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Title:
SYSTEM AND METHOD FOR AUTOMATICALLY SORTING ITEMS IN A PLURALITY OF BINS USING ROBOTS
Document Type and Number:
WIPO Patent Application WO/2020/208658
Kind Code:
A2
Abstract:
A system and method for sorting delivery items in a plurality of bins using a robotic system 203 are provided. The robotic system 203 includes (i) a barcode scanner 206 that scans a barcode of a delivery item that is received from a feeding unit 202, (ii) a control unit 204 that (a) determines a destination bin 208 on which the delivery item to be sorted by processing the scanned barcode and (b) determines a destination path for the robotic system 203 to reach the destination bin 208, (iii) an obstacle detection sensor 210 and a small obstacle detection sensor 212 that detect if any obstacle in the destination path, an inbuilt lifting unit 216 that place the delivery item in the destination bin 208 and a floor barcode unit 218 that localizes the robotic system in the floor for sorting the delivery item on the destination bin.

Inventors:
MEMON MOHAMMADSHAHID ABDULSHAKUR (IN)
GHADGE PRAMOD VASANT (IN)
Application Number:
IN2020/050347
Publication Date:
October 15, 2020
Filing Date:
April 12, 2020
Export Citation:
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Assignee:
UNBOXROBOTICS LABS PRIVATE LTD (IN)
International Classes:
B07C5/36; B07C3/10
Attorney, Agent or Firm:
BALA, Arjun Karthik (IN)
Download PDF:
Claims:
CLAIMS We claim:

1. A robotic system (203) for automatically sorting delivery items in a plurality of bins, wherein the robotic system (203) is connected to a feeding unit (202) to receive the delivery items for sorting, the robotic system (203) comprising:

a barcode scanner (206) that is configured to scan a barcode printed on a delivery item when the robotic system (203) is in operation;

a control unit (204) comprises a processor that

receives the scanned barcode from the barcode scanner (206) and processes the scanned barcode to determine a destination bin (208) on which the delivery item is to be sorted in a sorting area, characterized in that the sorting area comprises (i) a plurality of feeder area (402A-N) where the delivery items arrive for feeding to the robotic system (203), (ii) a plurality of robot walking area (412) where the robotic system (203) moves on the way to a sorting location, (iii) a plurality of rack layout area that comprises a plurality of racks in at least one of straight-line shape (424A-N) or U shape (422A-N), wherein the plurality of racks comprises a plurality of destination bin (208A-N) that are arranged vertically one on the top of another in each of the plurality of racks, wherein the plurality of robot walking area (412) is coupled with a sorting side of the plurality of rack layout area, and (iv) a plurality of bagging area (418A-N), wherein the plurality of bagging area (418A-N) is coupled with a bagging side of the plurality of rack layout area where sorted delivery items are bagged for distribution, in order to reduce the transition time, congestion and bagging operation time; and

determines a destination path for the robotic system (203) to reach the destination bin (208) for sorting the delivery item;

an obstacle detection sensor (210) and a small obstacle detection sensor (212) that detect obstacles in the destination path of the robotic system (203), wherein the obstacle detection sensor (210) and the small obstacle detection sensor (212) are communicatively connected to the control unit (204), wherein when the obstacle detection sensor (210) and the small obstacle detection sensor (212) detect an obstacle in the destination path of the robotic system (203), an alternative path for the robotic system (203) is determined using an obstacle avoidance system (214) to enable the robotic system (203) to reach the destination bin (208);

an inbuilt lifting unit (216) that is configured to simultaneously lift the delivery item to a height of the destination bin (208) to place the delivery item on the destination bin (208) when the robotic system (203) is moving towards the destination bin (208), thereby reducing an operation time of the robotic system (203); and

a floor barcode scanning unit (218) that reads a barcode on a floor of the sorting area using a bottom camera module (220) to localize the robotic system (203) in the floor that is positioned with respective destination bin (208) for sorting the delivery item on the respective destination bin (208).

2. The robotic sorting system (203) as claimed in claim 1, wherein the sorting area comprises a plurality of crossing area (414A-N) that enables the plurality of robot walking area (412) to decouple from a plurality of baggers and a trolleys passage area connecting the plurality of bagging area (418A-N) to enable unhindered passage of the robotic system (203), wherein the decoupling is achieved by vertically differentiating the plurality of robot walking area (412) from the plurality of baggers and trolleys passage area at the plurality of crossing area (414A-N).

3. The robotic sorting system (203) as claimed in claim 1, wherein the robotic system (203) is electrically connected to a charging station (222) to charge the robotic system (203) based on a calculated battery state.

4. The robotic system (203) as claimed in claim 1, wherein the control unit (204) further configured to (i) calculate a battery state of the robotic system (203) when in operation (ii) determine a charging station (222) in the sorting area if the battery state of the robotic system (203) is lower than a threshold value (iii) determine a destination path for the robotic system (203) to reach the charging station (222) and (iv) enable the robotic system (203) for docking with the charging station (222) for charging, wherein the control unit (204) determines the destination path for the destination bin (208) or the feeding unit (202) if the battery state of the robotic system (203) is higher than the threshold value.

5. The robotic system (203) as claimed in claim 1, wherein the inbuilt lifting unit (216) comprises a telescopic lifting unit or a scissor lifting unit or a hydraulic lifting unit or a pneumatic lifting unit.

6. The robotic system (203) as claimed in claim 1, wherein the robotic system (203) comprises an Automated Guided Vehicle (AGV) or an Unmanned Ground Vehicle (UGV).

7. The robotic system (203) as claimed in claim 1, wherein the robotic system (203) determines the destination path to (i) reach the destination bin (208) when the scanned barcode of the delivery item is valid or (ii) shift the delivery item to a rejection bin upon invalidation of the scanned barcode.

8. The robotic system (203) as claimed in claim 1, wherein, when in operation, when the robotic system (203) reaches a feeding position (406) in the plurality of feeder area (402), the feeding unit (202) feeds the delivery item using a manual or an automated process, wherein the feeding unit (202) comprises a weight scale to measure a weight of the delivery item to be sorted.

9. The sorting robotic system (203) as claimed in claim 1, wherein the plurality of bagging area (418A-N) is decoupled from the robotic system (203) for ensuring safety.

10. The robotic system (203) as claimed in claim 1, wherein the robotic system (203) comprises a delivery system, wherein the delivery system comprises one or more of (i) a tilting plate (502), (ii) a conveyor, (iii), a push system, (iv) a sliding system, (v) a passive delivery system or (vi) a tilted mechanism on which the delivery item is placed to shift the delivery item to the destination bin (208).

