Abstract:
Embodiments of the present disclosure refer to an article collation system and method for collating articles where ‘article’ may indicate an object, thing, item, unit, piece of merchandise, commodity, product, good or an entity synonymous with the definition provided. According to an embodiment of the present disclosure, an article collation system comprises at least one identifier associated with each article where one or more attributes are associated with each identifier. Further, the system comprises one or more transporters for moving each article along a common path to one of a plurality of collection points, where a plurality of diverters are associated with one or more said transporters for routing each article to said collection point, and a controller dynamically adapting operation of said transporters and said diverters to fulfill user requirements considering the attributes of each article and optimizing the system functions based on instantaneous load conditions.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    The field of the present disclosure pertains to an article collation system and method thereof, and particularly, collation involving combination and/or sortation of articles. 
       BACKGROUND 
       [0002]    The proliferation of e-Retailing systems covering a very wide range of uniquely different orders involving articles of several different sizes, shapes, weights, packaging and other characteristics such as special handling requirements, coupled with the constant pressure for very quick deliveries, has generated the need for highly flexible, automated/semi-automated “Combining” and “Shipping” systems (collectively termed “Collation systems”) at e-Retailing supplier warehouses. Additional complexities arise from special “priority shipping” requirements associated with specific orders, which need to be processed along with non-priority shipping orders, making the allocation of common items a difficult task. Existing Collation Systems, while providing many of the desired features fail to provide adequate dynamic configurability in a multi-level collation process that is necessary to meet these requirements. 
         [0003]    The problems are aggravated by the complexities imposed by two additional factors namely, the constraints imposed by “special” requirements for certain articles (such as special handling procedures), coupled with the unpredictable and sudden “peak load” conditions that occur frequently. Existing systems fall short in terms of efficiency and cost-effectiveness under such highly variable and unpredictable conditions. 
       SUMMARY 
       [0004]    Embodiments of the present disclosure refer to an article collation system and method for collating articles where ‘article’ may indicate an object, thing, item, unit, piece of merchandise, commodity, product, good or an entity synonymous with the definition provided. According to an embodiment of the present disclosure, an article collation system comprises at least one identifier associated with each article where one or more attributes are associated with each identifier. Further, the system comprises one or more transporters for moving each article along a common path to one of a plurality of collection points, where a plurality of diverters are associated with one or more said transporters for routing each article to said collection point, and a controller dynamically adapting operation of said transporters and said diverters to fulfill user requirements considering the attributes of each article and optimizing the system functions based on instantaneous load conditions. 
         [0005]    Another embodiment of the present disclosure refers to a method for collating articles comprising associating at least one identifier with each article, associating one or more attributes with each identifier, moving each article along a common path to one of a plurality of collection points using one or more transporters, routing each article to said collection point using a plurality of diverters associated with one or more of said transporters and adapting dynamically operation of said transporters and said diverters to fulfill user requirements considering the attributes of each article and optimizing the system functions based on instantaneous load conditions. 
         [0006]    According to exemplary embodiments of the present disclosure, collation system encompasses all aspects of an article combination and/or sortation system. In the instance, the collation system operates as a combination system, articles placed on the transporter are combined based on user requirements and orders placed by respective users to provide a combined order. In such a scenario, the collection points are specific to an order placed. The combined order is tagged in manner to identify delivery details of the order, service provider details for handling the order(s) besides any specific order handling procedure. In the instance, the system operates as a sortation system; orders are sorted at a single or multi level for an organized and efficient delivery of said orders. In such a scenario, orders with tags are diverted to collection points based on delivery details of said orders or service provider details. According to an embodiment, orders are accumulated at each collection point in a bag, where each bag has a unique seal tag placed upon sealing the bag. The collection point may indicate the need to seal a bag via a Put To Light mechanism using a Pick Put to Light (PPTL), where each PPTL is identified by a particular barcode. The PPTL blinks upon the need to seal a bag based on instances where the bag is full with articles or the bag is required for delivery based on the special handling requirements. Upon indication of the need to close the bag, the barcode of the PPTL and the seal tag of the bag are scanned to generate a manifest indicating attributes of every article in the sealed bag. The manifest therefore, indicates any special handling requirements of the sealed bag besides the categories of the articles within the sealed bags. 
