TECHNICAL FIELD

The present invention relates to the handling of parcels within a sorting or similar facility, and, more particularly, to a conveyor system for sorting parcels BACKGROUND OF THE INVENTION

In a sorting facility for parcels, various parcels are unloaded from trucks or other vehicles at unloading locations, sorted, and then loaded onto trucks or other vehicles at loading locations for delivery to the intended recipients. Thus, within the sorting facility, there is often a complex system of conveyors and equipment that facilitates transport and sorting of the various parcels within the facility.

When first introduced into the system of conveyors and equipment, the parcels are randomly positioned on a conveyor in a "bulk flow." Thus, within the sorting facility, the first step is often to sort the parcels, for example, by transforming the bulk flow into a singulated flow of parcels in which the parcels are positioned at substantially equal intervals and aligned (i.e., in a single file line) along a conveyor for subsequent processing. In other cases, the parcels are sorted as they are transported by a conveyor. A wide variety of sorters and singulators exists in the art, many of which employ various combinations of belt conveyors and/or roller conveyors to achieve the desired singulation of the parcels. However, there are certain deficiencies in such prior art systems.

Accordingly, there remains a need for systems and methods for sorting parcels in a bulk flow.

SUMMARY OF THE INVENTION

The present invention is a conveyor system for sorting parcels.

An exemplary conveyor system made in accordance with the present invention includes a conveyor section for moving a parcel along a conveying surface of the conveyor section. The conveyor section includes a plurality of modules. Each module includes a vertical shaft with a bracket at a distal end of the vertical shaft. The vertical shaft is configured for rotation about a vertical axis normal to the conveying surface of the conveyor section, and a first motor is operably connected to the vertical shaft to rotate the vertical shaft about the vertical axis. A drive wheel is mounted for rotation with respect to the bracket, and a second motor is operably connected to the drive wheel to rotate the drive wheel about a horizontal axis parallel to the conveying surface of the conveyor section.

According to some embodiments, the vertical shaft extends through a housing, and the first motor includes an array of permanent magnets secured to an internal surface of the housing and a corresponding array of electromagnetics mounted to the vertical shaft.

According to some embodiments, the first motor rotates the vertical shaft at intervals between -90° to +90° relative to a home position in which the horizontal axis is substantially perpendicular to a longitudinal axis of the conveyor section. In some embodiments, the first motor rotates the vertical shaft at intervals of 15°.

According to some embodiments, the first motor is further configured to move the vertical shaft along the vertical axis between an upper position in which the drive wheel engages a parcel moving along the conveying surface and a lower position in which the drive wheel does not engage a parcel moving along the conveying surface. According to some embodiments, the bracket includes two opposing legs, and a horizontal shaft extends between the opposing legs, and the drive wheel is mounted for rotation with respect to the horizontal shaft. According to some embodiments, the second motor is positioned between the horizontal shaft and the drive wheel. Furthermore, according to some embodiments, the second motor includes an array of permanent magnets secured to an internal surface of the drive wheel and a corresponding array of electromagnetics mounted to the horizontal shaft. According to some embodiments, the drive wheel includes an exterior surface configured to engage the parcel for moving the parcel along the conveying surface.

According to some embodiments, the module further includes two support axles and a belt extending around the drive wheel and the two support axles, such that when the drive wheel rotates the belt rotates around the drive wheel and the two support axles.

According to some embodiments, the module further includes signal and power connectors extending from a proximal end of the housing. In such embodiments, each of the plurality of modules is individually removable from the conveyor section. According to some embodiments, the plurality of modules are arranged in a matrix. DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an exemplary conveyor system made in accordance with the present invention;

FIG. 2 is a side view of an individual module of the exemplary conveyor system of FIG. 1;

FIG. 3 is another side view of the individual module of FIG. 2;

FIG. 4 is a perspective view of the individual module of FIG. 2;

FIG. 4A is an alternate perspective view of the individual module of FIG. 2, illustrating certain internal construction details;

FIG. 5 is a top view of the individual module of FIG. 2;