11. The robotic system (203) as claimed in claim 1, wherein the robotic system (203) comprises (i) two or more power wheels (514) which includes a motor to lead the transmission of the robotic system (203).

12. A method for automatically sorting a delivery item in a plurality of bins using a robotic system (203), the method comprising:

receiving, using the robotic system (203), a delivery item from a feeding unit (202) in a sorting area, wherein the feeding unit (202) feeds the delivery item to the robotic system (203) using a manual or an automated process:

scanning, using a barcode scanner (206), a barcode of the delivery item to be sorted when the robotic system (203) is in operation;

receiving, using a control unit (204) of the robotic system (203), the scanned barcode from the barcode scanner (206) and processing the scanned barcode to determine a destination bin (208) on which the delivery item is to be sorted in a sorting area, characterized in that

the sorting area comprises (i) a plurality of feeder area (402A-N) where the delivery items arrive for feeding to the robotic system (203), (ii) a plurality of robot walking area (412) where the robotic system (203) moves on the way to a sorting location, (iii) a plurality of rack layout area that comprises a plurality of racks in at least one of straight-line shape (424A-N) or U shape (422A-N), wherein the plurality of racks comprises a plurality of destination bin (208A-N) that are arranged vertically one on the top of another in each of the plurality of racks, wherein the plurality of robot walking area (412) is coupled with a sorting side of the plurality of rack layout area, and (iv) a plurality of bagging area (418A-N), wherein the plurality of bagging area (418A-N) is coupled with a bagging side of the plurality of rack layout area where sorted delivery items are bagged for distribution, in order to reduce the transition time, congestion and bagging operation time;

automatically determining, using the control unit (204) of the robotic system (203), a destination path for the robotic system (203) to reach the destination bin (208) in the sorting area; automatically determining, using an obstacle detection sensor (210) and a small obstacle detection sensor (212), an obstacle on the destination path of the robotic system (203), wherein the obstacle detection sensor (210) and the small detection sensor (212) are communicatively connected to the control unit (204);

automatically determining, using an obstacle avoidance system (214), an alternative path for the robotic system (203) to enable the robotic system (203) to reach the destination bin (208) when the obstacle detection sensor (210) and the small obstacle detection sensor (212) detect the obstacle in the destination path of the robotic system (203);

identifying in real-time, using a bottom camera module (220), a location of the robotic system (203) in the sorting area, wherein the bottom camera module (220) reads a barcode on a floor of the sorting area to localize the robotic system (203) to reach the respective destination bin (208);

simultaneously lifting, using an inbuild lifting unit (216), the delivery item to a height of the destination bin (208) to place the delivery item on the destination bin (208) when the robotic system (203) is moving towards the destination bin (208), thereby reducing operation time of the robotic system (203), wherein the inbuilt lifting unit (216) comprises a telescopic lifting unit or a scissor lifting unit or a hydraulic lifting unit or a pneumatic lifting unit, wherein the robotic system (203) comprises a delivery system that comprises one or more of (i) a tilting plate (502), (ii) a conveyor, (iii), a push system, (iv) a sliding system, (v) a passive delivery system or (vi) a tilted mechanism on which the delivery item is placed to shift the delivery item to the destination bin (208); and

verifying, using the robotic system (203), the destination bin (208) and if the destination either the feeding unit or a charging station based on the barcode on the floor, wherein the robotic system keeps moving until it reaches the valid destination bin (208).

Description:
SYSTEM AND METHOD FOR AUTOMATICALLY SORTING ITEMS IN A PLURALITY

OF BINS USING ROBOTS BACKGROUND

Technical Field

[0001] The embodiments herein generally relate to warehouse management, and more particularly, to a system and method for automatically sorting items in a plurality of destination bins using robots, for distribution.

Description of the Related Art

[0002] In general, order fulfillment is a complete process from point of sale inquiry to delivery of a product to a customer. An order fulfillment center includes a warehouse with a storage area and a packaging area. Nowadays, the internet makes it simple to order items or goods online. This, in turn, increases the volume of delivery items and packages for sorting and distribution. Generally, a sorting process is performed to categorize the delivery items or packages comprising the ordered items based on a destination for distribution. The items should reach the customers in a fast manner with accuracy to satisfy them. Hence, an effective solution is needed for sorting and delivering the ordered items to customers on time from warehouses.

[0003] In the conventional approach, the sorting and delivery process of ordered items or delivery items are performed by manual operation or by fixed automated systems that are difficult to scale up and require large infrastructure, space and increased installation time. In manual operation, the shortage of human labor for sorting during peak seasons is a major problem. This may lead to limited operation and results in customer dissatisfaction. Further, in the manual operation, there may be a chance of increasing the processing time, errors, mis sorting and shipment delay.

[0004] Automation helps to rectify the problems of manual operation in sorting and delivering the items to customers. In recent years, robotics technology has made a large impact on the world of e-commerce areas like logistics, distribution centers, and warehouses. The customers also get faster service and higher quality with this technology.

[0005] Existing automated approaches perform sorting and delivering the items using robots. However, these approaches are not effective with increasing sorting time and robot deficiency such as inability in determining obstacles on a path or alternate shortest path. [0006] Accordingly, there remains a need for a system and method for sorting the items in minimum space with improved speed, flexibility, and high efficiency.

SUMMARY

[0007] In view of foregoing, an embodiment herein provides a robotic system for automatically sorting delivery items in a plurality of bins. The robotic system is connected to a feeding unit to receive the delivery items for sorting, the robotic system. The robotic system includes (i) a barcode scanner that is configured to scan a barcode printed on a delivery item when the robotic system is in operation, (ii) a control unit includes a processor that (a) receives the scanned barcode from the barcode and processes the scanned barcode to determine a destination bin on which the delivery item is to be sorted in a sorting area, and (b) determines a destination path for the robotic system to reach the destination bin for sorting the delivery item,

(iii) an obstacle detection sensor and a small obstacle detection sensor that detect obstacles in the destination path of the robotic system, wherein when the obstacle detection sensor and the small obstacle detection sensor detect an obstacle in the destination path of the robotic system, an alternative path for the robotic system is determined using an obstacle avoidance system to enable the robotic system to reach the destination bin, (iv) an inbuilt lifting unit that is configured to simultaneously lift the delivery item to a height of the destination bin to place the delivery item on the destination bin when the robotic system is moving towards the destination bin, thereby reducing an operation time of the robotic system, and (v) a floor barcode unit that reads a barcode on a floor of the sorting area using a bottom camera module to localize the robotic system in the floor the is positioned with respective destination bin for sorting the delivery item on the respective destination bin. In some embodiments, the sorting area includes one or more bins that are arranged in a rack in order to reduce the transition time, congestion and bagging operation time. In some embodiments, the obstacle detection sensor and the small obstacle detection sensor are communicatively connected to the control unit. In some embodiments, the sorting area includes (i) one or more of feeder area where the delivery items arrive for feeding to the robotic system, (ii) one or more robot walking area where the robotic system moves on the way to a sorting location, (iii) one or more rack layout area that includes one or more racks in at least one of straight-line shape or U shape, wherein the one or more racks includes one or more destination bin that are arranged vertically one on the top of another in each of the one or more racks, wherein the one or more robot walking area is coupled with a sorting side of the one or more rack layout area, and (iv) one or more bagging area, wherein the one or more bagging area is coupled with a bagging side of the one or more rack layout area where sorted delivery items are bagged for distribution, in order to reduce the transition time, congestion and bagging operation time.

