Tray conveyor

The present disclosure relates to a tray locator assembly for aligning one or more trays in a tray-based automated storage and retrieval system. The tray locator assembly may include one or more guide pin assemblies having one or more guide pins engaging with one or more slots formed in a surface of at least one tray of the one or more trays. The tray locator assembly may further include at least one translational actuator to move the one or more guide pins inserted into the one or more slots so as to translate the at least one tray, wherein the translation of the at least one tray separates a second group of trays having a second size from a first group of trays having a first size along the conveyance plane to a second position in order to reduce tolerance stack up associated with the first group of trays.

TECHNOLOGICAL FIELD

Example embodiments of the present invention relate generally to material handling systems, and more particularly, to automated storage and retrieval systems for handling trays.

BACKGROUND

In a high-volume distribution and fulfillment center, tray handling methods and systems play an important part in overall efficiency of the distribution center. Trays are often used with pick and place systems to store and/or convey goods, such as totes, boxes, parcels, and the like. Automatic retrieving, conveying, and placing of trays for a pick and/or place operation is essential to the efficiency of the distribution center.

Applicant has identified several technical challenges associated with tray handling and other associated systems and methods. Through applied effort, ingenuity, and innovation, many of these identified challenges have been overcome by developing solutions that are included in embodiments of the present invention, many examples of which are described in detail herein.

BRIEF SUMMARY

The following presents a simplified summary to provide a basic understanding of some aspects of the disclosed tray conveyor. This summary is not an extensive overview and is intended to neither identify key or critical elements nor delineate the scope of such elements. Its purpose is to present some concepts of the described features in a simplified form as a prelude to the more detailed description that is presented later.

The illustrative embodiments of the present disclosure relate to systems and methods for handling trays in a material handling environment. According to at least one aspect of the present disclosure, a tray-based automated storage and retrieval system is provided. The tray-based automated storage and retrieval system may include a conveyor system for conveying a plurality of trays along a conveyance plane. The plurality of trays may be positioned together as a first group having a first size, and at least one tray of the plurality of trays may include one or more slots formed in a surface of the at least one tray. The tray-based automated storage and retrieval system may further include at least one tray locator assembly positioned adjacent the conveyance plane having one or more guide pin assemblies. The one or more guide pin assemblies may include one or more guide pins to engage the one or more slots of the at least one tray. The at least one tray locator assembly may include at least one translational actuator operatively coupled to the one or more guide pin assemblies and configured to move the one or more guide pins inserted into the one or more slots so as to translate the at least one tray, such that the translation of the at least one tray may separate a second group of trays having a second size from the first group of trays along the conveyance plane to a second position in order to reduce tolerance stack up associated with the first group of trays.

According to one or more embodiments of the present disclosure, the at least one translational actuator may separate the plurality of trays into the second group having the second size by moving the one or more guide pins inserted into the one or more slots from a start position to an end position. Further, in an embodiment, the second group may be smaller than the first group.

According to one or more embodiments of the present disclosure, the tray-based automated storage and retrieval system may include at least two tray locator assemblies periodically positioned below the conveyance plane separated by a predetermined distance, such that the predetermined distance may be proportional to a multiple of a dimension of the at least one tray. Further, in an embodiment, a first tray locator assembly may move one or more guide pins of the first tray locator assembly in a first direction and a second tray locator assembly may move one or more guide pins of the second tray locator assembly in a second direction, such that the second direction is opposite to the first direction.

According to one or more embodiments of the present disclosure, the tray-based automated storage and retrieval system may further include one or more sensors to detect a position of each of the plurality of trays on the conveyor system.

According to one or more embodiments of the present disclosure, the tray-based automated storage and retrieval system may further include a controller. The controller may detect a trigger event for actuating the at least one tray locator assembly, extend the one or more guide pins vertically into the one or more slots of the at least one tray, and actuate the translational actuator to translate the at least one tray, such that the translation of the at least one tray may separate the second group of trays having the second size from the first group of trays along the conveyance plane to the second position in order to reduce tolerance stack up associated with the first group of trays.