         [0007]    According to an exemplary embodiment of the present disclosure, the step of adapting dynamically operation of said transporters and said diverters comprises checking logs for load conditions and extracting load parameters in a defined time interval at all collection points. Collection points where load is above a threshold value are determined based on the extracted load parameters and the determined collection points are reassigned to optimize load distribution and handling. In an embodiment of the present application, load parameters may include peak load, mean load and in the instance of operation of the collation system as a sortation system, the bag closing activity is also taken into account. 
         [0008]    In an embodiment of the present disclosure, identifiers may refer to a barcode or a tag identifying the contents of a particular article. Further, the attributes associated with each identifier may provide information regarding the length, breadth and height of the article. The attributes may also include weight of the article, which may be identified based on load cells of an article. 
         [0009]    According to an embodiment of the present disclosure, the transporter utilizes plurality of conveyor belts to form a common path, where the common path may comprise a sensor at conjunction of two conveyor belts to evaluate the article on the path. In an embodiment, the controller adjusts the spacing of articles on the transporter to ensure sensing of the article by the sensor on the common path. 
         [0010]    In another embodiment of the present disclosure, each collection point scans a diverted article to ascertain accuracy of collation. If an article is not intended for the collection point, it blinks to relay the incorrect collation. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0011]    The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components. 
           [0012]      FIG. 1  illustrates a block diagram representation of an article collation system according to an embodiment of the present disclosure. 
           [0013]      FIG. 2  illustrates a flow diagram representation of a method for collating articles according to an embodiment of the present disclosure. 
           [0014]      FIG. 3  illustrates a flow diagram representation of load balancing according to an embodiment of the present disclosure. 
           [0015]      FIG. 4 a    illustrates a tabular representation of logs maintained by the server in an embodiment of the present disclosure. 
           [0016]      FIG. 4 b    illustrates a tabular representation of logs maintained by the server in an embodiment of the present disclosure. 
           [0017]      FIG. 4 c    illustrates a tabular representation of logs maintained by the server in an embodiment of the present disclosure. 
           [0018]      FIG. 4 d    illustrates a tabular representation of logs maintained by the server in an embodiment of the present disclosure. 
           [0019]      FIG. 5  illustrates a flow diagram representation of Put to Light blinking action according to an embodiment of the present disclosure. 
           [0020]      FIG. 6  illustrates a flow diagram representation of an article collation system according to an exemplary embodiment of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The following discussion provides a brief, general description of a suitable computing environment in which various embodiments of the present disclosure can be implemented. The aspects and embodiments are described in the general context of computer executable mechanisms such as routines executed by a general purpose computer e.g. a server or personal computer. The embodiments described herein can be practiced with other system configurations, including Internet appliances, hand held devices, multi-processor systems, microprocessor based or programmable consumer electronics, network PCs, mini computers, mainframe computers and the like. The embodiments can be embodied in a special purpose computer or data processor that is specifically programmed configured or constructed to perform one or more of the computer executable mechanisms explained in detail below. 
         [0022]    Exemplary embodiments now will be described with reference to the accompanying drawings. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. The terminology used in the detailed description of the particular exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting. In the drawings, like numbers refer to like elements. 
         [0023]    The specification may refer to “an”, “one” or “some” embodiment(s) in several locations. This does not necessarily imply that each such reference is to the same embodiment(s), or that the feature only applies to a single embodiment. Single features of different embodiments may also be combined to provide other embodiments. 
         [0024]    As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes”, “comprises”, “including” and/or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. Furthermore, “connected” or “coupled” as used herein may include wirelessly connected or coupled. As used herein, the term “and/or” includes any and all combinations and arrangements of one or more of the associated listed items. 
         [0025]    Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein. 
         [0026]    The figures depict a simplified structure only showing some elements and functional entities, all being logical units whose implementation may differ from what is shown. The connections shown are logical connections; the actual physical connections may be different. It is apparent to a person skilled in the art that the structure may also comprise other functions and structures. It should be appreciated that the functions, structures, elements and the protocols used in communication are irrelevant to the present disclosure. Therefore, they need not be discussed in more detail here. 
         [0027]    In addition, all logical units described and depicted in the figures include the software and/or hardware components required for the unit to function. Further, each unit may comprise within itself one or more components, which are implicitly understood. These components may be operatively coupled to each other and be configured to communicate with each other to perform the function of the said unit. 