[0008] In some embodiments, the sorting area includes one or more crossing area that enables the one or more robot walking area to decouple from one or more baggers and a trolleys passage area connecting the one or more bagging area to enable unhindered passage of the robotic system, wherein the decoupling is achieved by vertically differentiating the one or more robot walking area from the one or more baggers and trolleys passage area at the one or more crossing area.

[0009] In some embodiments, the robotic system electrically connected to a charging station to charge the robotic system based on a calculated battery state.

[0010] In some embodiments, the control unit further configured to (i) calculate a battery state of the robotic system when in operation (ii) determine a charging station in the sorting area if the battery state of the robotic system is lower than a threshold value (iii) determine a destination path for the robotic system to reach the charging station and (iv) enable the robotic system for docking with the charging station for charging, wherein the control unit (204) determines the destination path for the destination bin or the feeding unit if the battery state of the robotic system is higher than the threshold value.

[0011] In some embodiments, the inbuilt lifting unit includes a telescopic lifting unit or a scissor lifting unit or a hydraulic lifting unit or a pneumatic lifting unit.

[0012] In some embodiments, the robotic system includes an Automated Guided Vehicle (AGV) or an Unmanned Ground Vehicle (UGV).

[0013] In some embodiments, the robotic system determines the destination path to (i) reach the destination bin when the scanned barcode of the delivery item is valid or (ii) shift the delivery item to a rejection bin upon invalidation of the scanned barcode.

[0014] In some embodiments, the robotic system, when in operation, reaches a feeding position in a feeder area, the feeding unit in the feeder area feeds the delivery item using a manual or an automated process.

[0015] In some embodiments, the feeding unit includes a weight scale to measure a weight of the delivery item to be sorted.

[0016] In some embodiments, the bagging area that is decoupled from the robotic system for ensuring safety.

[0017] In some embodiments, the robotic system includes a delivery system. In some embodiments, the delivery system of the robotic system includes one or more of (i) a tilting plate, (ii) a conveyor, (iii), a push system, (iv) a sliding system, (v) a passive delivery system or

(vi) a tilted mechanism on which the delivery item is placed to shift the delivery item to the destination bin.

[0018] In some embodiments, the robotic system includes (i) two or more power wheels which include a motor to lead the transmission of the robotic system.

[0019] In another aspect, a method for automatically sorting a delivery item in a plurality of bins using a robotic system is provided. The method includes (i) receiving, using the robotic system, a delivery item from a feeding unit in a sorting area, (ii) scanning, using a barcode scanner, a barcode of the delivery item to be sorted when the robotic system is in operation, (iii) receiving, using a control unit of the robotic system, the scanned barcode from the barcode scanner and processing the scanned barcode to determine a destination bin on which the delivery item is to be sorted in a sorting area, (iv) automatically determining, using the control unit of the robotic system, a destination path for the robotic system to reach a destination bin in the sorting area, (v) automatically determining, using an obstacle detection sensor and a small obstacle detection sensor, an obstacle on the destination path of the robotic system, (vi) automatically determining, using an obstacle avoidance system, an alternative path for the robotic system to enable the robotic system to reach the destination bin when the obstacle detection sensor and the small obstacle detection sensor detect the obstacle in the destination path of the robotic system,

(vii) identifying in real time, using a bottom camera module, a location of the robotic system in a sorting area, wherein the bottom camera module reads a barcode on a floor of the sorting area to localize the robotic system to reach the respective destination bin, (viii) simultaneously lifting, using an inbuild lifting unit, the delivery item to a height of the destination bin to place the delivery item on the destination bin when the robotic system is moving towards the destination bin, thereby reducing operation time of the robotic system, and (ix) verifying, using the robotic system, the destination bin and if the destination either the feeding unit or a charging station, wherein the robotic system keep moving until it reaches the valid destination bin. In some embodiments, the feeding unit feeds the delivery item to the robotic system using a manual or an automated process. In some embodiments, the sorting area comprises one or more of bins that are arranged in a rack in order to reduce the transition time, congestion and bagging operation time. In some embodiments, the obstacle detection sensor and the small detection sensor are communicatively connected to the control unit. In some embodiments, the sorting area includes

(i) one or more of feeder area where the delivery items arrive for feeding to the robotic system,

(ii) one or more robot walking area where the robotic system moves on the way to a sorting location, (iii) one or more rack layout area that includes one or more racks in at least one of straight-line shape or U shape, wherein the one or more racks includes one or more destination bin that are arranged vertically one on the top of another in each of the one or more racks, wherein the one or more robot walking area is coupled with a sorting side of the one or more rack layout area, and (iv) one or more bagging area, wherein the one or more bagging area is coupled with a bagging side of the one or more rack layout area where sorted delivery items are bagged for distribution, in order to reduce the transition time, congestion and bagging operation time. In some embodiments, the inbuilt lifting unit includes a telescopic lifting unit or a scissor lifting unit or a hydraulic lifting unit or a pneumatic lifting unit. In some embodiments, the robotic system includes a delivery system that includes one or more of (i) a tilting plate, (ii) a conveyor, (iii), a push system, (iv) a sliding system, (v) a passive delivery system or (vi) a tilted mechanism on which the delivery item is placed to shift the delivery item to the destination bin.

