Abstract:
The invention concerns a method and device for the automatic loading of e.g. commissioned goods in the form of articles into or onto individual transport containers such as cardboard boxes or pallets. The goods, all or some of which may be commissioned, are conveyed to at least one pre-defined loading point past which the transport containers continuously move. The goods are placed in or on the appropriate transport container at the loading point. The supplying and loading of the goods and the movement of the transport containers are controlled in timely, i.e. synchronized, fashion by a control unit.

Description:
FIELD OF THE INVENTION 
     The invention relates to a process and to a device for automatic provision of piece-type, optionally commissioned, goods into or onto individual transport units such as cartons, pallets or such like. 
     BACKGROUND OF THE INVENTION 
     Particularly in the mail-order business it is necessary to commission piece-type goods—ie, to assemble them according to number and type from a stock of an extremely wide range of goods in accordance with a specified order, to fill them into a dispatch carton and to dispatch them to the client. Fundamentally similar operations are to be observed when piece-type goods are deposited onto dispatch pallets or when they are mounted, such as by being suspended, onto transport units similar to clothes-rails. So long as goods of a single type are to be processed exclusively, the operations are relatively simple. However, as mentioned, goods of highly variable type and size have to be processed in the mail-order business. In accordance with the state of the art there have been attempts to automate, to a very large extent, the selection of the individual goods in question and the assembling thereof into a consignment corresponding to a specified order. Embodiments and examples of such processes and devices for commissioning individual articles are described, for example, in EP 0 457 158 B1, EP 0 183 074 A1, DE 34 12 025 A1, in the periodical “Industrie-Anzeiger” Volume 95, No. 40, May 11, 1973, Leinfelden-Echterdingen (DE), pp 824-826; W Fürdenschess: “Möoglichkeiten automatischer Kommissioniersysteme” and in the periodical “Fördern und Heben”, Volume 19, 1969, Number 12, pp 727-731, K Heptner, “Methoden der Warenverteilung und Auftragszusammenstellung in den USA”. 
     All these printed publications cited from the state of the art are concerned with the assembly of a consignment with as little effort as possible in terms of storage area and with an error-rate that is as low as possible. According to the state of the art the assembled consignment is passed in a heap onto an output conveyor and optionally introduced into an intermediate container. EP 0 457 158 B1 mentions in passing that, instead of an intermediate container, use may also be made of a dispatch carton, since the data pertaining to a consignment are known. However, the operations between assembly of a consignment and provision for final dispatch are not simply structured; on the contrary, errors may occur which not only block this area but can influence the entire plant, that is to say, also the assembly of the consignment. It is therefore desirable to automate the operations between assembly of a consignment and release to the dispatch department as far as possible and to take all necessary measures into account in the process. It is furthermore desirable to accelerate the speed of these operations as much as possible. 
     At the same time the needs of the mail-order business are to be taken into account. The assembled consignment is to be introduced into an appropriate container such as a dispatch carton or is to be placed onto an appropriate pallet or suspended on an appropriate transport unit such as an arrangement similar to a clothes-rail. After this packing operation a check is to be carried out, which conventionally is a visual check. Furthermore, dispatch documents are to be made available and added. Frequently a complementing operation is necessary, which ordinarily consists in adding filling or supporting material, free gifts and/or advertising leaflets. After a sealing step which may possibly be necessary, the dispatch addresses are applied and the data necessary for dispatch are ascertained and noted—for instance, weight, format or the like—in order also to be able to establish the costs of dispatch, whereby a distinction is to be made depending on whether the recipient or the sender has to bear the costs of dispatch, whether the recipient has to pay not only the costs of dispatch but also the total costs at the same time (for instance, in the case of a cash-on-delivery shipment) and such like. 
     SUMMARY OF THE INVENTION 
     It is therefore the object of the invention to design a process and a device of the type specified in the introduction in such a way that, with a very largely automated and rapid sequence of operations, there is no increased risk of error. 
     These and other objects, features, and advantages of the present invention are achieved by the process and the apparatus disclosed and described herein. Various modifications and alternative constructions are also disclosed that fall within the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention is elucidated in more detail below on the basis of several embodiment examples. Illustrated are: 
     FIG. 1 schematically, the processing sequence under the control of a common control device, 
     FIGS. 2-8 schematically, various practice-related embodiment examples. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 shows, to begin with, the basic sequence of the process according to the invention and therefore also the arrangement of associated devices in conformity with the system. 