FIG. 6 is a side view of an alternative module for use in the exemplary conveyor system of FIG. 1; FIG. 7 is another side view of the alternative module of FIG. 6;

FIG. 8 is a perspective view of the alternative module of FIG. 6;

FIG. 9 is a top view of the alternative module of FIG. 6;

FIG. 10 is a schematic diagram of a vision and control subsystem for the exemplary conveyor system of FIG. 1 according to the present invention;

FIG. 11 is a schematic view of an exemplary conveyor system made in accordance with the present invention, illustrating the use of the conveyor system to sort and singulate parcels into two discrete lines for subsequent delivery to two downstream conveyors;

FIG. 12 is a schematic view of an exemplary conveyor system made in accordance with the present invention, illustrating the use of the conveyor system to receive parcels from multiple inbound conveyors and then sort and singulate the parcels into a line;

FIG. 13 is a schematic view of another exemplary conveyor system made in accordance with the present invention;

FIG. 14 is a schematic view of another exemplary conveyor system made in accordance with the present invention;

FIG. 15 is a schematic view of another exemplary conveyor system made in accordance with the present invention;

FIG. 16 is a schematic view of another exemplary conveyor system made in accordance with the present invention; and

FIG. 17 is a schematic view of another exemplary conveyor system made in accordance with the present invention.

DESCRIPTION OF THE INVENTION

The present invention is a conveyor system for sorting parcels. Referring first to FIG. 1, an exemplary conveyor system 10 made in accordance with the present invention comprises a plurality of modules 100, with each module 100 being independently controlled, as further described below. As shown in FIG. 1, in this exemplary implementation, there is a first (or inlet) conveyor section 10a, a second conveyor section 10b that comprises the plurality of modules 100 arrayed in a rectangular matrix, and a third (or outlet) conveyor section 10c.

FIGS. 2, 3, 4, 4A, and 5 illustrate an individual module 100 of the conveyor system 10. As shown in FIGS. 2, 3, 4, 4A, and 5, each module 100 generally includes a housing 110 with a cylindrical shape, a vertical shaft 120 that is mounted for rotation relative to the housing 110 about a substantially vertical axis, and a drive wheel 150 that is mounted to the distal (upper) end of the vertical shaft 120, above the housing 110, for rotation about a substantially horizontal axis. Specifically, in this exemplary embodiment, the vertical shaft 120 is mounted in an internal volume defined by the housing 110, rotating relative to a bearing 122 positioned at a lower end of the housing 110 and another bearing 123 positioned at an upper end of the housing 110. Each module 100 is connected to the conveyor system 10 through signal and power connectors 112, 114 located at the proximal (lower) end of the housing 110, as discussed further below.

Referring now to FIGS. 4 and 4A, to drive rotation of the vertical shaft 120, in this exemplary embodiment, a first motor 140 is provided within the housing 110 and operably connected to the vertical shaft 120. In the exemplary embodiment shown in FIGS. 4 and 4A, a brushless motor arrangement is employed in which an array of permanent magnets 142 is secured to the internal surface of the housing 110 and a corresponding array of electromagnets 144 is then mounted to the vertical shaft 120. By controlling current to the electromagnets 144, the vertical shaft 120 can be rotated to a desired angular position. To this end, a set of cables 146 connects the first motor 140 to one of the connectors 112. The exemplary cables 146 are configured and sized to allow for rotation of the vertical shaft 120 at least 180°, as discussed further below. Of course, this is but one way to control the rotation and angular positioning of the vertical shaft 120 relative to the housing 110, and various other means for rotating the vertical shaft 120 relative to the housing 110 could be employed without departing from the spirit and scope of the present invention. For example, synchronous permanent magnet motors, step motors, or other electric motors could be integrated into the housing 110 to effectuate the desired rotation of the vertical shaft 120. Furthermore, it is contemplated that such motors would be controlled without an encoder, i.e., in a "sensorless" manner.

