffer conveyors and corresponding said case transfer device;
- engaging corresponding one said clutch mechanism for engaging another one of said plurality of buffer conveyors with corresponding said case transfer device;
- and rotating the common drive shaft to operate said another one of said plurality of buffer conveyors with corresponding said case transfer device to transfer a case of product in or out thereof.
A method for the replenishment of a plurality of buffer conveyors with cases of one of a plurality of products, each said buffer conveyor having cases of a respective one said plurality of products thereon for a selective output of said cases onto an output device according to predetermined order sequences, the method comprising the steps of:
- a) queuing one said buffer conveyor onto a list of empty ones of said buffer conveyors available for replenishment by cases of one of the plurality of products after said one said buffer conveyor dispenses a last one of the cases located thereon;
- b) determining a next one of said plurality of products required to be stored on at least one said empty buffer conveyor from the list, said next one of said plurality of products being determined based on predetermined batches of cases;
- c) adding a replenishment quantity of cases of said next one of said products;
- d) selecting said at least one said empty buffer conveyor from the list for replenishment thereof with cases of said next one of said plurality of products.
A method for storing cases of products on a plurality of powered non-accumulating buffer conveyors being substantially parallel to one another, and selectively dispensing the cases of products according to predetermined order sequences, each said buffer conveyor accumulating at least one case of a respective said products, and wherein at least two of said buffer conveyors connect to a common drive shaft selectively engaging said at least one buffer conveyor located along a shaft axis, said method, for storing or selectively dispensing the cases of products, comprising the steps of:
- 1) stopping rotation of the common drive shaft;
- 2) disengaging a clutch from a currently engaged one of said at least two buffer conveyors;
- 3) engaging a clutch for engaging another one of said at least two buffer conveyors;
- and
- 4) rotating the common drive shaft to operate another one of said at least two buffer conveyors to transfer a case of product in or out thereof.
A method for storing cases of products on a plurality of powered non-accumulating buffer conveyors being substantially parallel to one another, and selectively dispensing the cases of products onto a powered output sequencing transport conveyor according to predetermined order sequences, each said buffer conveyor accumulating at least one case of a respective said products, the output sequencing transport conveyor being locally substantially perpendicular to a respective downstream end of the at least one non-accumulating buffer conveyors for sequential transferring of cases of the products therefrom using, for each said plurality of buffer conveyors, a powered case transfer device connecting to the downstream end of respective said at least one non-accumulating buffer conveyor for selectively transferring a case of the products therefrom, each said case transfer device having a respective downstream end thereof connecting to the output sequencing transport conveyor for selectively transferring the corresponding case of products thereon, the method comprising, for dispensing each predetermined order sequence of cases of products, the steps of:
- a) for each case of the predetermined order sequence, deactivating the output sequencing transport conveyor when a pre-assigned empty location for receiving a predetermined one of the cases of product thereon is aligned with a corresponding one of the at least one non-accumulating buffer conveyor having the predetermined one of the cases of product stored thereon;
- b) activating the corresponding one of the at least one non-accumulating buffer conveyor and the corresponding case transfer device for transferring the predetermined one of the cases of product on the pre-assigned empty location of the output sequencing transport conveyor;
- c) deactivating the corresponding one of the at least one non-accumulating buffer conveyor and the corresponding case transfer device;
- d) activating the output sequencing transport conveyor until a second pre-assigned empty location for receiving a predetermined one of the cases of product thereon is aligned with a corresponding one of the at least one non-accumulating buffer conveyor having the predetermined one of the cases of product stored thereon.
Dependencies are inferred from the claim text.