According to another aspect of the present disclosure, a tray locator assembly for aligning one or more trays in a tray-based automated storage and retrieval system is provided. The tray locator assembly may include one or more guide pin assemblies having one or more guide pins for engaging with one or more slots formed in a surface of at least one tray of the one or more trays. The tray locator assembly may further include at least one translational actuator, operatively coupled to the one or more guide pin assemblies, for moving the one or more guide pins inserted into the one or more slots so as to translate the at least one tray, such that the translation of the at least one tray may separate a second group of trays having a second size from a first group of trays having a first size along the conveyance plane to a second position in order to reduce tolerance stack up associated with the first group of trays.

According to one or more embodiments of the present disclosure, the tray locator assembly may further include a mounting plate movably coupled to the translational actuator. The mounting plate may mount the one or more guide pin assemblies such that the translation actuator may move the mounting plate to move the one or more guide pins inserted into the one or more slots from a start position to an end position. In an embodiment, the mounting plate may include at least two guide pin assemblies, mounted at each end of the mounting plate, having at least two guide pins to be inserted in at least two slots of the at least one tray.

According to one or more embodiments of the present disclosure, the translational actuator may include a belted actuator driven by a drive assembly.

According to one or more embodiments of the present disclosure, the translational actuator may move the one or more guide pins in a first direction and a second direction, such that the second direction is opposite to the first direction.

According to one or more embodiments of the present disclosure, the one or more guide pin assemblies may further include at least one actuator for extending the one or more guide pins into the one or more slots and for retracting the one or more guide pins back to an original position.

According to one or more embodiments of the present disclosure, the tray locator assembly may further include one or more proximity sensors for detecting a position of the one or more slots of the at least one tray and/or an extend and/or retract position of the one or more guide pins.

According to another aspect of the present disclosure, a method of operating a tray-based automated storage and retrieval system is provided. The method may include conveying a plurality of trays along a conveyance plane, such that the plurality of trays is positioned together as a first group having a first size, and at least one tray of the plurality of trays includes one or more slots formed in a surface of the at least one tray. The method may further include detecting, by a controller of the tray-based automated storage and retrieval system, a trigger event for actuating a tray locator assembly positioned underneath the conveyor system. The method may further include engaging one or more guide pins, of one or more guide pin assemblies of the tray locator assembly, with the one or more slots of the at least one tray, and translating, by a translational actuator operatively coupled to the one or more guide pin assemblies, the at least one tray, such that the translation of the at least one tray may separate a second group of trays having a second size from the first group of trays along the conveyance plane to a second position in order to reduce tolerance stack up associated with the first group of trays.

According to one or more embodiments of the present disclosure, the method may further include separating the plurality of trays into the second group having the second size by moving the one or more guide pins inserted into the one or more slots from a start position to an end position, such that the second group is smaller than the first group.

According to one or more embodiments of the present disclosure, the trigger event may include an indication, by one or more sensors of the tray-based automated storage and retrieval system, of the at least one tray being positioned adjacent the tray locator assembly.

According to one or more embodiments of the present disclosure, the trigger event may include an indication, by one or more sensors of the tray-based automated storage and retrieval system, of receiving the plurality of trays on the conveyance plane.

According to one or more embodiments of the present disclosure, the trigger event may include an indication, by one or more sensors of the tray-based automated storage and retrieval system, of misalignment of the at least one tray from a determined position.

According to one or more embodiments of the present disclosure, the method may further include determining, by the controller, the end position based on at least a degree of misalignment of the at least one tray from the determined position.

DETAILED DESCRIPTION

The components illustrated in the figures represent components that may or may not be present in various embodiments of the invention described herein such that embodiments may include fewer or more components than those shown in the figures while not departing from the scope of the invention.

Turning now to the drawings, the detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts with like numerals denote like components throughout the several views. However, it will be apparent to those skilled in the art of the present disclosure that these concepts may be practiced without these specific details.