     An order-picking step  1  designates a part of the plant or a process step in which piece-type goods are made available in the requisite number as desired by a customer. In practice, but not necessarily, it will also be a question of different goods, so that it is actually possible to speak of order picking. A provisioning step  2  designates a part of the plant or a process step in which the transport unit that is necessary in the given case is made available, for example is selected from a stock and prepared for the receipt of goods. These transport units may be dispatch cartons, dispatch containers, bags, pouches, but also pallets or such like, depending on the goods in question and also depending on the dispatch route that is appropriate in the given case. A filling stretch  3  designates a part of the plant or a process step in which the goods made available in the order-picking step  1  are filled, placed or mounted into or onto the transport unit supplied in the provisioning step  2 . The filling stretch  3  may be followed by a conventional further processing step such as a completion step  4  in which completeness is checked, it being possible for this completion step  4  also to include an ascertainment of weight, the insertion of dispatch documents, complementing such as by means of free gifts, filling or supporting material and/or advertising leaflets. At the end of the completion step  4  the transport unit is optionally sealed. The sealed assembly consisting of goods and associated transport unit is subsequently supplied to a conventional dispatch step  5 . 
     The synchronised control of the order-picking step  1 , of the provisioning step  2  and of the filling stretch  3  is effected by a common control device  6  which not only emits commands to the individual devices performing these process steps but also receives status and acknowledgement messages and, over and above these, also messages concerning the orders to be executed and the sequence thereof and also messages concerning the individual components, goods and transport units supplied and removed, designated concisely in FIG. 1 by “inventory”. 
     An essential element of the present invention is that an acceleration can be achieved by reason of the chosen sequence and the common control by the control device  6 , inasmuch as that in the course of the transition from the order-picking step  1  to the filling stretch  3  the particular goods or consignments that have been assembled are dispensed directly into or onto the appropriate transport unit, in which connection the transport unit does not have to stop on the filling stretch  3  but is continuously conveyed there past the dispensing point for the goods supplied in the order-picking step. This avoids the risk of congestion and nevertheless ensures that all orders are executed accurately. 
     This will be explained in more detail on the basis of the various embodiments. 
     In the case of the embodiment according to FIG. 2, individual transport units represented by square frames, such as transport cartons  11 , are transported continuously on a conveyor belt  12  (arrows  13 ). The goods  14 , represented here by circles, are supplied in the order-picking step  1  (FIG. 1) to a stationary dispensing point  16  via a supply arrangement represented schematically as a chute  15  and are dispensed in the required quantity to the transport cartons  11  passing said dispensing point continuously. For this purpose a sluice, a shutter or such like (not represented in any detail) may be provided at the dispensing point  16  of the supply arrangement  15 , the opening of said sluice or shutter being brought about by the control device  6  (FIG.  1 ), depending on whether a transport carton  11  is or is not present at the dispensing point  16 , this being determined by means of a detector (not represented). Subsequently, as is conventional, a check is carried out (the devices required for this purpose are not represented in any detail) as to whether the item of merchandise  14  is actually present in the transport carton  11 . In the affirmative case, dispatch documents  17  are added. 
     The embodiment example according to FIG. 3 differs from that according to FIG. 2 substantially by virtue of a different type of supply arrangement, so that, to a very large extent, use is made of the same reference symbols as in FIG.  2 . 
     In the case of the embodiment example according to FIG. 3 the empty transport units, namely empty transport cartons  11  which are symbolised by smaller squares, are supplied via another conveyor belt  19  in accordance with the arrow  20 , whereas the goods  14  are supplied via another conveyor  21 . The goods  14  here may also be constituted by consignments. Goods  14  and transport carton  11  may accordingly be brought together by means of the conveyor belt  19  at a conveying speed of the empty transport cartons  11  differing from the other, conventional processing on the conveyor belt  12 . By this means a buffering can be achieved. 
     The embodiment example according to FIG. 4 likewise makes reference to the embodiment examples according to FIGS. 2 and 3 and differs, on the one hand, by virtue of a somewhat more concrete representation and also by virtue of a different supply arrangement for the order-picking step  1 , so that, here too, use has very largely been made of the same reference symbols. 