[0020] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The embodiments herein will be better understood from the following detailed description with reference to the drawings, in which:

[0022] FIG. 1 illustrates a flow diagram showing an overall process of ordering and shipping an item;

[0023] FIG. 2 is a block diagram which illustrates a system for automatically sorting delivery items in one or more bins for bagging and delivering sorted items, according to some embodiment herein;

[0024] FIG. 3 is a block diagram which illustrates a method of sorting the delivery items in one or more distribution bins for bagging and delivering sorted items, according to some embodiment herein;

[0025] FIGS. 4A, 4B, and 4C illustrate the layouts of a sorting area where the sorting method as illustrated in FIG. 3 is to be executed, according to some embodiments herein;

[0026] FIG. 5A is a top view of a robot that is used for executing the sorting method as illustrated in FIG. 3 according to some embodiments herein;

[0027] FIG. 5B is a bottom view of a robot that is used for executing the sorting method as illustrated in FIG. 3 according to some embodiments herein;

[0028] FIG. 5C is a front view of a robot that is used for executing the sorting method as illustrated in FIG. 3 according to some embodiments herein;

[0029] FIGS.6A-6D illustrate a schematic diagram of a robot in one or more lifting positions for placing delivery items in one or more distribution bins, according to some embodiments herein;

[0030] FIG. 7 is a flowchart which illustrates an overview of the delivery item processing method, according to some embodiments herein;

[0031] FIG. 8 illustrates a method for sorting delivery items in one or more bins using robots, according to some embodiments herein;

[0032] FIG. 9 is a block diagram that illustrates an overall view of a method for processing the delivery items, according to some embodiments herein; and

[0033] FIG. 10 illustrates a software system that controls a sorting system / a robotic sorting system for warehouse management or manufacturing management according to some embodiments herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0034] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0035] Accordingly, there remains a need for a system or a method for automatically sorting the items in minimum space with improved speed, flexibility, and high efficiency. The embodiments herein achieve this by proposing a system and method for automatically sorting one or more items in one or more bins which placed in a sorting area using sorting robots for bagging and delivering sorted items. Referring now to the drawings, and more particularly to FIGS. 1 through 10, where similar reference characters denote corresponding features consistently throughout the figures, preferred embodiments are shown.

[0036] FIG. 1 illustrates a flow diagram showing an overall process of ordering and shipping an item. At step 102, the customer places an order of their desired items online. In some embodiments, the customer places an order of their desired items offline. At step 104, the order information is sent to a relevant warehouse where one or more items or one or more goods, or one or more inventories are stored. In some embodiments, the order information includes, but not limited to, an item name, an item specification, customer information and the like. At step 106, an order pick list is generated for a picking system and the picking system picks the order items and forwards to the next process step. In some embodiments, the picking system could be a manual picking system or an automated picking system. At step 108, the picked items are packed and labeled. In some embodiments, the label of the picked item includes, but not limited to, the customer information, a destination address and the like. At step 110, the packed and labeled items are sorted based on the destinations. In the preferred embodiment, the packed items are sorted by robots. At step 112, the sorted items are shipped to the destination and received by the customer.

[0037] FIG. 2 is a block diagram which illustrates a system for automatically sorting delivery items in one or more bins for bagging and delivering sorted items, according to some embodiment herein. The system includes one or more feeding units 202, at least one robotic system 203, a destination bin 208, a charging station 222 and an obstacle avoidance system 214. The feeding unit 202 picks and feeds the delivery items on the robotic system 203. In some embodiments, the robotic system 203 is connected to the feeding unit 202 to receive the delivery items for sorting. In some embodiments, the feeding unit 202 is a feeding station. In some embodiments, the feeding unit 202 is a human-operated feeding unit. In some embodiments, the feeding unit 202 is an automated feeding unit. The robotic system 203 receives a delivery item from the feeding unit 202 and starts the sorting process. In some embodiments, the robotic system 203 is an Automated Guided Vehicle (AGV) or Unmanned Ground Vehicle (UGV) that can carry delivery items.

[0038] The robotic system 203 includes one or more robots that include a barcode scanner 206, a control unit 204, an obstacle detection sensor 210, a small obstacle detection sensor 212, an inbuilt lifting unit 216, a floor barcode scanning unit 218, and a bottom camera module 220. The barcode scanner 206 scans a barcode printed on the delivery item. The control unit 204 receives the scanned barcode from the product barcode scanner 206 and processes the scanned barcode to determine a destination bin 208 at which the delivery item to be sorted. The control unit 204 determines a destination path (e.g. route) for the robotic system 203 to reach the destination bin 208. In some embodiments, the control unit 204 determines the shortest possible path for the delivery item to reach the destination bin 208. The obstacle detection sensor 210 optionally detects obstacles if any on the destination path of the robotic system 203. In some embodiment, the obstacle detection sensor 210 detects large to medium-sized obstacles in the destination path. The small obstacle detection sensor 212 detects small obstacles in the destination path accurately. If the obstacle detection sensor 210 and small obstacle detection sensor 212 detect an obstacle in the destination path, it communicates to the control unit 204. The control unit 204 determines an alternate destination path to be followed by the robotic system 203 to reach the destination bin 208 for sorting the delivery item. In some embodiments, the control unit 204, using the obstacle avoidance system 214, determines the alternate destination path to be followed by the robotic system 203 to reach the destination bin 208 for sorting the delivery item. In some embodiments, the obstacle avoidance system 214 present inside the robotic system 203.

[0039] The floor barcode scanning unit 218 reads barcode on a floor of the sorting area and localizes the robotic system 203 in the floor that is positioned with respective destination bin 208 for sorting the delivery item in the respective destination bin 208. In some embodiments, the floor of the sorting area printed with a plurality of barcode which are mapped with corresponding destination bin 208. In some embodiments, the floor barcode scanning unit 218 reads the barcode on the floor of the sorting area and localizes the robotic system 203 in the floor that is positioned with respective destination bin 208 for sorting the delivery item in the respective destination bin 208 by mapping barcode on the floor with destination bin 208. In some embodiments, the floor barcode scanning unit 218, using the bottom camera module 220 scans the barcode present on the floor of the sorting area to localize the robotic system 203 on the floor.

[0040] In some embodiments, the robotic system 203 can be localized in the floor of the sorting area using lidar or any other suitable method known in the art. In one embodiment, the obstacle detection sensor 210 includes, but not limited to an ultrasonic sensor, a lidar sensor, and an infrared (IR) sensor. In one embodiment, the small obstacle sensor 212 includes, but not limited to IR laser scanners.

[0041] The barcode scanner 206 scans the barcode of the delivery items placed on the robotic system 203 and the control unit 204 processes barcode data to determine a destination bin 208 for the robotic system 203 in which the delivery item is placed by the robotic system 203. In one embodiment, the robotic system 203 is designed with an inbuilt lifting unit 216 which helps to reach the destination bin height to place the delivery item on the destination bin 208. In one embodiment, the inbuilt lifting unit 216 maybe, but not limited to, a telescopic lifting unit, a scissor lifting unit, a hydraulic lifting unit or a pneumatic lifting unit. In some embodiments, the inbuilt lifting unit 216 simultaneously lifts the delivery item to a height of the destination bin 208 to place the delivery item on the destination bin 208 when the robotic system 203 is moving towards the destination bin 208, thereby reducing an operation time of the robotic system (203).