As described above, in a conventional distribution and/or order fulfillment centers, trays are generally used for storing items, for temporary handling, and/or for conveying to a pick and/or place station. Often, a distribution and/or order fulfillment center may include a tray-based storage and retrieval system. The tray-based storage and retrieval system may have a plurality of trays on a conveyor pushing against one another to shift positions for each pick and/or place cycle. A conventional pick and/or place system may include a set of grippers that are programmed to automatically pick from and/or place items into the tray. Thus, the set of grippers may be positioned at a pitch that may depend on the tray's dimensions and/or location. Any deviation in the tray size, position, and/or orientation may lead to a jam or other impingement of the tray and/or misplacement of items on the trays.

Further, temperature and/or other ambient conditions may vary in a typical storage system in a distribution and/or order fulfillment center. As a result, a tray's dimensions may be susceptible to changes due to at least a thermal expansion or compression of the tray's material. As a row of several trays are pushed together on the conveyor system, these variations in each tray's dimensions may result in a very large discrepancy from a desired tray location (e.g. compounded by the number of trays). As described above, these discrepancies may cause grippers or other elements to be misaligned with corresponding elements of the tray resulting in the jamming of trays and/or the misplacement of items. Accordingly, devices of the present application provide for an external device that may relocate the trays to reduce these discrepancies (e.g., tolerance stack up) to provide for precisely-aligned, repeatable pick and place processing.

The tray-based storage and retrieval system described herein, in accordance with one or more embodiments of the present disclosure, includes a tray locator assembly for relocating trays to correct any misalignment from a desired tray location and/or to separate trays from a large size group of trays into one or more small size groups.

FIG. 1illustrates a perspective view of a tray-based automated storage and retrieval system100, in accordance with one or more embodiments of the present disclosure. As shown inFIG. 1, the tray-based automated storage and retrieval system100may include a conveyor system105for conveying trays110. In an embodiment, the conveyor system105may receive trays110retrieved from a storage unit (not shown) for a pick and/or place operation. That is, the conveyor system105may convey and/or position the trays110at a specific pick and place location, such that, a picker (e.g., a robotic arm) may pick items from and/or place items into the trays110. Additionally or alternatively, a robotic arm may grasp and/or lift one or more trays110and/or products off the surface of the trays110positioned at a specific location. The conveyor system105may include any means of conveying the trays110, such as, but not limited to, belted conveyors, roller conveyors, slide rails, idler roller rails, and the like. In an example embodiment, the conveyor system105may include a conveyor frame and a plurality of rollers disposed along at least one side of the conveyor frame, such that, the plurality of rollers may support and move the trays110forward in a direction of conveyance. Thus, the trays110may be supported and conveyed by the conveyor system105along a conveyance plane115.

Further, as shown inFIG. 1, the conveyor system105may receive a group of trays110together in a slug (e.g., a collection of trays110located substantially end-to-end). In an embodiment, the conveyor system105may receive and/or convey trays110in a first group having a first size n along the conveyance plane115, as shown inFIG. 1. In an exemplary embodiment, the first group of size n may include nine trays110, received and/or pushed by the conveyor system105together (e.g., as a slug). It should be noted that the term size as referred above may refer to any dimension depending upon the application of the system. As described above, pushing and/or conveying a slug of trays110may result in a degree of misalignment between a current position of the one or more trays110and a desired position, such as, a predetermined pick and place location. As would be evident to one of ordinary skill in the art in light of the present disclosure, the potential for misalignment attributed to the discrepancy of each tray110may be referred to herein as tolerance stack up (e.g., the compounding of tolerance misalignment).

Further, the trays110may include one or more slots120defined by a surface125of the trays110(e.g., a bottom surface). The term “slots” as used herein may refer to any opening, depression, and/or any other engagement feature in a surface of the tray. Since the trays110may be supported by the conveyor system105at the sides of the trays110, the bottom surface125and/or the slots120at the bottom surface125may be accessible from either side of the trays110. For the sake of convenience of description, reference is made herein to a bottom surface125and slots accessible from beneath the conveyance plane115.