         [0028]      FIG. 1  of the present disclosure illustrates a general block diagram of an article collation system according to an embodiment of the present disclosure. Articles  101   a ,  101   b ,  101   c  are input through the input area on the system, which comprises one or more transporters  102   a ,  102   b ,  102   c ,  102   d  for moving each article along a common path to one of a plurality of collection points  103   a ,  103   b ,  103   c ,  103   d . The transporters  102   a ,  102   b ,  102   c ,  102   d  may be a plurality of conveyor belts functioning at differential speed. Each article has an associated identifier and each identifier has associated attributes. The system further comprises a plurality of diverters  104   a ,  104   b ,  104   c ,  104   d  associated with one or more of the transporters  102   a ,  102   b ,  102   c ,  102   d  for routing each article to said collection point. The system further comprises a controller  105  to dynamically adapt operation of the transporters  102   a ,  102   b ,  102   c ,  102   d  and the diverters  104   a ,  104   b ,  104   c ,  104   d  to fulfill user requirements considering the attributes of each article and optimizing system functions based on load conditions. According to an embodiment of the present disclosure, the identifier associated with the article  101   a ,  101   b ,  101   c  comprises a barcode or a tag identifying the content of an article. Further, each identifier is associated with one or more attributes such as length, breadth and height of the article. The attribute may further comprise weight of the article, which may be ascertained by various mechanisms such as based on load cells. 
         [0029]    The routing by the article collation system disclosed may be utilized at any level of combination or sortation of articles. It may be utilized at a single level or at a multi-level, which adds to the adaptability of the system disclosed. The diverters  104   a ,  104   b ,  104   c ,  104   d  are actuated only when the article on the transporter  102   c ,  102   d  is meant for respective collections points  103   a ,  103   b ,  103   c ,  103   d . Each collection point  103   a ,  103   b ,  103   c ,  103   d  utilizes Put to Light mechanism to collate articles while using Pick Put to Light (PPTL) in an embodiment. Each PPTL is unique and has an associated barcode. 
         [0030]    The controller  105  is coupled to a server  106 , which stores a database of logs of load conditions, instantaneous and previous, for each diverter apart from a database for all orders and requirements by users. The logs may comprise identification numbers of each diverter and their associated PPTLs with their unique barcode. These logs are essential to the dynamic adaptation of operation of the system  100 , which may be controlled even during its operation i.e. there is no requirement to shut the system down to reconfigure the collation performed based on load conditions. The controller  105  extracts information from the server  106  for the instantaneous load conditions as well as the previous load conditions apart from PPTL activity. The logs are utilized, as illustrated in further figures, to optimize the efficiency of the system. 
         [0031]    An embodiment of the system additionally comprises a sensor  107  at conjunction of two conveyor belts. The sensor  107  may be a motion based sensor or an infra red sensor, to detect all articles placed on the transporter  102   a ,  102   b , 102   c , 102   d  The controller  105  controls the first transporter  102   a  at a speed such that each article is placed at a specific distance for effective detection by the sensor and an scanning conducted. According to an embodiment of the disclosure, the system comprises a scanner  108  controlled by the controller  105 , which ascertains the length, breadth and width of the article placed and relays the information to the controller  105 , which is further stored in the server  106 . The scanner  108  is further configured to ascertain the weight of the article placed using volumetric measurement systems (VMS) and this information too, is stored in the server  106 . 
         [0032]    Further, the collation system  100  encompasses all aspects of an article combination and/or sortation system. In the instance, the collation system  100  operates as a combination system, articles  101   a ,  101   b ,  101   c  placed on the transporters  102   a ,  102   b ,  102   c ,  102   d  are combined based on user requirements and orders placed by respective users to provide a combined order. In such a scenario, the collection points  103   a ,  103   b ,  103   c ,  103   d  are specific to an order placed. The combined order is tagged in manner to identify delivery details of the order, service provider details for handling the order(s) besides any specific order handling procedure. In the instance, the system  100  operates as a sortation system; orders are sorted at a single or multi level for an organized and efficient delivery of said orders. In such a scenario, orders with tags are diverted to collection points based on delivery details of said orders or service provider details. 
