Patent Publication Number: US-2023159203-A1

Title: Sorting system sorting packages into bags

Description:
BACKGROUND 
     The invention relates generally to power-driven conveyors and more particularly to sorting conveyors sorting packages into multiple bags at multiple discharges. 
     In various industries such as in package- and parcel-handling, sorting conveyors are used to sort packages to assigned destinations, such as bags. Often the packages are discharged from a main sorting conveyor onto chutes leading to an assigned destination bag. If many sorting destinations are required, the main sorting conveyor can be long and occupy significant floor space. 
     SUMMARY 
     One version of a bagging device embodying features of the invention comprises a pair of slide tracks and a slider movable along the slide tracks. and attachable to two bags. An actuator slides the slider along the slide tracks in a first direction opening an opening into a first one of the bags and closing an opening into a second one of the bags and in an opposite second direction opening an opening into the second one of the bags and closing the opening into the first one of the bags. 
     One version of a sorting system embodying features of the invention comprises first and second destination bags and a bagging device. The bagging device includes first and second slide tracks and a slider movable along the first and second slide tracks and attachable to the first and second destination bags. An actuator coupled to the slider slides the slider along the first and second slide tracks in a first direction opening an opening into the first destination bag and closing an opening into the second destination bag and in an opposite second direction opening the opening into the second destination bag and closing the opening into the first destination bag. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is an isometric view of one version of a sorting conveyor embodying features of the invention in a bagging device for sorting packages selectively from a chute to assigned destination bags. 
         FIGS.  2 A and  2 B  are side elevation views of the bagging device of  FIG.  1    shown in two sorting positions. 
         FIGS.  3 A- 3 E  are isometric views depicting the sequence of steps taken to remove filled bags from the bagging device of  FIG.  1   . 
         FIG.  4    is an isometric view of a latching mechanism used to connect and disconnect slide tracks in the bagging device of  FIG.  1    so that filled bags can be removed and replaced by empty bags. 
         FIG.  5    is an enlarged view of a load sensor on a slide track for detecting the delivery of a package to a destination bag. 
         FIG.  6    is a block diagram of a control system for the sorting conveyor of  FIG.  1   . 
         FIG.  7    is a flowchart of the program steps executed by a controller usable with the bagging device of  FIG.  1    and the load sensors of  FIG.  5    to monitor the sorting operation. 
         FIG.  8    is an isometric view of another version of a bagging device embodying features of the invention including a motorized rack-and-pinion actuator. 
         FIG.  9    is an enlarged view of a portion of the bagging device of  FIG.  8    with one of the bags removed. 
         FIG.  10    is an enlarged view of another version of a bagging device as in  FIG.  8   , but with a different bag retainer. 
         FIG.  11    is an isometric view of another version of a bagging device as in  FIG.  8   , but with a rotatable wheeled cart. 
         FIG.  12    is an enlarged view of an upper portion of the bagging device of  FIG.  11   . 
         FIGS.  13 A and  13 B  are enlarged views of a locking pin in locked and unlocked positions in the bagging device of  FIG.  11   . 
         FIG.  14    is an isometric view of a bagging device as in  FIG.  11    mounted on a rotatable platform. 
         FIG.  15    is an enlarged view of the rotatable platform of  FIG.  14   . 
         FIG.  16    is an isometric view of another version of a bagging device embodying features of the invention including collapsible bag sleeves. 
         FIG.  17    is an exploded view of the upper portion of the bagging device of  FIG.  16   . 
         FIG.  18    is an exploded view of the lower portion of the bagging device of  FIG.  16   . 
         FIGS.  19 A- 19 C  are isometric views of another version of a bagging device embodying features of the invention shown in first, transitional, and second sorting positions. 
         FIG.  20    is an enlarged isometric view of the slider assembly of  FIGS.  19 A- 19 C . 
         FIGS.  21 A- 21 C  are isometric views depicting the sequence of steps taken to remove filled bags from the bagging device of  FIGS.  19 A- 19 C . 