FIG. 2illustrates a perspective view of the tray-based automated storage and retrieval system100, in accordance with one or more embodiments of the present disclosure. As shown inFIG. 2, the tray-based automated storage and retrieval system100may further include tray locator assemblies200positioned underneath (e.g., adjacent a surface of the trays) the trays110, below the conveyance plane115. In accordance with one or more embodiments of the present disclosure, the tray locator assemblies200may relocate the trays110to position them at desired pick and/or place positions. Further, the tray locator assemblies200may separate a large size group of trays110(e.g., first group having a first size) pushed together into small size groups of trays110(e.g., second group having a second size) so as to reduce discrepancies from variations in one tray size and/or position causing discrepancies in position of all trays in the group.

As shown inFIG. 2, a first group of trays110may include trays110a-110i. The tray locator assemblies200may be positioned underneath the conveyance plane115at periodic intervals. In an example embodiment, the tray locator assemblies200may be separated by a predetermined distance d, as shown inFIG. 2. In an embodiment, the predetermined distance d may be determined based on a one or more dimensions of the tray110. For example, the predetermined distance d may be proportional to a multiple of a dimension, such as, width w, of the tray110. For example, if the width w of a tray110is x units, the predetermined distance d between adjacent tray locator assemblies200may be 3x, if a spacing of three trays is desired. As shown inFIG. 2, the tray locator assemblies200may be positioned underneath trays110cand110g.

In an example embodiment, the tray locator assemblies200may engage with the trays110cand110g, as will be described later, to push the trays110cand110gfrom a first position to a second (i.e. desired) position. In an embodiment, the trays110cand110gmay subsequently push other trays when trays110cand110gare being pushed by the tray locator assemblies200. For example, tray110cmay be pushed by the tray location assembly in a first direction205, as shown inFIG. 2. The tray110cmay push tray110badjacent to110c, which may further push tray110ain the first direction205. Similarly, tray110gmay be pushed by the tray location assembly in a second direction210, as shown inFIG. 2. The tray110gmay push tray110hadjacent to110g, which may further push tray110iin the second direction210. Thus, a large size group of trays110may be broken into a second group or one or more smaller sized groups n1, n2, n3, as shown inFIG. 2. Thus, as described above, the tray locator assemblies200may relocate the trays110to reduce a degree of misalignment between a first position and a second position. Further, the tray locator assemblies200may separate the trays110from a large sized group into one or more small size groups, as shown inFIG. 2.

FIG. 3aillustrates a perspective view of the tray locator assembly200, in accordance with one or more embodiments of the present disclosure. As described above, the tray locator assembly200may engage with a tray110positioned above the tray locator assembly200to relocate the tray110. As shown inFIG. 3a, the tray locator assembly200may include one or more guide pin assemblies305. In an example embodiment, the tray locator assembly200may include a first guide pin assembly305aand a second guide pin assembly305b. The guide pin assemblies305a,305bmay further include one or more guide pins310for engaging with the tray110. In an example embodiment as shown inFIG. 3a, the first guide pin assembly305amay include a first guide pin310aand the second guide pin assembly305bmay include a second guide pin310b. Each of the first and second guide pin assemblies305aand305bmay further include a bearing block307that houses a bearing308positioned as a sleeve to the guide pin310, as shown inFIG. 3a. The first and second guide pin assemblies305aand305bmay further include a mounting bracket309for mounting the first and second guide pin assemblies305aand305bto a mounting plate320of the tray locator assembly200. The mounting plate320may include a plate and/or any other structure suitable for mounting one or more guide pin assemblies305. In an example embodiment, the mounting plate320may include the first guide pin assembly305amounted at a first end of the mounting plate320and the second guide pin assembly305bmounted at a second end of the mounting plate320. A space between the first and second guide pin assemblies305aand305bmay be based on the spacing between two slots of the tray110.