[0042] The charging station 222 charges the robot 203 based on a calculated battery state. In some embodiments, the robotic system, using the control unit 204, (i) calculates a battery state of the robotic system 203 when in operation (ii) determines the charging station 222 in the sorting area if the battery state of the robotic system 203 is lower than a threshold value (iii) determines a destination path for the robotic system 203 to reach the charging station 222 and (iv) enables the robotic system 203 for docking with the charging station 222 for charging. In some embodiments, the control unit 204 determines the destination path for the destination bin 208 or the feeding unit 202 if the battery state of the robotic system 203 is higher than the threshold value.

[0043] FIG. 3 is a block diagram which illustrates a method of sorting the delivery items in one or more distribution bins for bagging and delivering sorted items, according to some embodiment herein. The method is applied to the system for sorting the delivery items as shown in FIG. 2.

[0044] Hereinafter, the method of sorting the delivery items according to some embodiments herein will be described in detail with reference to FIG. 3. At step 302, a robotic system 203 queues in the line at a feeder location to receive a delivery item. In one embodiment, the delivery item is a delivery item. In another embodiment, the delivery item can be any material that can be material handling. At step 304, the robotic system 203 receives the delivery item from a feeding unit 202 in the feeder location. At step 306, a barcode scanner 206 scans a barcode printed on the delivery item for validating barcode printed on the delivered item and determining a destination bin 208 on which the delivery item is to be sorted in a sorting area by processing the scanned barcode. At step 308, the robotic system 203 shifts the delivery item to a rejection bin, if the scanned barcode is not valid and queues back to the feeder location. At step 310, the robotic system 203 determines, using the control unit 204, a destination path for the robotic system 203, if the scanned barcode is valid. At step 312, the robotic system 203 moves towards the destination bin 208 once it gets the destination bin location by barcode scanning. At step 314, it is checked whether the destination has arrived or not. At step 316, if the destination does not arrive, it is checked whether an obstacle is detected in the destination path the obstacle detection sensor 210 and the small obstacle detection sensor 212. If the obstacle is detected, the robotic system 203 goes to step 318 for obstacle avoidance. If there is no obstacle, then the robotic system 203 goes back to step 312. At step 318, the robotic system 203 does obstacle avoidance and determines an alternate path for the robotic system 203 to reach the destination bin 208. At step 320, the robotic system 203 moves to the destination until it arrived. At step 322, it is checked whether the destination bin 208 is reached or not. At step 324, if the destination bin 208 is not reached, it is checked whether the destination is a feeder/feeding unit or not. If the destination is the feeder, the robotic system 203 goes back to step 302. At step 326, the robotic system 203 dumbs the delivery item in the destination bin 208, if the destination is the destination bin 208. At step 328, it is checked whether the battery state of the robot is below a threshold or not. At step 330, if the battery state of the robotic system 203 has enough battery, the next optimal feeder is calculated and the robotic system 203 goes to step 310. At step 332, if the battery state of the robotic system 203 is below the threshold, an optimal charging station is calculated and then the robotic system 203 goes to step 310. At step 334, if the destination of the robotic system 203 is a charging station, the robotic system 203 docks itself to the charging station 222. At step 336, the charging of the robotic system 203 starts and it goes to step 330 once the charging is completed. At step 338, if the charging is not completed, the robotic system 203 goes to step 336 and then goes step 330.

[0045] FIGS. 4A, 4B, and 4C illustrate the layouts of a sorting area where the sorting method as illustrated in FIG. 3 is to be executed, according to some embodiments herein. In some embodiments, a layout 400A with one or more crossing area 414A-N as shown in FIG. 4A may use for sorting the delivery items in larger areas and may also work if conveyors are used for feeding the delivery items in the sorting area. The layout 400A includes (i) one or more feeder area 402A-N, where the delivery items arrive for feeding to a robot 404 that has a turn for feeding on the delivery item and moving it to the destination bin 208, (ii) a feeding position 406 in each of the one or more feeder area 402A-N from where the robot 404 feeds with the delivery items, (iii) a feeder 408 in the feeding position 406 of each of the one or more feeder area 402A- N that feeds the delivery items on the robot 404, (iv) a barcode & volumetric scanner 410 in each of the one or more feeder area 402A-N that scans the delivery items on the robot 404 on the go, (v) one or more robot walking area 412, where the robot 404 moving on the way to a sorting location, (vi) one or more crossing area 414A-N which has space for robot 404 passage and there is an entry-exit door for baggers and trolleys to pass at the one or more crossing area 414A-N, (vii) a rack layout border 416 that decouples the one or more robot walking area 412 and one or more bagging area 418A-N, (viii) one or more bin 208 A-N in which the delivery items are shifted, (ix) one or more bagging area 418A-N, (xi) a bagger 420 (xii) one or more rack layout area. In some embodiments, one or more rack layout area includes one or more racks arranged in at least one of straight-line shape 424A-N or U shape 422A-N.

[0046] In some embodiments, the one or more racks includes one or more destination bin 208A-N that are arranged vertically one on the top of another in each of the one or more of racks. In some embodiments, the robot walking area 412 is at least one of a longitudinal robot walking area 428 or a lateral robot walking area 426. In some embodiments, there is at least one crossing of a longitudinal robot walking area 428 with a lateral robot walking area 426. [0047] In some embodiments, the bagger 420 is human. In some embodiments, the bagger 420 is an automated machine. In one embodiment, a weight scale is there in feeding position 406 to calculate the weight of the delivery item. The weight is calculated by subtracting total weight with the robot weight. In one embodiment, the feeder 408 is a human. In one embodiment, the feeder 408 is an automated machine.

[0048] In some embodiments, the one or more crossing area 414A-N that enables the one or more robot walking area 412 to decouple from one or more baggers and a trolleys passage area connecting the one or more bagging area 418A-N to enable unhindered passage of the robot 404. In some embodiments, the decoupling is achieved by vertically differentiating the one or more robot walking area 412 from the one or more baggers and trolleys passage area at the one or more crossing area 414A-N.

[0049] In some embodiments, the one or more robot walking area 412 is coupled with a sorting side of the one or more rack layout area. In some embodiments, the one or more bagging area 418A-N is coupled with a bagging side of the one or more rack layout area where sorted delivery items are bagged for distribution, in order to reduce the transition time, congestion and bagging operation time.