     
    
    
     DETAILED DESCRIPTION 
     A portion of a sorting system embodying features of the invention is shown in  FIG.  1   . The sorting system comprises a main sorting conveyor  10 , which can be realized as a powered roller conveyor, a shoe sorter, or a conveyor belt advancing packages in a main conveying direction  12 . Selected Packages P are sorted off the main sorting conveyor  10  in the direction of arrow  13  onto chutes  14  by conventional diverting mechanisms suitable for use with the kind of sorting conveyor used. Examples of conventional diverting mechanisms include shoes, pushers, cross belts, swivel sorters, and activated roller belts, such as the INTRALOX® Series 7000 activated roller belt manufactured and sold by Intralox, L.L.C. of Harahan, La., U.S.A. 
     Packages P assigned a destination in either of the bags B 1 , B 2  are sorted off the main conveyor  10  onto the chute  14 . Packages assigned to other destinations along the main sorting conveyor  10  are sorted off onto chutes at those sorting locations and into the assigned bags. 
     As also shown in  FIGS.  2 A and  2 B , the bags B 1 , B 2  each have a mouth  16  bounded by a lip  18 . The lip  18  has two opposing flat sides  20 ,  21  joined by two pleated sides  22 ,  23 , which make the bags collapsible. The bags B 1 , B 2  are suspended from a pair of slide tracks in the form of rails, or tusks  24 ,  25 , in a bagging device. Eyelets  26 ,  27  in the flat side  20 ,  21  of the bag lips  18  slidably receive the tusks  24 ,  25 . The tusks  24 ,  25  are supported in parallel in a horizontal plane by legs  28  standing up from the floor. 
     A slider  30  in the bagging device is slidably mounted on the tusks  24 ,  25  between the lips  18  of the two bags B 1 , B 2 . In particular the slider  30  is mounted between the flat side  21  of the first bag B 1  and the flat side  20  of the second bag B 2 . The slider  30  is attached to the arm  32  of an actuator  34 , such as a linear actuator, attached at one end at the bottom side of the chute  14 . The slider  30  is also attached to the bags B 1 , B 2 . The actuator  34  slides the slider  30  along the tusks  24 ,  25  in a first direction to a first position, shown in  FIG.  2 A , in which the mouth  16  of the first bag B 1  is open and forms an opening into the first bag and in which the mouth of the second bag B 2  is closed, and in an opposite second direction to a second position, shown in  FIG.  2 B , in which the mouth of the second bag is open and forms an opening into the second bag and in which the mouth of the first bag is closed. In  FIG.  2 A  a package P, assigned to the destination bag B 1 , rides down the chute  14  into the open bag B 1 . In  FIG.  2 B  a package P′ assigned to the destination bag B 2 , rides down the chute  14  into the open bag B 2 . 
     In the first position the slider  30  and the first flat side  21  of the first bag B 1  are positioned just below the lower end  36  of the chute  14 . In the second position the slider  30  and the lip&#39;s flat side  20  of the second bag B 2  are positioned outward of the lower end  36  of the chute  14 . In both positions the other flat side  20  of the first bag B 1  and the other flat side  21  of the second bag B 2  remain in position on the tusks  24 ,  25 . In that way the actuator  34  acting on the slider  30  opens one bag while closing the other and positions the mouth of the open bag to receive a package exiting the chute  14 . 
       FIGS.  3 A- 3 E  depict the sequence of removing bags from the tusks. As shown in  FIG.  3 A , a bag B 1  to be removed is first disconnected from the slider  30 . The connection can be formed by hooks  38  on the bag&#39;s lip  18  extending through holes  40  in the slider  30 , but other connections, such as snaps on the slider and mating snaps on the bags&#39; lips  18 , could be used. ( FIG.  3 A  also shows detents  42 —dips in the tusks—that serve as retainers loosely retaining the outer flat side  20  of the lip  18  of the first bag B 1  in place.) In  FIG.  3 B , the tusks  24 ,  25  are pulled from the legs  28  at the outer end of the bag support assembly. As shown in  FIG.  4   , the top end  44  of each leg  28  has a narrow diameter stub  46  with a ball lock pin  48  that is received in the hollow end of the tusks  24 ,  25 . With the legs  28  supported from the tusks  24 ,  25 , the bag B 1  is slid outward along the tusks until it clears their ends as shown in  FIG.  3 C . Once clear of the tusks  24 ,  25 , the bag B 1  can be carried off, as shown in  FIG.  3 D . The removal of the second bag B 2  is accomplished similarly, as shown in  FIG.  3 E . To replace the bags, the process is reversed. 