Further, the tray locator assembly200may include a translational actuator315operatively coupled to the guide pin assemblies305for moving the guide pin assemblies305engaged with the tray110thereby pushing the tray110. In an example embodiment, the mounting plate320having the first and second guide pin assemblies305aand305bmay be movably coupled to the translational actuator315. The translational actuator315may include any means for causing a translational motion in the mounting plate320coupled to the translational actuator315. For example, the translation actuator315may include a belted actuator325coupled to a drive assembly330, as shown inFIG. 3a. The mounting plate320may be coupled to the belted actuator325, and the belted actuator325may be driven by the drive assembly330to be movable in a first direction327or in a direction opposite to the first direction327. Specifically, the drive assembly330may include a drive (not shown), such as, but not limited to, a motor, driving a roller (not shown). A belt340may be driven by the roller, as shown inFIG. 3a. The belted actuator325may be coupled to the belt340, such that, when the belt340is driven in the first direction327, the belted actuator325and subsequently the mounting plate320, move in the first direction327. In an example embodiment, the translational actuator315may include a timing belt (not shown) for controlled motion of the belted actuator325. Thus, the translational actuator315may move the guide pin assemblies305from a start position, for example a current position of the tray110, to an end position, for example a desired position of the tray110, thereby pushing the tray110from the first position to the second position.

FIG. 3billustrates a sectional view of the guide pin assembly305, in accordance with one or more embodiments of the present disclosure. As described above, the guide pin assembly305may include one or more guide pins310for engaging the tray110. In an example embodiment, the guide pin310may be insertable in or otherwise received by a slot120at the bottom surface125of the tray110, as shown inFIG. 1. Further, the guide pin310may reciprocate vertically, that is, may extend to be inserted into the slot120of the tray110, and may retract back to an original position (e.g., not in engagement with the slots120).

As shown inFIG. 3b, the guide pin assembly305may further include the bearing308housed in the bearing block307. The bearing308may act as a sleeve around the guide pin310. Further, the guide pin assembly305may include a spring355and an actuator360, as shown inFIG. 3b. The spring355and the actuator360may be operatively coupled to the guide pin310, such that the guide pin310may be actuated by the actuator360so as to push the guide pin310outwards and into the slot120of the tray110. The guide pin310, when actuated, may push against the spring355that may act as return spring for retracting the guide pin310back into an original position. In an example embodiment, the actuator360may include short stroke air cylinders.

The tray locator assembly200may further include a reed switch345, as shown inFIG. 3a, for detecting a position of the actuator360before initiating a pushing motion by the translational actuator315. Specifically, the actuator360may include a magnetic section made of a magnetic and/or ferrous material such that the reed switch345may detect an upward and downward motion of the actuator360based on the magnetic section. Thus, the translational actuator315may be actuated only when the reed switch345detects that the guide pin310is fully extended so as to prevent damage and/or breaking of the guide pin310. Further, the guide pin assembly305including the mounting bracket309and the actuator360may be mounted on the mounting plate320, as shown inFIG. 3b. Thus, for relocating the tray110, the tray locator assembly200may control the actuator360to extend the guide pin310to be inserted into the slot120of the tray110, and may control the translational actuator315to move the guide pin310from a start position to an end position, thereby pushing the tray110from the first position to the second position.

FIG. 4illustrates a perspective view of the tray-based automated storage and retrieval system100, in accordance with one or more embodiments of the present disclosure.FIG. 4depicts the tray locator assembly200engaging with the tray110located on the conveyor system105. As shown, the tray locator assembly200is positioned underneath the tray110and below the conveyance plane115. As described above, the guide pin310of the tray locator assembly200may be inserted into the slot120of the tray110. Further, to relocate the tray110, the translational actuator315of the tray locator assembly200may move the guide pin310, operatively coupled to the translational actuator315and inserted into the slot120, from a start position to an end position in and/or against a direction of conveyance.