[0050] In some embodiments, the straight line shape 424 A-N rack layout area has two sides and includes a sorting side coupled to the one or more robot walking area 412 and a bagging side coupled to the one or more bagging area 418 A-N. The robot 404 gets the delivery item from the one or more feeding area 402A-N and is guided by the barcodes on the floor to take an efficient delivery route to the sorting side of the one or more rack layout area, to the one or more destination bin 208 A-N and shifts the delivery item to the one or more destination bin 208 A-N, which can be removed from the bagging side at the one or more bagging area 418A-N.

[0051] In some embodiments, the U shape 422A-N rack layout area has four sides and includes one or more sorting sides coupled to the one or more robot walking area 412 and one or more bagging sides coupled to the one or more bagging area 418 A-N. The robot 404 gets the delivery item from the one or more feeding area 402A-N and is guided by the barcodes on the floor to take an efficient delivery route to the one or more sorting side of the one or more rack layout area, to the one or more destination bin 208 A-N and shifts the delivery item to the one or more destination bin 208A-N, which can be removed from the one or more bagging sides at the one or more bagging area 418A-N. In some embodiments, at least one side of the U shape 422A- N rack layout area is one or more crossing area 414A-N. In some embodiments, the combination of the U shape 422A-N rack layout area and the straight line shape 424 A-N rack layout area is used.

[0052] In some embodiment, the robot 404 matches the delivery item vertical distance to the destination bin 208 using the inbuilt lifting unit 216, at the one or more robot walking area 412. In some embodiments, on reaching the destination bin 208, the robot 404 shifts the delivery item to the destination bin 208 from the sorting side of the rack layout area.

[0053] In some embodiments, the method for automatically sorting a delivery item in a plurality of bins using the robotic system 203 or a robot 404 includes simultaneously lifting, using an inbuild lifting unit 216, the delivery item to a height of the destination bin 208 to place the delivery item on the destination bin 208 when the robotic system 203 is moving towards the destination bin 208, thereby reducing operation time of the robotic system 203, wherein the inbuilt lifting unit 216 includes a telescopic lifting unit or a scissor lifting unit or a hydraulic lifting unit or a pneumatic lifting unit, wherein the robotic system 203 includes a delivery system that comprises one or more of (i) a tilting plate 502, (ii) a conveyor, (iii), a push system, (iv) a sliding system, (v) a passive delivery system or (vi) a tilted mechanism on which the delivery item is placed to shift the delivery item to the destination bin 208.

[0054] According to the layout 400A as shown in FIG. 4A, the one or more bagging area 418A-N is decoupled from the one or more robot walking area 412. This, in turn, decouples the bagger 420 from the robot 404 that ensures safety.

[0055] In some embodiments, the sequence of combination of the rack layout area is (i) a first end side straight line shape 424A rack layout area, (ii) U shape 422A rack layout area and U shape 422D rack layout area, (iii) U shape 422 B rack layout area and U shape 422E rack layout area, (iv) U shape 422C rack layout area and U shape 422N rack layout area, (v) U shape 422N rack layout area and U shape 422N rack layout area and (vii) a second end side straight line shape 424 N rack layout area, wherein the at least one of the straight line shape 424A rack layout area or U shape 422A rack layout area are coupled to one or more robot walking area 412 that are arranged between at least one of the straight line shape 424A rack layout area or U shape 422A rack layout area, wherein the one or more feeder area 402A-N connect to the one or more robot walking area 412 as shown in Fig.4A. As an example, the robot 404 picks up a delivery item from the feeder 402A, the delivery bin 208 is located at one of the racks in right sorting side at the U shape 422D layout area, arranged at the rack on vertical level 3, the robot 404 lifts the delivery item to the corresponding height of the delivery bin 208 at level 3, while passing through the longitudinal walking area 428 and stops in front of the rack where the identified delivery bin 208 is located before transferring the delivery item to the delivery bin from the sorting side of the rack. The bagger located at the bagging area 418G may take out the delivery item from the bagging side of the rack at 422D from where the delivery item may be taken out of the layout 400 from the crossing area 414D for dispatch.

[0056] In some embodiments, one or more racks are arranged in straight-line shape 424A-N forms a straight line with one or more bins 208A-N that are arranged vertically one above another in each rack.

[0057] In another embodiment, a layout 400B of the sorting area without one or more crossing area 414A-N as shown in FIG. 4B which is useful if conveyors are not used for transferring the delivery items to a feeding unit. The layout 400B includes all the components as described in the layout 400A except the one or more crossing area 414A-N. In some embodiments, the one or more racks includes one or more distribution bins 208A-N that are vertically arranged one on the top of another.

[0058] In one embodiment, a layout 400C of the sorting area with a smaller number of racks and through put as shown in FIG. 4C is used for small scale installation. The layout 400C includes at least two U shape racks 422 arrangement with one or more distribution bins 208A-N that are vertically arranged one on the top of another in each of the one or more racks in U shape racks 422 arrangement. In some embodiments, one or more racks are arranged in U shape 422A- N includes three sides with one or more bins 208A-N that are suitably arranged in U shape according to the layout of the sorting area.

[0059] In some embodiments, one or more racks includes both a bagging side where the bagging operation occurs and a sorting side where the sorting operation occurs.

[0060] According to the embodiment s herein, the rack layout as shown in FIG. 4A for an arrangement of the one or more destination bins 208A-N in vertically one above another helps to reduce the robot 404 travel time, congestion and also reduces the bagging operation time.

[0061] In some embodiments, the number of rack layout and the number of distribution bins are increased or decreased based on the size of warehouse or material handling area.

[0062] In some embodiments, the robot includes a tilting plate in which the delivery item is placed, a robot body which includes all the components like battery, motors, drive systems, controllers/control unit and computers, an On/Off switch that enables to turn on and off the robot, a charging pin, an emergency stop switch for the safety and a lifting unit which helps to lift the tilting plate vertically up to the height of the destination bins. In some embodiments, the robot includes a conveyor, (iii), a push system, (iv) a sliding system, (v) a passive delivery system or (vi) a tilted mechanism for receiving and placing the delivery item to the destination bin 208.

[0063] In one embodiment, the robotic system 203 flips the tilting plate to shift the delivery item to the destination bin 208. In one embodiment, the robot includes a small cross belt conveyor that moves the delivery items to the bin from the robot. The charging pin of the robot acts as an access point for charging wires to be connected to the robot. In one embodiment, the charging is done manually. In one embodiment, the charging is done by autonomously using docks. The emergency stop switch is used to deactivate the robot instantly in an emergency situation. In some embodiments, the emergency stop switch is activated manually. In some embodiments, the emergency stop switch is activated automatically during the emergency situation. The lifting unit of the robot lifts the tilting plate vertically to shift the delivery items on the bin based on the different height of the bin. In one embodiment, the lifting unit can be, but not limited to a telescopic lifting unit, a scissor lifting unit, a hydraulic lifting unit, or a pneumatic lifting unit.