     The sorting conveyor is controlled by a controller  54 , such as a programmable logic controller or other processor or programmable computer, as shown in  FIG.  6   . The controller, executing program steps in its program memory, receives package identifying data from a scanner  56  scanning all the packages. From that data the controller  54  assigns each package to a destination bag. Position sensors  58  along the main sorting conveyor provide position information to the controller  54  that enable each package to be tracked. From weight signals sent to the controller  54  by load sensors  50  at the chutes, the controller detects packages delivered to the bags and confirms correct deliveries, reports missorts (packages sorted to the wrong destination bag), reports undelivered packages, and reports full bags. The controller  54  notifies operators of those operational issues on a monitor  62  or with an indicator light or an audible alarm or other alert. The controller  54  also controls motors  60  that drive the main conveyor and the slider actuators  34  at each chute. 
     It can happen that a package is sorted to the wrong destination bag.  FIG.  5    shows the load sensor  50  mounted to a plate  52  slidably attached at a top end to the tusk  24 . The other end of the plate  52  is stationary. When a package lands in the open bag B 1 , the tusk  24  deflects downward against the load sensor  50 , which then reports the increased weight of the bag B 1  indicating the reception of a package in one of the bags. The load sensor  50  reports the weight to the sorting-conveyor controller, which interprets weight increases as package detections. And with knowledge of the assigned package destination, the states of the sliders at each chute, and the position of each assigned bag, the controller can determine if the package has been missorted. A load sensor can be attached to each tusk or to only one. 
     The program steps in program memory executed by the controller to detect and report missorted packages are shown in  FIG.  7   . The weight signals from the load sensors, which are continuously monitoring the bags, are used by the controller to detect the reception of a package in a bag. When a package is detected, the controller then determines if the package has been missorted, i.e., delivered to the wrong bag, as described in the previous paragraph. If a package is determined to have been delivered to the wrong destination bag, the controller notifies an operator of a bag with a missorted package by means of an indicator light, a message or indication on a display, an alarm, or other alert. Otherwise, the controller confirms the delivery of a package to a correct destination bag and accumulates the bag&#39;s weight. In either event the controller then determines if the accumulated weight of the bag exceeds a maximum weight value. If so, the controller notifies the operator that a bag is full so that it can be replaced with an empty bag and the controller then resets the accumulated weight to zero for the replacement bag. If a package was expected to have been delivered, but was not detected by the load sensor at the expected destination bag, the controller notifies the operator that a package was not delivered. If no package is detected and delivered and none was expected, the controller sends no alerts. 
     Another version of a bagging device is shown in  FIG.  8   . The bagging device  140  differs from the bagging device of  FIG.  1    in that a motorized rack-and-pinion actuator is used instead of a linear actuator. The rack-and-pinion actuator comprises a rack gear  142  attached at one end to the slider  144 . A pinion gear  146  on the shaft of a motor  148  engages the rack gear  142 . Rotation of the motor&#39;s shaft and the pinion gear  146  translates the rack gear  142  and the slider  144  along its slide track  150  to open and close the openings into the bags B 1 , B 2 . A similar motorized rack-and-pinion actuator could be attached to the other side of the slider  144 . The motor  148  is supported by motor mount  149  suspended from the chute  14 , for example. 
     Alternative means for removably attaching the bags B to a slider  152  are shown in  FIGS.  9  and  10   . In  FIG.  9    spring gates  154  spaced apart laterally on both faces of the slider  152  are used instead of the hooks shown in  FIG.  3 A  to attach the bags&#39; lips  156  to the slider. The spring gates  154  have a lower pivot end  158  and an upper free end  159  that is biased against the slider  152  by a spring. The gates  154  extend through the eyelets on the bags&#39; lips  156 . The spring gates  154  open easily under slight outward pressure for bag installation and removal. Instead of spring gates, spring latches  160  through the bags&#39; eyelets are used to releasably attach the bags B to the slider  152  in  FIG.  10   . Hooks  162  depending from the spring latches  160  hook the bags&#39; eyelets to retain the bags B. 
       FIG.  11    shows a bagging device  164  with a wheeled platform  166  that allows the resulting bag cart to rotate for easy bag insertion and removal. The platform  166  has caster wheels  168  at each corner. 