In an example embodiment, the conveyor system105and/or the tray locator assembly200may include one or more sensors, such as, but not limited to, photoeyes, cameras, proximity sensors, and the like. The one or more sensors may detect at least a position of the one or more trays110. Further, a controller (e.g., controller500inFIG. 5) of the tray-based automated storage and retrieval system100, as will be described later, may receive data from the one or more sensors. The controller may further be communicatively coupled to one or more components of the tray-based automated storage and retrieval system100, such as, but not limited to, the conveyor system105, the tray locator assembly200, and the like.

In an example embodiment, the tray-based automated storage and retrieval system100and/or the controller may control the actuation of the tray locator assembly200based on a trigger event. The term “trigger event” as used herein may refer to a change in a function and/or operation of the tray-based automated storage and retrieval system100that may be detected by the tray-based automated storage and retrieval system100as a trigger to actuate the tray locator assembly200. The trigger event may, in some embodiments, include an indication, by the one or more sensors, of the tray110positioned above the tray locator assembly200. For example, a photoeye sensor positioned on the conveyor system105above the tray locator assembly200may detect a presence of the tray110at the position above the tray locator assembly200and may provide an indication of the trigger event to the tray-based automated storage and retrieval system100and/or the controller (e.g., controller500inFIG. 5).

In another embodiment, the trigger event may include an indication, by the one or more sensors, of receiving the plurality of trays110on the conveyor system105. For example, one or more sensors and/or the controller may detect that a slug of trays110is received on the conveyor system105. Further, based on the number of trays110in the slug, dimensions, such as width of each tray110and/or a speed of conveyance, the tray-based automated storage and retrieval system100and/or the controller may detect a trigger event for actuating the tray locator assembly200based on a time taken by the tray110to travel to a position above the tray locator assembly200.

Further, in another embodiment, the trigger event may include an indication, by the one or more sensors, of misalignment of the tray110from a determined position. For example, the one or more sensors may determine that the tray110is positioned inaccurately at a determined pick and/or place position, and may provide an indication of the misalignment to the tray-based automated storage and retrieval system100and/or the controller. In response, the tray-based automated storage and retrieval system100and/or the controller may detect a trigger event for actuating the tray locator assembly200. Further, the tray locator assembly200and/or the controller may determine a start position and an end position for the guide pin310based on a degree of misalignment of the tray110from the determined position.

In an example embodiment, the tray locator assembly200may include one or more sensors, such as, but not limited to, proximity sensors, for detecting a slot120of the tray110. For example, a photoeye facing upwards may be mounted on the tray locator assembly200next to the guide pin310such that a slot120may be determined to be present if the photoeye is unblocked. Thus, the tray locator assembly200may ensure that the slot120is present above the guide pin310before actuating the guide pin310.

Further, as described above, with reference toFIG. 3a, the tray locator assembly200may include two guide pins310to be inserted into two corresponding slots120of the tray110. Thus, two guide pins310pushing the tray110together may ensure that tray110stays in alignment with the conveyor system105while moving so as to prevent skewing of the tray110.

FIG. 5illustrates a schematic block diagram of a controller500for controlling the operation of the tray-based automated storage and retrieval system100, in accordance with one or more embodiments of the present disclosure. As shown, the controller500may include at least one processor520, memory525, communication module530, and input/output module535. The processor520may be configured with processor executable instructions to perform operations described herein. Processor520may, for example, be embodied as various means including one or more microprocessors with accompanying digital signal processor(s), one or more processor(s) without an accompanying digital signal processor, one or more coprocessors, one or more multi-core processors, one or more controllers, processing circuitry, one or more computers, various other processing elements including integrated circuits such as, for example, an ASIC (application specific integrated circuit) or FPGA (field programmable gate array), or some combination thereof. Accordingly, although illustrated inFIG. 5as a single processor, in some embodiments processor520may comprise a plurality of processors. The plurality of processors may be embodied on a single device or may be distributed across a plurality of devices. The plurality of processors may be in operative communication with each other and may be collectively configured to perform one or more functionalities of the controller500as described herein. In an example embodiment, processor520is configured to execute instructions stored in memory525or otherwise accessible to processor520. These instructions, when executed by processor520, may cause controller500to perform one or more of the functionalities of controller500, as will be described with reference toFIG. 6.

