AUTONOMOUS PIVOT WHEEL ASSEMBLY FOR PACKAGE HANDLING

A package handling diverter, merge and sorter for package sortation is disclosed. The system includes at least one base frame with individual, cellular and autonomous pivot wheels mounted to the frame, in plurality, and can be combined together to form a complete sortation system. Each autonomous pivot wheel is a cellular design possessing its own drive motors so each can perform autonomously, yet in concert with other autonomous pivot wheels. The system is cable of diverting, merging and sorting packages. The autonomous pivot wheels are interactively coupled for communication therebetween whereby packages are selectively moved about configurable paths.

BACKGROUND OF THE INVENTION

The system described herein relates generally to an apparatus and method for arranging packages being processed on a conveyor system or the like. The present embodiments more specifically include a novel apparatus employing a plurality of robotic assemblies for diverting; merging, splitting, sorting, orienting and conveying packages with no manual user input.

In conventional package conveying systems utilized in e-commerce applications packages being conveyed usually need to be sorted by one of many criteria, often by destination addresses for example, or any one of many different shipping criteria. These prior art systems frequently use some type of vision system or reader to examine each package's label, thereby providing a wide variety of package information to an automated control system used to sort and direct packages to a customer or other end user. Package labels and/or bar codes can provide information including, but not limited to customer names, addresses, transportation information, billing information and delivery options. However, once the sorting information for each package is known the packages must then be directed or diverted to branching conveyor systems or end destination storage for further processing, for example loading on a truck or aircraft for delivery to another location.

Some prior art systems simply use manual labor to sort and divert packages, which are simply positioned by hand as the packages are being conveyed. Obviously these systems require constant human attention and are prone to slow-downs and errors when multiple mis-oriented packages require repositioning in a short span of time. Some systems utilize a variety of different systems such as mechanical diverters or even package handling robots to divert and reorient packages, but these systems are often slow and prone to mechanical issues, again requiring human input to repair or correct.

Accordingly, one disadvantage with prior art package sorting systems is the ability to provide high throughput sorting in an automated system. Another disadvantage of prior art systems is their relative inability to accept and sort a plurality of packages from multiple flow streams such as a plurality of converging conveyor systems. Additionally, many prior art systems are incapable of orienting and diverting packages on the fly, or while moving.

Accordingly, there is a need for an automated package conveying system that overcomes the many disadvantages of the prior art.

SUMMARY OF THE INVENTION

In various aspects and embodiments the system described herein provides a novel conveying system employing a plurality of autonomous pivot wheel assemblies systems to sort and arrange a moving package stream. A wide variety of embodiments and uses may be employed implementing the apparatus and system utilizing a variety of structures without departing from the teachings of this specification.

In some aspects and embodiments the autonomous pivot wheel system includes a plurality of pivot roller assemblies to simultaneously move and orient packages through a packaging conveyor system. A plurality of autonomous pivot wheels may be disposed at various locations around a sorting table or area of a conveyor without departing from the scope of the embodiments disclosed.

In various embodiments and aspects system disclosed herein utilizes a plurality of pivot roller assemblies disposed on a conveyor surface that are each electrically operated via computer control such that each pivot roller is individually controllable. Furthermore, each pivot roller is capable of rotation around a 360 degree vertical axis so an assembly, or a group of assemblies, can be oriented to direct a package in any direction along the conveyor surface, responsive to a computer input representative of a desired package direction.

As used herein for purposes of the present disclosure, the term “pivot roller” can be used to refer to any automated, computer controlled wheel that can be disposed or mounted on a conveyor surface, and that can be oriented in a plurality of directions for conveying, orienting a moving package of a predetermined size. Any of a wide variety of pivot rollers may be utilized with the concepts and embodiments of the invention as taught herein without limiting the scope of the claims appended hereto.

These and other advantages and features, which characterize the embodiments, are set forth in the claims appended hereto and form a further part thereof. However, for a better understanding of the embodiments and of the advantages and objectives attained through their use, reference should be made to the Drawing Figures and to the accompanying specification, in which there are described exemplary embodiments. This summary is merely provided to introduce a selection of concepts that are further described below in the detailed description, and is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in limiting the scope of the claimed subject matter.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Numerous variations and modifications of the apparatuses and embodiments of the disclosed invention will be apparent to one of ordinary skill in the art, as will be readily seen from the detailed description of the system set forth below. Therefore, the invention is not limited to the specific implementations discussed herein.