Furthermore, in addition to controlling rotation of the vertical shaft 120, the first motor 140 can, in some embodiments, also affect movement of the vertical shaft 120 along the vertical axis (i.e., up and down in FIGS. 4 and 4A). To this end, the lower bearing 122 and the upper bearing 123 are configured to allow the vertical shaft 120 to rotate and also slide within the bearings 122, 123 along the vertical axis. When current is provided to the electromagnets 144, the permanent magnets 142 are attracted to the electromagnets 144 and the vertical shaft 120 is maintained in an upper position, but when no current is provided to the electromagnetics 144, the vertical shaft 120 is allowed to drop slightly to a lower position. A stop (not shown) can be provided to ensure that when the vertical shaft 120 is in the lower position, the permanent magnets 142 are still sufficiently close to the electromagnets 144 that, when current is once again provided to the electromagnetics 144, the vertical shaft 120 is drawn upward into the upper position. Other means of moving the vertical shaft 120 up and down could also be employed without departing from the spirit and scope of the present invention.

Referring again to FIGS. 2, 3, 4, 4A, and 5, as noted above, the drive wheel 150 is mounted to the distal (upper) end of the vertical shaft 120. Specifically, in this exemplary embodiment, a bracket 124 is mounted to the distal (upper) end of the vertical shaft 120. As such, the bracket 124 rotates with the vertical shaft 120 relative to the housing 110. The bracket 124 includes a base portion 126 and two opposing legs 128a, 128b that extend upward from each end of the base portion 126. A horizontal shaft 130 extends between the opposing legs 128a, 128b and defines a substantially horizontal axis, and the drive wheel 150 is mounted for rotation with respect to the horizontal shaft 130 about the horizontal axis.

Referring now to FIGS. 4 and 4A, a second motor 160 is provided within the drive wheel 150 and operably connected to the horizontal shaft 130. In the exemplary embodiment shown in FIGS. 4 and 4A, a brushless motor arrangement is again employed in which an array of permanent magnets 162 is secured to the internal surface of the drive wheel 150, and a corresponding array of electromagnets 164 is then mounted to the horizontal shaft 130. By providing current to the electromagnets 164, the drive wheel 150 is activated and rotates. To this end, a set of cables 166 connects the second motor 160 to another one of the connectors 114. The exemplary cables 166 are directed through an interior of the vertical shaft 120 as well as at least a portion of the bracket 124 and horizontal shaft 130 in order to connect to the second motor 160. As such, the exemplary cables 166 are preferably flexible enough to allow for the above described connection to be maintained even during rotation of the vertical shaft 120. Of course, this is but one way to effectuate the rotation of the drive wheel 150, and various other means for rotating the drive wheel could be employed without departing from the spirit and scope of the present invention. For example, synchronous permanent magnet motors, step motors, or other electric motors could be integrated into the drive wheel 150 to effectuate the desired rotation. Furthermore, it is contemplated that such motors would be controlled without an encoder, i.e., in a "sensorless" manner.

As a result of such a construction, each module 100 can be independently controlled to rotate the vertical shaft 120 and thus reposition the drive wheel 150 at a desired angular orientation. To simplify operation and control, in some exemplary implementations, the vertical shaft 120 may rotate between fixed positions at 15° intervals relative to a home position (0°) : -90°, -75°, -60°, -45°, -30°, -15°, 0, +15°, +30°, +45°, +60°, +75°, +90°. As used herein, the "home position" for the vertical shaft 120 is when the horizontal axis is substantially perpendicular to a longitudinal axis of the conveyor system. However, it is contemplated that other predetermined home positions can also be used depending on the configuration of the conveyor system.

Furthermore, as a result of such construction, each module 100 can be independently controlled to activate and rotate the drive wheel 150.

Further still, the signal and power connectors 112, 114 allow each module 100 to readily be installed/removed from a conveyor system. That is to say, the conveyor system includes a plurality of connection points (not shown) which each correspond to the location of the modules 100. The module 100 is then installed by inserting the signal and power connectors 112, 114 into the respective connection points. This not only provides greater flexibility in design but improves efficiencies in maintenance as individual modules 100 can readily be replaced.