     The goods  14  here are brought round on a circulating conveyor  22 , having been applied, also for example in the form of a consignment, onto this circulating conveyor  22  at another point. During a certain section of its path the circulating conveyor  22  runs parallel to and substantially at a similar speed as the conveyor belt  12  on which the initially empty transport cartons  11  are located. The circulating conveyor  22  contains tipping mechanisms  23  on which the goods  14  in question are located. In the aforementioned section of synchronism the tipping mechanism  23  is actuated, controlled by the control device  6  (FIG.  1 ), as a result of which said tipping mechanism tips the goods  14  into the initially empty transport carton  11 , which is situated roughly at the same height, in accordance with the path of movement symbolised by the arrow  24 . 
     In a station  25  which is represented schematically by a type of bridge a conventional weighing of the carton  11  that is provided with goods  14  is carried out. This weighing in the station  25  may already suffice to achieve the check within the completion step  4  according to FIG. 1 as to whether all or the correct goods  14  have been inserted into the associated transport carton  11 , since the weights of each item of merchandise  14  are known very precisely, and it can accordingly also trigger the supply of associated dispatch documents (not represented here). 
     With regard to the weighing station  25  it is also to be noted that it is known as such to be able to weigh goods conveyed on a conveying belt  12  without removing them from the conveyor belt. Of course, use may also be made of weighing stations  25  that are independent of the conveying belt  12  and that, after the weighing operation, pass the goods on to an additional conveying belt (not represented in detail). 
     The embodiment example according to FIG. 5 differs substantially from the embodiment example according to FIG. 4 by virtue of the different type of supply arrangement. In the case of the supply arrangement  28  represented in FIG. 5 it is a question, for example, of an automated order-picking machine such as is elucidated in detail in EP 0 457 158 B1. Accordingly, individual goods  14 , which may be of extraordinarily different type, are supplied via a supply conveyor  29  and, controlled by a computer, distributed onto various inclined conveyors  30  in preferred orientation. Via these inclined conveyors  30  the individual goods are distributed onto the empty transport cartons  11  supplied via conveyor belts  19  in accordance with the specification of the consignment in question, synchronously with the latter and controlled by the control device  6  (FIG.  1 ). The transport cartons  11  provided with the individual goods  14  assembled in accordance with a special consignment then reach a common conveyor belt  12  and via the latter reach the weighing station  25 , as is conventional. Prior to sealing, a conventional complementing step known as such may be carried out, the complementing materials being supplied in accordance with the arrow  31 , for example via a chute or another conveyor  32 , to an already weighed or checked carton  11  filled with goods  14 . As already mentioned, the complementing materials may comprise filling or supporting material but may also comprise free gifts and advertising leaflets. 
     The embodiment example according to FIG. 6 differs from that according to FIG. 5 by virtue of a different configuration of the supply arrangement. The supply arrangement  33  therein is designed in such a way that intermediate containers  34  are supplied via the conveyor  29 , in which connection the intermediate containers  34  contain the goods  14 , the consignments or only parts thereof. At suitable points these intermediate containers  34  are emptied, the appropriate goods then being supplied via chutes  35  to the empty transport cartons  11  supplied via the conveyor belt  19 , optionally at several points along the conveyor belt  19 . 
     Further handling is effected as in the embodiment example according to FIG.  5 . 
     The embodiment example according to FIG. 7 follows the model of that according to FIG. 4 to the extent that a circulating conveyor  22  is provided. Goods  14  or assembled consignments or partial consignments are supplied to the circulating conveyor  22  via several supply conveyors  36  and  37 . Parallel conveyor belts  12  and  12   a  run past the circulating conveyor  22 , on which, as already explained with reference to FIG. 4, transport cartons  11  are located, into which the goods  14  are surrendered at suitable points, individually or in the form of consignments or partial consignments. This is symbolised by arrows  38  and may be carried out by, for instance, tipping mechanisms, as explained with reference to FIG.  4 . The embodiment according to FIG. 7 permits several transport cartons  11  to be filled simultaneously with different goods  14  and/or a transport carton  11  to be filled at several points in succession. 
     FIG. 7 also shows another option schematically. A transport carton  11  which as yet is not completely filled can be moved past the circulating conveyor  22  again via a feedback loop  39 . 