         [0033]    According to an embodiment, orders are accumulated at each collection point in a bag, where each bag has a unique seal tag placed upon sealing the bag. The collection point  103   a ,  103   b ,  103   c ,  103   d  may indicate the need to seal a bag using PPTL. The PPTL blinks upon the need to seal a bag based on instances where the bag is full with articles or the bag is required for delivery based on the special handling requirements. Upon indication of the need to close the bag, the barcode of the PPTL and the seal tag of the bag are scanned to generate a manifest indicating attributes of every article in the sealed bag. The manifest therefore, indicates any special handling requirements of the sealed bag besides the categories of the articles within the sealed bags. 
         [0034]      FIG. 2  illustrates a flow diagram representation of a method to collate articles according to an embodiment of the present disclosure. The method comprises associating an identifier with each article  201  and one or more attributes are associated with each identifier  202 . According to embodiments, identifier comprises a barcode or a tag identifying the content of an article. Further, each identifier is associated with one or more attributes such as length, breadth and height of the article. The attribute may further comprise weight of the article, which may be ascertained by various mechanisms such as based on load cells. Each article is moved along a common path  203  to one of a plurality of collection points using one or more transporters. As disclosed in the illustration of  FIG. 1 , conveyor belts may be utilized as transporters, which function at differential speed. Further, each collection point comprises a plurality of Pick Put to Light (PPTL), to enable further collation of articles. The collation implemented by the method disclosed is utilized in the scenario of combination of orders or sortation of orders. The method disclosed adapts dynamically the operation  205  of the transporters and the diverters to fulfill requirements of each order while considering the attributes of each article and optimizing system functions based on load conditions. 
         [0035]    In an embodiment of the present disclosure, the method utilizes a load balancing mechanism for dynamically adapting the operation illustrated in  FIG. 3 . According to the embodiment, the controller  105  checks logs for load  302  at the server  106  to extract load parameters at defined time intervals  303 . Based on the extracted parameters, the controller  105  ascertains the collection points to be reassigned  304  and verifies if the bag has been sealed at the reassigned collection points  305 . If the bags have been sealed, the logs stored in a database at the server  106  are updated with the reassigned collection points  307 , else the system waits  306  to check the log information at another time interval. 
         [0036]    The embodiment is further illustrated vide  FIGS. 4 a , 4 b , 4 c  and 4 d   . As referred to previously, the log of  FIG. 4 a   , shows each diverter associated with the number of PPTLs. The log refers to ‘Armid’, which is the identity of the diverter along with its PPTL information in Start PPTL and End PPTL. Further, as illustrated in description of  FIG. 1 , each diverter may be associated with a service provider (DSP Name and a DSP code) and a Hubcode apart from PPTLid. The log information under  FIG. 4 b    also refers to the state of good i.e. whether the articles being collated refer to dangerous/non-dangerous goods or articles meant for exchange. Each Hubcode is associated with a pincode, which is referenced within the attributes of each article. The log containing the Hubcode may be updated by providing references to the NewHubcode, OldHubcode and the pincode as illustrated in  FIG. 4 c   . The controller  105  then ascertains the load conditions from the log, shown in  FIG. 4 d   , stored in the server  106 . As seen from said figure, at a defined time interval, 20 packets are received at PPTL 10 of Armid 3 while 200 packets are received at PPTL2 with Armid 5. The controller judges that there is an unproductive load distribution as Armid 5 has higher load to address. Accordingly, the controller  105  dynamically adapts PPTL10 of Armid 3 to exchange the load activity with PPTL2 of Armid 5. This exchange of load activity is done in real time and does not require shut down of the collation system. Therefore, as seen in  FIG. 4 e   , PPTL10 of Armid 3 handles 200 packets while PPTL2 of Armid 5 handles 20 packets, and hence, the load at diverters referenced Armid 3 and Armid 5 is balanced and optimized. 
         [0037]      FIG. 5  of the present disclosure illustrates the operation of PPTL according to an embodiment. As illustrated previously, PPTL blinks to indicate the need to seal a bag, either when the bag is full or based on the user direction.  FIG. 5  illustrates an embodiment, when the system  100  functions as a sortation system with a fixed time delivery requirement. The embodiment addresses a scenario where a truck has arrived to take articles for delivery. The embodiment calculates the current time  501  and ascertains if it is equivalent to the scheduled time  502 . If they are equal, the system  100  sends an interrupt  503  in order to facilitate blinking of the PPTLs  504 . However, if the current time calculated is not equivalent to the scheduled time, the time taken to reach a destination is predicted based on real time traffic condition  505 . A number of known mechanisms may determine the real time traffic condition. If the predicted time is under the specified time of delivery  506 , an interrupt is sent  503  to blink the PPTLs  504 . However, if the predicted time is not within the specified time, a delay of one minute  507  in the calculation of current time  501  is given. 