FIG. 10 is a schematic diagram of a vison and control subsystem 200 for the exemplary conveyor system 10 described above. As shown in FIGS. 1 and 10, one or more cameras 210a, 210b, 210n are positioned to view parcels (not shown) that are being transported by the conveyor system 10. In this regard, it is important to recognize that, in the present application, the term "parcel" is not intended to be limiting and can include any article, item, or object that may be transported in the manner specified within the present disclosure.

Referring still to FIG. 10, each camera 210a-n is configured to acquire two- dimensional and/or three-dimensional image data and may further include a processor configured to execute instructions (routines) stored in a memory component or other computer-readable medium to process images acquired by the camera. For example, suitable cameras for use in the conveyor system 10 include three-dimensional image sensors manufactured and distributed by ifm Effector Inc. of Malvern, Pennsylvania.

Referring still to FIG. 10, the vision and control subsystem 200 further includes a controller 220 with a processor 222 configured to execute instructions stored in a memory component 224 or other computer-readable medium. For instance, the controller 220 may be a programmable logic controller or other industrial controller. The controller 220 is connected to the cameras 210a-n to facilitate the transmission of data from the respective cameras 210a-n to the controller 220 and, as necessary, the communication of instructions from the controller 220 to the cameras 210a-n, either by wired connection (e.g., Ethernet connection) or by wireless connection (e.g., via a network) using known interfaces and protocols.

Referring still to FIG. 10, the controller 220 is also operably connected and configured to transmit control instructions to a motor control system 230 that controls operation of the plurality of modules 100. For example, suitable motor control systems for use in the present invention include ControlLogix® controllers, which are part of the Allen-Bradley product line manufactured and distributed by Rockwell Automation, Inc. of Milwaukee, Wisconsin. Specifically, and as discussed above, the motor control system 230 communicates instructions to each module 100 that (i) rotate the vertical shaft 120 and thus reposition the drive wheel 150 at a desired angular orientation and (ii) activate or deactivate the drive wheel 150. Furthermore, motor control system 230 can move the vertical shaft 120 between the lower position in which the drive wheel 150 will not engage a parcel and the upper position in which an exterior surface of the drive wheel 150 is capable of engaging the parcel.

Thus, in use, as parcels are being transported by the conveyor system 10 in a bulk flow, each module 100 is ordinarily in a home position and activated, such that the drive wheel 150 of the individual modules work to transport parcels in a first direction, i.e., a longitudinal axis of the conveyor system 10 from left to right in FIG. 1. As parcels are being transported by the conveyor system 10, the one or more cameras 210a-n acquire two-dimensional and/or three-dimensional image data of the parcels as the parcels approach and/or are positioned in the second conveyor section 10b. The image data is transmitted from the cameras 210a-n to the controller 220, which analyzes the image data, identifies individual parcels in the bulk flow, and then makes decisions as to how to manage each individual parcel, i.e., whether to move the parcel transversely along a lateral axis (i.e., perpendicular to the longitudinal axis) toward the inner edge or outer edge while it is in the second conveyor section 10b. The parcel is therefore able to move any direction along a conveying surface collectively defined by the plurality of modules 100, as further described below. With respect to identification of the parcels in the bulk flow, one suitable methodology for identifying and ranking parcels for acquisition is described in U.S. Patent Nos. 10,646,898 and 10,994,309. However, various image analysis techniques, machine learning techniques, and/or artificial intelligence techniques could be used to carry out the identification of parcels without departing from the spirit and scope of the present invention.

Once each parcel has been identified, and a decision has been made as to how to manage the parcel, the controller 220 communicates instructions to the motor control system 230, which, in turn, communicates instructions to activate and control selected modules 100 near the parcel to effectuate any desired transverse movement. Such transverse movement will be further described in connection with certain examples described below reference to FIGS. 11-18 below. It is contemplated that the process of acquiring image data, identifying parcels, and managing individual parcel movement can be done recursively as the parcels move along the conveyor system 10 or the full movement required of each parcel can be determined from the analysis of a single image.