Memory525may comprise, for example, volatile memory, non-volatile memory, or some combination thereof. Although illustrated inFIG. 5as a single memory, memory525may comprise a plurality of memory components. The plurality of memory components may be embodied on a single device or distributed across a plurality of devices. In various embodiments, memory525may comprise, for example, a hard disk, random access memory, cache memory, read only memory (ROM), erasable programmable read-only memory (EPROM) & electrically erasable programmable read-only memory (EEPROM), flash memory, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, a compact disc read only memory (CD-ROM), digital versatile disc read only memory (DVD-ROM), an optical disc, circuitry configured to store information, or some combination thereof. Memory525may be configured to store information, data (including item data and/or profile data), applications, instructions, or the like for enabling controller500to carry out various functions in accordance with example embodiments of the present invention. For example, in at least some embodiments, memory525may buffer input data for processing by processor520. Additionally or alternatively, in at least some embodiments, memory525may store program instructions for execution by processor520. Memory525may store information in the form of static and/or dynamic information. This stored information may be stored and/or used by the controller500during the course of performing its functionalities.

Communications module530may be embodied as any device or means embodied in circuitry, hardware, a computer program product comprising computer readable program instructions stored on a computer readable medium (e.g., memory525) and executed by a processing device (e.g., processor520), or a combination thereof that is configured to receive and/or transmit data from/to another device and/or network, such as, for example, sensors, conveyor system105, tray locator assemblies200, and the like. In some embodiments, communications module530(like other components discussed herein) may be at least partially embodied as or otherwise controlled by processor520. In this regard, communications module530may be in communication with processor520, such as via a bus. Communications module530may include, for example, an antenna, a transmitter, a receiver, a transceiver, network interface card and/or supporting hardware and/or firmware/software for enabling communications with another device. Communications module530may be configured to receive and/or transmit any data that may be stored by memory525using any protocol that may be used for communications between devices. Communications module530may additionally or alternatively be in communication with the memory525, input/output module535and/or any other component of the controller500, such as via a bus.

Input/output module535may be in communication with processor520to receive an indication of a user input and/or to provide an audible, visual, mechanical, or other output to a user. As such, input/output module535may include support, for example, for a keyboard, a mouse, a joystick, a display, a touch screen display, a microphone, a speaker, a RFID reader, barcode reader, biometric scanner, and/or other input/output mechanisms. In embodiments wherein the controller500is embodied as a server or database, aspects of input/output module535may be reduced as compared to embodiments where the controller500is implemented as an end-user machine (e.g., remote worker device and/or employee device) or other type of device designed for complex user interactions. In some embodiments (like other components discussed herein), input/output module535may even be eliminated from the controller500. Alternatively, such as in embodiments wherein the controller500is embodied as a server or database, at least some aspects of input/output module535may be embodied on an apparatus used by a user that is in communication with the controller500. Input/output module535may be in communication with the memory525, communications module530, and/or any other component(s), such as via a bus. One or more than one input/output module and/or other component can be included in the controller500.

Embodiments of the present invention have been described above with reference to block diagrams and flowchart illustrations of methods, apparatuses, systems and computer program goods. It will be understood that each block of the circuit diagrams and process flowcharts, and combinations of blocks in the circuit diagrams and process flowcharts, respectively, can be implemented by various means including computer program instructions. These computer program instructions may be loaded onto a general purpose computer, special purpose computer, or other programmable data processing apparatus, such as processor520, as discussed above with reference toFIG. 5, to produce a machine, such that the computer program product includes the instructions which execute on the computer or other programmable data processing apparatus create a means for implementing the functions specified in the flowchart block or blocks.