         [0038]      FIG. 6  of the present disclosure provides an exemplary embodiment wherein the collation system  100  is utilized under three different scenarios. According to an embodiment, the articles are scanned  601  and based on the identifier and associated attributes, the id of a particular diverter is identified by the controller  602  from the database stored in the server  106 . The article moves on the common path and is diverted to the allocated collection point  603 . In the instance, the collation system  100  functions as a sortation system, the diverted article is scanned again  604 . If a PPTL workstation blinks (for example, it blinks green)  605 , the article is placed in the respective bag  606 . If the PPTL workstation does not blink, the article is scanned again at the first instance  601 . During the operation of the system  100 , it is determined whether the bag is full  607  or the PPTL associated with said bag is blinking  608 . If it is not so, then the system waits or either situation to be fulfilled  609 . However, if the bag is full or the PPTL is blinking, a bag manifest comprising information of the articles collated is printed  610  and the bag is sealed  611 . 
         [0039]    The collation system  100  is further used in In-house Logistic Company (ILC) Arms  612 , where the article is scanned  613  and if a particular collection point blinks  614 , it is determined whether the article is within the category of dangerous goods(DG)  615 . If the article is classified as a DG, then it is forwarded to respective ILC pigeonhole collection point  616 . If the PPTL associated with the pigeonhole collection point blinks  617 , a manual decision is made as to whether a new bag should be placed for items under DG category  620 . If the PPTL associated with the pigeonhole collection point does not blink, it is determined whether the pigeonhole is full  618 . If it is, step  620  is implemented, else the system waits till PPTL blinks  619 . 
         [0040]    If a positive decision is taken for opening a new bag for items under category DG, then existing bag is closed  621  and the packet is re-scanned  622  and given a separate packaging altogether  623  as it is a DG classified article. However, if the decision is made not to open a new bag, the packet is rescanned  624  and forwarded to the respective ILC bag  625 . In the event, it is ascertained that the article is classified as a DG  615 , it is sent to the respective ILC bag  625 . The ILC bag is checked to see whether it is full  626  and if it is, a bag manifest is printed  629  and the bag is sealed  630 . However, if the bag is not full, it is determined whether the PPTL is blinking  627 . If it is, then the bag is sealed  630  after printing a manifest  629  to provide information of the articles collated. However, if the PPTL is not blinking, the system waits till the bag is full or the PPTL blinks  628 . 
         [0041]    In another embodiment, the article is scanned  601 , however, it is rejected  631 . The rejected packet is scanned again  632  to determine whether a collection point is indicated  633  for the article. If the collection point is indicated, it is determined whether the identifier (barcode) on the article is damaged  634  and if it is, the damaged identifier (barcode) is sent for re-printing  640 . It may be determined whether there is a weight mismatch  635  or change in delivery details (address)  636  for the article and in the event it is, the article is sent for a manual decision  639 . In the event, it is determined that the article pertains to a cancelled order  637 , the article is returned to the processing area  639 . 
         [0042]    As will be appreciated by one of skill in the art, the present invention may be embodied as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, a software embodiment or an embodiment combining software and hardware aspects all generally referred to herein as a “circuit” or “module.” Furthermore, the present invention may take the form of a computer program product on a computer-usable storage medium having computer-usable program code embodied in the medium. 
         [0043]    Furthermore, the present invention was described in part above with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. 
         [0044]    It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. 
         [0045]    Instructions may also be stored in a computer-readable memory 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 memory produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks. 
         [0046]    Instructions may also be loaded onto a computer or other programmable data processing apparatus like a scanner/check scanner 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 which execute on the computer or other programmable apparatus provide steps for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. 
         [0047]    The flowchart and schematic diagrams of  FIGS. 4-6  illustrate the architecture, functionality, and operations of some embodiments of methods, systems, and computer program products for integrated capture and analysis of documents. In this regard, each block may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in other implementations, the function(s) noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending on the functionality involved. 
         [0048]    In the drawings and specification, there have been disclosed exemplary embodiments of the invention. Although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined by the following claims