FIGS. 6-9 illustrate an alternate module 300 for the conveyor system 10. As shown in FIGS. 6-9, each alternate module 300 again includes a housing 310 with power connectors 312, 314 and a vertical shaft 320 that is mounted for rotation relative to the housing 310. Rotation of the vertical shaft 320 can be controlled in the same manner described above with respect to the exemplary embodiment illustrated in FIGS. 4 and 4A or any other known means. However, in this alternative, a belt drive assembly is mounted to the distal (upper) end of the vertical shaft 320.

Referring still to FIGS. 6-9, in this exemplary embodiment, a drive wheel 350 is also employed, with rotation of the drive wheel 350 controlled in the same manner described above with respect to the exemplary embodiment illustrated in FIGS. 4 and 4A or any other known means. However, two additional support axles 332 are also provided which are positioned above the drive wheel 350 and on either side of the drive wheel 350 with a belt 334 extending around the drive wheel 350 and support axles 332. To this end, and as perhaps best shown in FIGS. 7 and 8, the bracket 324 mounted to the distal (upper) end of the vertical shaft 320 includes a base portion 326 and two opposing legs 328a, 328b that extend upward from each end of the base portion 326. Each of the legs 328a, 328b is substantially T-shaped. The horizontal shaft (not shown) on which the drive wheel 350 is mounted extends between the vertical member of the opposing legs 328a, 328b, while each of the support axles 332 extend between respective arms of the T-shaped opposing legs 328a, 328b. During operation, when then drive wheel 350 is rotated, it causes the belt 334 to rotate around the drive wheel 350 and two support axles 332. It is contemplated that the belt 334 provides for greater surface contact with the parcels as compared to the drive wheel 150 shown and described in FIGS. 2, 3, 4, 4A, and 5. Furthermore, replacement of the belt 334 is simpler compared to replacement of the drive wheel 150 shown and described in FIGS. 2, 3, 4, 4A, and 5.

According to some other exemplary embodiments, as opposed to including a single drive wheel 350 and two support axles 332 which extend across substantially the entire width of the bracket 324, a belt drive assembly of the present invention can include multiple drive wheels and corresponding support axles. That is to say, two or more drive wheels are mounted along the same axis extending between two opposing legs of the bracket. A set of corresponding support axles is then provided for each of these drive wheels. Likewise, one of multiple belts extend around each drive wheel and corresponding support axles. In some embodiments, the axis about which each of the support axles rotates is contained within a plane such that the contact surface defined by the multiple belts is substantially flat, similar to the contact surface provided by the single belt 334 shown in FIGS. 6-9. However, by adjusting the position of the support axles within this plane, the shape of the contact surface defined by the multiple belts can have, for example, a generally circular shape as compared to the rectangular contact surface provided by the single belt 334 shown in FIGS. 6-9. This configuration provides a larger contact surface without increasing the overall size of the module.

FIG. 11 is a schematic view of an exemplary conveyor system 400 made in accordance with the present invention. In this exemplary implementation, there is a first (or inlet) conveyor section 410a, a second conveyor section 410b that comprises a matrix of the modules 100 described above (or the alternate modules 300 described above), a third (or outlet) conveyor section 410c, and two downstream conveyors 412, 414. As shown, the conveyor system 400, via the control and use of the modules 100 (or modules 300) is used to sort and singulate parcels into two discrete lines for subsequent delivery to the two downstream conveyors 412, 414.

FIG. 12 is a schematic view of an exemplary conveyor system 500 made in accordance with the present invention. In this exemplary implementation, there are multiple inbound conveyors 502, 504, 506, 507, 508, which may be collectively characterized as an first (or inlet) conveyor section, with each of the inbound conveyors 502, 504, 506, 507, 508 feeding parcels into a second conveyor section 510b that comprises a matrix of the modules 100 described above (or the alternate modules 300 described above). The parcels are then directed to a third (or outlet) conveyor section 510c. As shown, the conveyor system 500, via the control and use of the modules 100 (or modules 300) is used to sort and singulate parcels into a line for delivery to the outlet section 510c.