These computer program instructions may also be stored in a computer-readable storage device (e.g., memory525) that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable storage device produce an article of manufacture including computer-readable instructions for implementing the function discussed herein. The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions that execute on the computer or other programmable apparatus provide steps for implementing the functions discussed herein.

Accordingly, blocks of the block diagrams and flowchart illustrations support combinations of means for performing the specified functions, combinations of steps for performing the specified functions and program instruction means for performing the specified functions. It will also be understood that each block of the circuit diagrams and process flowcharts, and combinations of blocks in the circuit diagrams and process flowcharts, can be implemented by special purpose hardware-based computer systems that perform the specified functions or steps, or combinations of special purpose hardware and computer instructions.

FIG. 6illustrates an example method600for operating the tray-based automated storage and retrieval system100, in accordance with one or more embodiments of the present disclosure. The method600may include conveying a plurality of trays110along the conveyance plane115such that the plurality of trays110is positioned together as a first group having a first size n, as shown inFIG. 1, at block605. As described above, in an embodiment, trays110may include one or more slots120at a surface125of the tray110. The method600may further include detecting, by the tray-based automated storage and retrieval system100and/or the controller500, a trigger event for actuating a tray locator assembly200positioned adjacent the conveyor system105, at block610. As described above, the tray-based automated storage and retrieval system100and/or the controller may control the actuation of the tray locator assembly200based on a trigger event. The term ‘trigger event’ as used here may refer to a change in a function and/or operation of the tray-based automated storage and retrieval system100that may be detected by the tray-based automated storage and retrieval system100as a trigger to actuate the tray locator assembly200. In an embodiment, the trigger event may include an indication, by the one or more sensors, of the tray110being adjacent the tray locator assembly200. In another embodiment, the trigger event may include an indication, by the one or more sensors, of receiving the plurality of trays110on the conveyor system105. Further, in another embodiment, the trigger event may include an indication, by the one or more sensors, of misalignment of the tray110from a determined position.

Further, if, at block615, it is determined, by the tray-based automated storage and retrieval system100and/or the controller500, that a trigger event is not detected, the method600may proceed to block605. However, if, at block615, a trigger event is detected, by the tray-based automated storage and retrieval system100and/or the controller500, the method600may proceed to block620.

At block620, the method600may include engaging, by the tray locator assembly200and/or the controller500, one or more guide pins310of the tray locator assembly200with the one or more slots120of the tray110, as shown inFIG. 4. As described above, with reference toFIG. 3b, the actuator360of the guide pin assembly305may actuate the guide pin310to extend vertically upwards into the slot120of the tray110. Thus, engaging the tray locator assembly200with the tray110.

The method600may further include actuating, by the tray locator assembly200and/or the controller500, a translational actuator320to move the at least one tray110such that the translation of the at least one tray110separates a second group of trays having a second size from the first group of trays along the conveyance plane to a second position in order to reduce tolerance stack up associated with the first group of trays, at block625. As described above, with reference toFIG. 3aandFIG. 4, the translational actuator315of the tray locator assembly200may move the belted actuator325and subsequently the mounting plate320having the guide pin310towards and/or away from a direction of conveyance of the trays110. Thereby, separating a smaller sized group (i.e. second group) from a large sized group (i.e. first group) of trays in order to reduce discrepancies caused by multiple trays110being pushed together (e.g., reduce tolerance stack up).

Thus, the tray-based automated storage and retrieval system100may automatically relocate the trays110to correct any misalignment from a desired pick and/or place position. The tray-based automated storage and retrieval system100may also separate trays110being pushed in a large group size into one or more small size groups, for reducing tolerance stack up.

While it is apparent that the illustrative embodiments of the invention herein disclosed fulfill the objectives stated above, it will be appreciated that numerous modifications and other embodiments may be devised by one of ordinary skill in the art. Accordingly, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which come within the spirit and scope of the present invention.