[0064] In some embodiments, the robotic system 203 further includes two or more power wheels, a floor barcode scanning unit and one or more freewheels for support. In some embodiments, two or more power wheels includes a motor to lead a transmission system of the robotic system 203. In some embodiments, the transmission system connects the motor and the power wheel. In one embodiment, the motor includes, but not limited to BLDC or DC or AC. In one embodiment, the drive system can be, but not limited to a motorized drive system or an engine based drive system. The floor barcode scanning unit reads the barcodes on the floor and localizes the robotic system 203 in the environment. In one embodiment, the robotic system 203 can be localized in the environment using a camera, a lidar or any other suitable method known in the art. The freewheels gives the necessary support to the robotic system 203. In one embodiment, the robotic system 203 can comprise zero or more freewheels for movement across the one or more robot walking area 412 depending on the robot design.

[0065] In some embodiments, the robotic system 203 further includes an emergency stop switch which is another stop switch for quick accessibility in the emergency events, a front camera module, an obstacle detection sensor and a small obstacle detection sensor.

[0066] In one embodiment, the camera can be used, but not limited, for scanning and mapping the location of the robot in the environment. The obstacle detection sensor detects the obstacles accurately in a destination path of the robotic system 203 and makes sure that the robotic system 203 does not meet with an accident. In one embodiment, the obstacle detection sensor includes, but not limited to an ultrasonic sensor, a lidar sensor, and an IR sensor. The small obstacle detection sensor detects very small obstacles accurately in a destination path of the robotic system 203 for smooth robotic system 203 operation. In one embodiment, the small obstacle detection sensor includes, but not limited to, IR laser scanners.

[0067] In one embodiment, the lifting unit includes, but not limited to a telescopic lifting unit, a scissor lifting unit, a hydraulic lifting unit, and a pneumatic lifting unit. In one embodiment, the robotic system 203 is moved to the destination bin 203 location and simultaneously the robotic system 203 lifts the tilting plate to the level of destination bin 208 and transfers the delivery item. This saves the time of the sorting process.

[0068] FIG. 5A is a top view of a robot 500 that is used for executing the sorting method as illustrated in FIG. 3 according to some embodiments herein. The robot 500 includes a tilting plate 502 in which the delivery item is placed, a robot body 504 which includes all the components like battery, motors, drive systems, controllers/control unit and computers, an On/Off switch 506 that enables to turn on and off the robot 500, a charging pin 508, an emergency stop switch 510 for the safety and a lifting unit 512 which helps to lift the tilting plate 502 vertically up to the height of the destination bins. In some embodiments, the robot 500 includes a conveyor, (iii), a push system, (iv) a sliding system, (v) a passive delivery system or (vi) a tilted mechanism for receiving and placing the delivery item to the destination bin 208.

[0069] In one embodiment, the robot 500 flips the tilting plate 502 to shift the delivery items to a particular bin. In one embodiment, the robot 500 includes a small cross belt conveyor that moves the delivery items to the bin from the robot 500. The charging pin 508 of the robot 500 acts as an access point for charging wires to be connected to the robot 500. In one embodiment, the charging is done manually. In one embodiment, the charging is done by autonomously using docks. The emergency stop switch 510 is used to deactivate the robot 500 instantly in an emergency situation. In some embodiments, the emergency stop switch 510 is activated manually. In some embodiments, the emergency stop switch 510 is activated automatically during the emergency situation. The lifting unit 512 of the robot 500 lifts the tilting plate 502 vertically to shift the delivery items on the bin based on the different height of the bin. In one embodiment, the lifting unit 512 can be, but not limited to a telescopic lifting unit, a scissor lifting unit, a hydraulic lifting unit, or a pneumatic lifting unit.

[0070] FIG. 5B is a bottom view of a robot that is used for executing the sorting method as illustrated in FIG. 3 according to some embodiments herein. The robot 500, further includes two or more power wheels 514, a floor barcode scanning unit 516 and a freewheel 518 for support. In some embodiments, two or more power wheels 514 includes a motor to lead a transmission system of the robotic system (203).

[0071] In some embodiments, the transmission system connects the motor and the power wheel 514. In one embodiment, the motor includes, but not limited to BLDC or DC or AC. In one embodiment, the drive system can be, but not limited to a motorized drive system or an engine based drive system. The floor barcode scanning unit 516 reads the barcodes on the floor and localizes the robot 500 in the environment. In one embodiment, the robot 500 can be localized in the environment using a camera, a lidar or any other suitable method known in the art. The freewheel 518 gives the necessary support to the robot 500. In one embodiment, the robot 500 can comprise zero or more freewheel 518 depending on the robot design.

[0072] FIG. 5C is a front view of a robot that is used for executing the sorting method as illustrated in FIG. 3 according to some embodiments herein. The robot 500, further includes an emergency stop switch 520 which is another stop switch for quick accessibility in the emergency events, a front camera module 522, an obstacle detection sensor 524 and a small obstacle detection sensor 526.

[0073] In one embodiment, the camera 522 can be used, but not limited, for scanning and mapping the location of the robot 500 in the environment. The obstacle detection sensor 524 detects the obstacles accurately in a destination path of the robot 500 and makes sure that the robot 500 does not meet with an accident. In one embodiment, the obstacle detection sensor includes, but not limited to an ultrasonic sensor, a lidar sensor, and an IR sensor. The small obstacle detection sensor 526 detects very small obstacles accurately in a destination path of the robot 500 for smooth robot operation. In one embodiment, the small obstacle detection sensor 526 includes, but not limited to, IR laser scanners.

[0074] FIGS. 6A-6D illustrate a schematic diagram of a robot in one or more lifting positions for placing delivery items in one or more distribution bins, according to some embodiments herein.

[0075] FIG. 6A shows a normal position of a robot with a tilting plate to carry delivery items, according to an embodiment herein. In the preferred embodiment, the robot is designed with an inbuilt lifting unit. FIG. 6B shows a first elevated position of the robot by lifting the tilting plate of the robot using the inbuilt lifting unit, according to an embodiment herein. FIG. 6C shows a second elevated position of the robot by lifting the tilting plate of the robot using the inbuilt lifting unit, according to an embodiment herein. FIG. 6D shows an elevated position tilting plate of the robot by flipping the tilting plate of the robot for shifting delivery items to the bin once it reaches the right bin height, according to an embodiment herein. After shifting the delivery items on the particular bin, the lifting unit lowers the height of the robot to come back the robot to the normal position as shown in FIG. 6A.