     As shown in  FIG.  12   , a locking bar  170 , to which the actuators  172  are attached at each end, sits atop the slider  152 . A bolt  174  has an unthreaded shank between the bolt head and an opposite threaded end. The bolt  174  extends through an unthreaded through hole in the top center of the locking bar  170  and is screwed into a threaded hole in the top center of the slider  152 . In that way the slider  152 , the bolt  174 , and the bags B 1 , B 2  can be rotated on the caster wheels  168  relative to the locking bar  170 , as shown in  FIG.  11   , for easy bag replacement. 
     A locking pin  176  extends through a hole in the locking bar  170  and into an aligned hole in the top of the slider  152  to prevent rotation of the slider relative to the locking bar during normal operation of the bagging device. When a bag B has to be replaced, an operator lifts the locking pin  176  by its handle  178  from the locked position shown in  FIG.  13 A  to the unlocked position shown in  FIG.  13 B . A spring  180  coiled around a drawbar portion of the locking pin  176  between a spring seat  182  formed on the bottom face of a U-shaped pin support  184  fastened to the top of the locking bar  170  and a spring-retainer stub  186  biases the locking pin into its locked position in  FIG.  13 A . To unlock the slider  152  from the locking bar  170 , the operator pulls the handle  178  upward against the spring pressure to lift the end of the locking pin  176  from the hole in the slider so that the bagging device can be rotated for access to the bags. 
     Instead of a rotatable bagging device with caster wheels as in  FIG.  11   , the bagging device  190  of  FIG.  14    is wheelless. Its legs  192  are mounted to a lower platform  194  that has a pivot pin  196  extending down centrally from its bottom side as shown in  FIG.  15   . The pivot pin  196  is received in a bearing block  198  mounted to the floor. The bearing block  198  supports the bagging device  190  and allows it to be rotated for bag replacement. 
     Another version of a bagging device  200  is shown in  FIG.  16   . One difference from the previously described bagging devices is that sleeves S 1 , S 2  are interposed between the chute  14  and the bags B 1 , B 2 . The upper lips  202  of the sleeves are attached to a slider  204  and to slide tracks  206  through eyelets  208 . The sleeves S 1 , S 2  extend downward from their lips  202  and into the mouths of the bags B 1 , B 2 . The mouths of the bags B 1 , B 2  can remain permanently open, while the mouths  210  of the sleeves S 1 , S 2  serve as collapsible openings into the bags. 
     As shown in  FIG.  17   , the slider  204  is attached to actuators  212 , which move the slider and the upper lips  202  of the sleeves S 1 , S 2 , along two rod-like rails  214  forming slide tracks. The rails  214  are attached at the end to a rail support  216  mounted to the bottom of the chute  14 . The rails  214  are also supported by the slider  204  and its attachment to the actuators  212 . Sleeve stops  218  in the form of pairs of rings spaced apart along the length of the rails  212  define a translation range for the sleeves S 1 , S 2 , along the rails, between each pair. And the outer lips of the sleeves S 1 , S 2  are retained between the stops  218  of each pair of rings, which serve as sleeve retainers. Ring magnets  220  around the eyelets  222  in the slider  204  attract ferrous metal rings  224  surrounding the eyelets in the sleeves&#39; lips  202  to hold the sleeves S 1 , S 2  to the slider. As the slider  204  is moved back and forth on the slide tracks  214 , it opens one sleeve, while closing the other so that packages dropped in the open sleeve are deposited in the associated bag. 
     The bags B 1 , B 2  are supported in a bag stand  226  as shown in  FIG.  18   . The bag stand  226  has four legs  228  each with a hook  230  at the top. The bags B 1 , B 2  are suspended at their outer sides from the hooks  230  received in eyelets  232  in the bags&#39; lips  234 . A central bag support stand  236  has legs  238  mounted to a lower platform  240 . The bag support stand  236  has hooks  242  on each face to which the inner lips of the bags B 1 , B 2  are hooked through eyelets. Caster wheels  244  may be attached to the bottom of the platform  240  to allow the bag stand to be moved easily. 
     Another version of a bagging device for depositing packages in bags is shown in  FIG.  19 A . The bagging device comprises a bag support assembly  74  and a cart  70  constructed of tubular members. The cart  70  has caster wheels  72  at the bottom in contact with the floor. At the upper end of the cart  70  is the bag support assembly  74  supporting two bags B 1 , B 2  on opposite sides of a slider  76 . The bag support assembly  74  comprises the slider  76 , coil springs  78  attached at one end to posts  80  at the top of the cart  70  and at the other end to the outer sides of lips  82  lining the tops of the bags B 1 , B 2 , and a slide actuator assembly  84  that selectively moves the slider to open and close the bags. 