FIG. 13 is a schematic view of an exemplary conveyor system 600 made in accordance with the present invention. In this exemplary implementation, there is a first (or inlet) conveyor section 610a, a second conveyor section 610b that comprises a matrix of the modules 100 described above (or the alternate modules 300 described above), and multiple outbound conveyors 612, 614, 616, 617, 618, which may be collectively characterized as a third (or outlet) conveyor section, with each of the outbound conveyors 612, 614, 616, 617, 618 receiving parcels from the second conveyor section 610b. In this example, the conveyor system 600, via the control and use of the modules 100 (or modules 300) is used to sort and deliver parcels to each of the outbound conveyors 612, 614, 616, 617, 618.

FIG. 14 is a schematic view of an exemplary conveyor system 700 made in accordance with the present invention. In this exemplary implementation, there is a first (or inlet) conveyor section 710a, a second conveyor section 710b that comprises a matrix of the modules 100 described above (or the alternate modules 300 described above), and a third (or outlet) conveyor section 710c. As shown, the conveyor system 700, via the control and use of the modules 100 (or modules 300) is used to sort and singulate parcels. Specifically, in this example, the parcels are singulated into three discrete lines based on some common characteristic and then directed to the third (or outlet) conveyor section 710c for subsequent downstream processing.

FIG. 15 is a schematic view of an exemplary conveyor system 800 made in accordance with the present invention. In this exemplary implementation, there is a first (or inlet) conveyor section 810a, a second conveyor section 810b that comprises a matrix of the modules 100 described above (or the alternate modules 300 described above), and a third (or outlet) conveyor section 810c. As shown, the conveyor system 800, via the control and use of the modules 100 (or modules 300) is used to sort and singulate parcels. Specifically, in this example, the parcels are singulated into a single line and then directed to the third (or outlet) conveyor section 810c for subsequent downstream processing. Furthermore, by selectively or periodically deactivating certain modules 100, it is possible to buffer parcels in the second conveyor section 810c, and then deliver parcels in batches to the third (or outlet) conveyor section 810c.

FIG. 16 is a schematic view of an exemplary conveyor system 900 made in accordance with the present invention. In this exemplary implementation, there is a first (or inlet) conveyor section 910a, a second conveyor section 910b that comprises a matrix of the modules 100 described above (or the alternate modules 300 described above), and a third (or outlet) conveyor section 910c. As shown, the conveyor system 900, via the control and use of the modules 100 (or modules 300) is used to sort and singulate parcels. Specifically, in this example, the parcels are singulated into three discrete lines and then directed to the third (or outlet) conveyor section 910c for subsequent downstream processing. Again, by selectively or periodically deactivating certain modules 100, it is possible to buffer parcels in the second conveyor section 910b, and then deliver parcels in batches to the third (or outlet) conveyor section 910c.

FIG. 17 is a schematic view of an exemplary conveyor system 1000 made in accordance with the present invention. In this exemplary implementation, there is a first (or inlet) conveyor section 1010a, a second conveyor section 1010b that comprises a matrix of the modules 100 described above (or the alternate modules 300 described above), and a third (or outlet) conveyor section 1010c. As shown, the conveyor system 1000, via the control and use of the modules 100 (or modules 300) is used to sort and singulate parcels. Specifically, in this example, the parcels are accumulated into bundles and then directed to the third (or outlet) conveyor section 1010c for packaging or other downstream processing. Of course, the exemplary conveyor systems shown in FIGS. 11-17 and described above are merely exemplary of the various ways in which a matrix of the modules 100 (or the alternate modules 300) can be used to sort and singulate parcels, and the specific number or configuration of inlet conveyor sections, outlet conveyor section, and intermediate conveyor sections is not limited.

One of ordinary skill in the art will also recognize that additional embodiments and implementations are also possible without departing from the teachings of the present invention. This detailed description, and particularly the specific details of the exemplary embodiments and implementations disclosed therein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the present invention.