     As mentioned, an item of merchandise can be inserted into the same transport carton  11  at different points in succession. This is of significance when a consignment comprises goods that differ greatly from one another and/or when it is expedient or necessary to arrange certain goods underneath other goods. By way of example, a consignment will be imagined that consists of a large-format heavy book, packaged shirts or blouses and also other small components, possibly even components that are susceptible to breakage. It is then necessary to place the book, optionally even in a precisely predetermined location, into a transport carton  11  first, to deposit the packaged shirt or packaged blouse thereupon and subsequently to charge the remaining components. The sequence of the introduction of certain goods and partial consignments into a certain transport carton  11  can be controlled automatically and in synchronised manner by the control device  6  (FIG.  1 ). 
     The embodiment according to FIG. 8 is also based on the schematic representations of the previous embodiment examples. In FIG. 8 it is shown that transport cartons  11   a,    11   b,    11   c,  . . . , which may have extremely different dimensions, are conducted successively on the conveyor belt  12  past dispensing points  16  of a supply arrangement  40 . The individual transport cartons are drawn from a stock and erected automatically in associated erecting machines. In this connection a specific stock and a specific erecting machine is assigned to each transport-carton format. For instance, a stock  41   a  and a carton-erecting machine  42   a  are assigned to the transport carton  11   a,  a stock  41   b  and a carton-erecting machine  42   b  are assigned to the transport carton  11   b,  etc, with the carton  11   a,    11   b,    11   c,  . . . that is necessary in the given case being placed, controlled automatically by the control device  6  (FIG.  1 ), onto the conveyor belt  12  in the sequence according to the arrow  43 , which is likewise controlled by the control device  6  on the basis of certain orders and, to be specific, also subject to a given spacing. At the at least one dispensing point  16  the goods  14  in question are then dispensed into the appropriate carton  11   a,    11   b,    11   c,  . . . , likewise controlled automatically by the control device  6 . The goods can be supplied separately or jointly via appropriate automated order-picking machines  45   a,    45   b,    45   c,  . . . to conveyors  44   a,    44   b  pertaining to the supply arrangement  40  which lead to dispensing points  16 . Filling of the cartons  11   a,    11   b,    11   c,  . . . is then continued further in the manner already explained in detail. 
     Alternatively the complementing materials may also be supplied upstream of the weighing station  25 , particularly if they have an appreciable weight and the total weight necessarily has to be ascertained for dispatch purposes. Furthermore, in those cases where the station is unable to process all available formats of transport cartons  11  it is possible to provide a switch and to process them further in various appropriate stations. Of course, these steps may be carried out by hand, as is likewise known as such and traditionally conventional. 
     The invention was elucidated above on the basis of embodiments in which goods  14  are filled into transport cartons  11  by way of transport units. In principle, the same operations are possible and feasible when goods are filled into dispatch containers, into bags, pouches or such like and also when goods are placed onto pallets, in which connection it may be expedient or even necessary under certain circumstances to relocate and to deposit individual goods at the appropriate dispensing point. Similar remarks apply to other types of transport unit, for instance to units that are similar to clothes-rails. The appropriate goods are then grasped and unhitched there by means of appropriately formed gripping units. Furthermore it should be pointed out that, even though chutes and tipping mechanisms were mentioned above, the item(s) of merchandise  14  may also be dispensed into or onto the transport units in a different manner, for instance by the force of gravity or by means of a suitable apparatus operating mechanically, from top to bottom, with or without inclination (for example, from top right to below at the rear or such like), etc. Depending on the type of goods, stacking or a different special operation optionally enters into consideration. 
     The essential point is that the transport units, for instance the transport cartons  11 , are continuously conducted past the at least one dispensing point  16 , in which connection the goods  14 , a whole consignment or merely a partial consignment is available at this time—ie, synchronously—at the appropriate dispensing point  16 . It is furthermore essential that the supply to the dispensing point  16 , the conveying-past of the transport unit, such as the transport carton  11 , and the dispensing of the goods  14  available to the transport unit, such as the transport carton  11 , at the dispensing point  16  are controlled by a common control device  6 . By this means the packaging step which is essential in the mail-order business can not only be automated to a very large extent but can also be adapted in its progress to the mode of operation, and above all the speed, of the order-picking apparatus. Furthermore, great flexibility is possible, so that combinations of transport units and goods that, in particular, fluctuate considerably but are also constant over relatively long time-intervals are possible in reliable manner and at high speed.