       FIGS.  19 A- 19 C  illustrate the sequence of depositing a first package P in the first bag B 1  and then a second package P′ in the second bag B 2 . In  FIG.  19 A  the slider  76  is shown in a first position at an end of its range of translation closing the second bag B 2  and opening the mouth of the first bag B 1  so that the inner side  86  of the first bag&#39;s lip  82  is under the lower end  88  of a chute  90  to receive the package P.  FIG.  19 B  shows the slider  76  in a transition position as it slides to a second position to close the first bag B 1  and to open the second bag B 2  to receive a package P′ from the chute  90  as shown in  FIG.  19 C . The coil springs  78  attached to the posts  80  at one end are attached to the outer sides of the lips  82  of the bags B 1 , B 2  at the other end by hooks  98  through eyelets  92  in the lips. The springs  78  apply forces that bias the outer sides of the bags B 1 , B 2  away from the slider  76 , which helps keep the bags open during a package deposit. Hooks  94  on the cart  70  hook onto rings  96  attached to the sides of the bags B 1 , B 2  to provide the main support for the bags. 
     Details of the slider  76  and the slide actuator assembly  84  are shown in  FIG.  20   . The slider  76  is a plate with a pair of hooks  98  on each face of the plate for hooking into the bag&#39;s eyelets so that the inner lips of the bags move with the slider plate. Upper and lower stubs  100 ,  102  protrude laterally outward from opposite sides of the slider  76 . T-shaped guides  104 ,  106  bracket the slider  76 . The crossbars  105  of the guides  104 ,  106  have horizontal slots  108  in which the upper stubs  100  are received. The horizontal slots  100  in the crossbars  105  form slide tracks defining a translation range for the top end of the slider plate  76 . The posts  110  of the T-shaped guides  104 ,  106  have vertical slots  112  that receive the lower stubs  102  of the slider  76  and give the slider the freedom of movement to tilt as the plate translates along the horizontal slots  108 . Linear actuators  114  have extension arms  116  attached to the upper stubs  100  by couplings  118 . 
     As shown in  FIG.  19 C , the actuators  114  are attached to the cart  70  by retaining rings  120  at the tops of outwardly bent upstanding tubular members  122 . In  FIG.  19 A  the actuators&#39; arms  116  are shown extended to open the mouth of the first bag B 1  and close the mouth of the second bag B 2 . In  FIG.  19 C  the actuators&#39; arms  116  are shown retracted to open the second bag B 2  and close the first bag B 1 . As seen in  FIGS.  19 B and  20   , retaining rings  124 ,  126  on the outer sides of the T-shaped guides  104  attached to horizontal members  128  of the cart  70  hold the guides in place. 
       FIGS.  21 A- 21 C  show how the bags B 1 , B 2  are removed from the cart  70 . First, the coil springs  78  are unhooked from the eyelets  92  in the bags&#39; lips  82 . Then end gates  130 ,  132  attached to the carts&#39; side frame at hinges are swung open as shown in  FIG.  21 A . Next, the first bag B 1 , which is outward of the chute  90 , is unhooked from the slider plate  76  and removed through the open gateway in the end of the cart  70 , as shown in  FIG.  21 B . As shown in  FIG.  21 C , the cart  70  is then rotated 180° or as far as necessary to access the second bag B 2  and remove it through the other open end. Replacement bags are installed in the cart by performing the removal steps in reverse. 
     Although the invention has been described with respect to a few exemplary versions, other versions are possible. For example, the actuators in any of the versions can be realized as linear actuators, such as pneumatic, hydraulic, or electromagnetic actuators, as rack-and-pinion actuators, or by other equivalent devices capable of translating a slider along slide tracks. As another example, the various bagging devices could attach the bags or sleeves to the slides by hooks, spring gates, spring latches, magnetic attraction, or any attachment making bag replacement easy. And the term “package” is meant to generically refer to any conveyable objects, such as envelopes, cartons, boxes, and parcels, for example. And other features shown in some of the bagging devices are usable in others of the bagging devices. So, as these few examples suggest, the scope of the claims is not meant to be limited to the exemplary versions disclosed in detail.