Furthermore, the embodiments discussed herein will focus on the implementation of the described techniques and apparatuses for a robotic system for sorting and culling packages. While the embodiments described herein will refer generally to implementation of a robotic package sorting and culling system one of ordinary skill will recognize that the invention may be practiced with a broad array of automated, mechanically controlled structures and components without departing from the scope thereof.

Referring now to drawingFIGS.1-2and in accordance with various aspects and embodiments, herein is described a novel autonomous pivot wheel system for sorting, conveying, diverting, and orienting packages. One of ordinary skill in the art will recognize that a wide variety of components and structures may be employed in conjunction with the embodiments without departing from the scope thereof. For example, the embodiments described herein are capable of being employed and/or adapted for use in a conventional package conveyor, as depicted inFIG.1. However, many other embodiments and uses may be employed implementing the apparatus and system utilizing a variety of structures without departing from the teachings of this specification.

The autonomous pivot wheel system10embodiments disclosed herein are suited for use with a package conveyor, or a plurality thereof, and in some embodiments forms a portion of the surface of a conveyor or conveyors. As seen inFIG.1an autonomous pivot wheel assembly20includes a frame30that generally encloses and protects the various components of assembly20as well as a enable quick change-out of a damaged pivot wheel assembly20. Frame30has an open top portion32that through which a rotating roller40extends so that the top surface of the roller is slightly above the surface of frame30opening32. Roller40has an exterior surface42that contacts a package being conveyed, and further includes a brushless direct current (DC) motor44that drives roller40and is journaled for rotation in a roller frame assembly46. Frame assembly46is also capable of independent rotation around a vertical axis, as will be discussed herein. In some embodiments roller40, driven by motor44is capable of rotation at variable rates of speed depending upon package conveying requirements. In some aspects roller40may operate at a rate sufficient to convey packages at 700 feet per minute, far in excess of many prior art conveyors.

It should be noted that roller motor44as well as all electrical controls of pivot wheel system10may be advantageously controlled by a processor having concomitant memory and operable inputs and outputs (not shown) that executes an instruction set to actuate and control the various electrical elements set forth herein.

Referring again toFIGS.1-6in various embodiments pivot wheel assembly20also includes a pivot50, operatively coupled to a controller. Pivot50also includes a brushless DC motor52and is rotatable by operation of motor52around a vertical axis. Pivot50is secured to Roller40frame46such that pivot50is capable of rotating frame46and thus roller40fully 360 degrees. In some embodiments and similar to roller40pivot50is operatively coupled to a controller output such that pivot50can accurately and quickly orient roller50in a particular drive direction. Accordingly, pivot wheel assembly20may advantageously be rotated to any directional orientation, and then driven at any speed by automated operation.

In some aspects and embodiments and as best seen inFIGS.6-8, a plurality of pivot wheel assemblies20can be arranged on a conveyor table to form a sorting and orienting conveyor1. Each assembly20can be individually controlled as discussed herein above, and furthermore groups of pivot wheel assemblies20can be operated together to achieve a desired package path and orientation. For example, a package that needs to exit the conveyor at a second end on the left side may enter conveyor1at a first end on the right side and then be driven diagonally across the conveyor1by a plurality of rollers40oriented to provide diagonal motion. Similarly, as can be readily seen, where a specific package has been identified to on a side of conveyor1, or even be turned around or reoriented, pivot wheel assemblies20can simply be operated via processor outputs to provide the required package direction and motion.

It is to be understood that the embodiments are not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The system described herein is capable of other embodiments and of being practiced or of being carried out in various ways. Unless limited otherwise, the terms “connected,” “coupled,” “in communication with,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.

While the present system has been shown and described herein in what are considered to be the preferred embodiments thereof, illustrating the results and advantages over the prior art obtained through the present system, the system is not limited to those specific embodiments. Thus, the forms of the system shown and described herein are to be taken as illustrative only and other embodiments may be selected without departing from the scope of the thereof, as set forth in the claims appended hereto.