[0076] In one embodiment, the lifting unit includes, but not limited to a telescopic lifting unit, a scissor lifting unit, a hydraulic lifting unit, and a pneumatic lifting unit. In one embodiment, the robot is moved to the right bin location and simultaneously the robot lifts the tilting plate to the height of the right bin. This saves the time of the sorting process.

[0077] FIG. 7 is a flowchart which illustrates an overview of the delivery processing method according to some embodiments herein. At step 702, the delivery item in the bags is brought to a distribution center or a dedicated sorting area where the delivery items are sorted. At step 704, the delivery items are sorted using robots as illustrated in FIG. 3. In one embodiment, the robots are Vertisort AGVs which have the structure design as described in FIGS. 5A-5C. At step 706, the sorted delivery items are bagged and put into the trucks for further connection. [0078] FIG. 8 illustrates a method for sorting delivery items in one or more bins using robots, according to some embodiments herein. At step 802, the delivery items in the bags are received in the inbound docks of the area. At step 804, the delivery items from the docks are carried to a feeder area where the sorting process happens. In one embodiment, the feeder area can be with a feeding station to pick the delivery items. In one embodiment, the feeder area can be with a human who will be picking the delivery items. At step 806, the delivery items are fed on sorting robots one by one from the different feeding stations. At step 808, a barcode on the delivery items is scanned using a barcode scanner. At step 810, the barcode scanner resolves the barcode data to a destination bin number for the robotic system 203 and sends it to the robotic system 203. At step 812, after getting the bin information, the robotic system 203 moves to the destination bin 208 and transfers the delivery item to the destination bin 208 that has a bag to accommodate many delivery items. At step 814, the bag is packed and removed from the bagging side of the rack, when it gets full and a new empty bag is put on the empty destination bin 208 for receiving next delivery item by the next robotic system 203. And, at step 816, the packed full bag is sent to the outbound dock for connecting the full bags to the transporters for delivery.

[0079] FIG. 9 is a block diagram that illustrates an overall view of a method for processing the delivery items according to some embodiments herein. At step 902, the delivery items in the bags are brought to a sorting facility inbound station. At step 904, the delivery item bags are moved to a starting area or a staging area where the bags are further connected to the facility. At step 906, the delivery item bags are moved to a feeding area using a trolley or a conveyor. At step 908, the bags are opened and the delivery items are taken out. At 910, the delivery item size is checked whether it is larger than the delivery item size will be handled by the robots or UGVs. In one embodiment, the delivery item size is calculated using a weight scale. At step 912, the delivery item is fed to UGV robot, if the delivery item is right in size. At step 914, the delivery item is moved to the different sorting area, if the delivery item is larger than the delivery item size will be handled by the UGV robot. In one embodiment, the sorting area is a manual station. In one embodiment, the sorting area could be an automated station. At step 916, a barcode scanner scans a barcode on the delivery item, once it is fed on the UGV. It is possible that the delivery item has no mapped bin or damaged barcode sticker. Hence, the barcode scanner checks whether the barcode is valid or not at this step 916. At step 918, the UGV gets a sorting bin location if the barcode is valid. At step 920, the UGV gets a rejection bin sorting point location if the barcode is not valid. At step 922, the UGV goes to an assigned sorting bin while elevating the delivery item platform or tilting plate to the destination bin 208 vertical level. At step 924, the UGV shifts the delivery item in the destination bin 208 by tilting the delivery item platform. In one embodiment, the delivery item is shifted using a conveyor. At step 926, a bag closing indication is given to an operator, once the bag is full. At step 928, the operator presses a button near the bag to indicate a bin closure until the bag is replaced with an empty bag. At step 930, the operator removes and closes the full bag and presses the button near the bin to indicate it as open, once the empty bag is placed on the bin. At step 932, the full bag is taken to the outbound using a conveyor or a trolley.

[0080] FIG. 10 illustrates a software system that controls a sorting system / a robotic sorting system for warehouse management or manufacturing management according to some embodiments herein. The sorting system includes (i) a client software 1002 have some

Application Programming Interface (API) 1004 to get a barcode data or any other relevant data to fulfill the sorting operation, (ii) barcode scanners, cameras and volumetric scanners 1006 (iii). an Equipment Control System (ECS) 1008 that controls various equipment’s in the sorting system like barcode scanners, cameras, and volumetric scanners 1006, (iv) a monitor or a graphical user interface (GUI) 1010 to display the relevant information to the client to control, monitor and operate the sorting system, (v) an alarm management system 1012 that takes care of the safety of the sorting system and triggers alarms in dangerous situations like fire and accident,

(vi). a Robotic control system or Vertisort Control System (VCS) 1014 does the fleet management and controls the sorting system, (vii) a database 1016 where all the relevant information is stored and retrieved like logging and delivery item information, (viii) a vertisort robot 1018 which is the robotic system 203 which operates the robot motors, sensors, communication, and battery management, and (ix) charging station 1020 that is used to make sure the charging is happening safely and monitor the battery health while charging. In some embodiments, the Vertisort Control System (VCS) 1014 is responsible for constantly monitoring and optimizing the robot fleet operations. The robotic system for automatic delivery here presented has multiple advantages. The system is optimized to save area and total cost of operation at the same time enabling a huge amount of delivery items to be sorted into multiple categories automatically with minimal human intervention. The robot pathway is unhindered and manages pick up and sorting of delivery items into vertically arranged number of destination bins. The bagging area is on the other side and there are multiple crossing areas to allow efficient movements.

[0081] Here is some data depicting delivery items handled per hour according to the experiments conducted. The robot per square feet is only in a range of 0.008-0.02 to handle delivery items in a range of 5000 to 15000 per hour. The warehouse area required corresponding to the delivery items per hour, is in a range of 6000 to 12000 square feet. The energy consumption to manage the operation for the same is in a range of 1.7 to 3.0 watts. The area can be increased or decreased and accordingly the number of delivery items per hour could change. There is 50-70% reduction in area required to store and sort amount of delivery items. The number of delivery items handled per hour is at least 100% more due to the efficient arrangement of the layout. The energy consumption is less, making the system cost effective and environment friendly.

[0082] The system and method according to the embodiments herein are applicable for all material handling facilities may include, but are not limited to, logistics, order fulfillment facilities, warehouses, distribution centers, packaging facilities, shipping facilities, manufacturing facilities, or other facilities or combination of facilities for performing one or more functions of material handling.

[0083] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope.