Patent Publication Number: US-2023159281-A1

Title: System and method for automated sortation

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This Application is a continuation in part of U.S. Pat. Applications Nos. 17/843,313 filed on Jun. 17, 2022, which is a continuation of U.S. Pat. Applications Nos. 17/566,527 filed on Dec. 30, 2021, which claims the benefit of U.S. Provisional Application No. 63/216,340, filed Jun. 29, 2021 in the United States Patent Office, the entire disclosures of all of which (including all attachments thereto) are incorporated herein by reference. 
    
    
     BACKGROUND 
     1. Field 
     Apparatuses and methods consistent with example embodiments relate to conveyors and conveyor operation, and more particularly sortation conveyor systems where smaller packages are accumulated into groups of packages in an automated consolidated bagging system. 
     2. Description of the Related Art 
     Related art automated sorters of smaller packages (hereinafter “smalls sorters”) used in conventional sortation systems divert loose small packages into bags to be accumulated. Once a specified number of packages accumulate in a bag or other container (hereinafter simply referred to as a “bag”), the bag is then logically and physically closed, all of the identifications (IDs) and information associated with the packages are associated with the bag and are logically stored. Then, a label is printed and applied to the outside of the bag so the packages in the bag can be tracked as a group within the bag, all such packages being associated with the bag ID. However, such smalls sorters may be undesirably less effective and less efficient because packages often miss the bag they are intended for, resulting in a miss-sorted package. This may require the use of additional material, such as an additional bag, and requires manual intervention, for example, to monitor and close the bag and then to move the bag for further processing on a conveyor system, to help direct packages into the bags, as well as dealing with packages that miss the bags. 
     SUMMARY 
     Example embodiments may address at least the above problems and/or disadvantages and other disadvantages not described above. Also, example embodiments are not required to overcome the disadvantages described above, and may not overcome any of the problems described above. 
     One or more example embodiments may provide a system and method allowing accumulation of packages into groups for further processing or tracking in a bagless and/or containerless manner. 
     One or more example embodiments may address at least such drawbacks as described above by providing systems and methods that remove the need to have loose packages accumulate into bags of an automated sortation device, such as a tilt-tray sorter or straight line shoe sorter, Activated Roller Belt™ (ARB™) sorter, and a pop-up wheel sorter. 
     One or more example embodiments may provide a system and method in which systems a number of parcels or packages are associated or grouped, without a need for a physical bag or container, such that the parcels or packages can be tracked as a group, for example with a unique group ID. According to an example aspect, an association of parcels or packages may be referred to as a logical group or a logical containerization of parcels or packages. A logical group may be tracked within a specified logical zone, for example on a conveyor, may be transported, may be sorted and/or may otherwise be processed as a unique logical group without a need to be contained in a physical bag or container. 
     One or more example embodiments may provide a system and method for automated sortation that can accumulate a set number of packages, or a set volume of packages, and then transfer the accumulated set number or volume of packages to a collector conveyor. 
     One or more example embodiments may provide a conveyor system comprising a smart bin that will accumulate a set number of packages and then transfer the packages, via a direct vertical drop, into a logical accumulation zone on a collector conveyor, thereby allowing for a quick transfer of the packages onto another conveyance system. This may decrease the opportunities for packages to miss a physical bag or container, resulting in a possibly miss-sorted package. The packages transferred to the accumulation zone may be tracked as a group, though they are not all within a same physical container such as a bag. 
     One or more example embodiments may provide a conveyor system and method in which packages are transferred to an accumulation zone, and the transferred packages are then tracked down a collector conveyor from which, for example, the packages may be fed onto a cleated conveyor with cleated zones or windows, for example to be elevated, and then transferred to another collector conveyor in zones, continuing to be tracked to a point at which the packages are transferred into a splitting hopper with an A/B flip gate to be diverted off to one of two chutes, or with an A/B/C flip gate to be diverted off intone of three shoots. In an example implementation of one or more embodiments, canvas guides and special lever and tusks can be provided to help hold a closeable container, such as bag, open for proper filling of the container where the group of package IDs can then be logically linked to that closable container, with a unique container ID, and a label can be printed and placed on the closable container for tracking from that point forward. 
     According to an aspect of an example embodiment, a smart bin system comprises: a smart bin comprising: a plurality of walls and a bottom, together defining a cavity therewithin; wherein the bottom comprises a gate moveable between a closed position configured to retain an item within the cavity, and an open position configured to allow an item to fall from within the cavity through the bottom; and a controller, functionally coupled to the gate and configured to move the gate between the closed position and the open position based on received data. 
     In an exemplary implementation, the received data may comprise a signal received at an input of the controller from an optical sensor, the signal indicating that the smart bin is full. 
     In an exemplary implementation, the received data may comprise a volume of each of one or more packages within the smart bin. 
     According to an aspect of an example embodiment, an automated sortation system comprises: a plurality of smart bins each configured to receive a package group, comprising at least one package of a plurality of packages, and to transfer the package group onto a collector conveyor; the collector conveyor, disposed at least partially beneath the plurality of smart bins and configured to convey the package group onto a cleated conveyor; the cleated conveyor configured to convey the package group into a hopper; the hopper comprising a gate configured to drop the package group into one of two or three bag fill chutes. 
     Each of the plurality of smart bins may comprise a plurality of walls and a bottom, together defining a cavity therewithin; wherein the bottom comprises a gate moveable between a closed position configured to retain an item within the cavity, and an open position configured to allow an item to fall from within the cavity onto the collector conveyor. 
     According to an aspect of an example embodiment, an automated sortation method comprises: diverting a package group, comprising at least one package of a plurality of packages, into one smart bin of a plurality of smart bins according to a sort criteria; accumulating one or more of the plurality of packages in at least the one smart bin; transferring the one or more of the plurality of packages as a package group comprising the one or more of the plurality of packages from the one smart bin onto a collector conveyor; moving the package group along the collector conveyor for further processing as the package group. 
     According to an example implementation, the transferring of the package group comprises emptying the one or more of the accumulated packages from the smart bin onto the collector conveyor based on at least one of a signal received from an optical sensor, a total volume of packages within the one smart bin, and a total number of packages within the one smart bin. 
     According to an example implementation, automated sortation method can further comprise moving the package group along the collector conveyor and onto a cleated conveyor; moving the package group along the cleated conveyor and into a hopper; releasing each package of the package group from the hopper into one of a plurality of chutes, and thereby into a bag. 
     The transferring the package group from the one smart bin onto the collector conveyor may comprise opening a gate of the one smart bin and thereby dropping the package group from the one smart bin onto the collector conveyor. 
     The transferring the package group from the one smart bin onto the collector conveyor may comprise transferring the package group onto a defined zone on the collector conveyor. 
     The moving the package group along the collector conveyor may comprise maintaining the package group within the defined zone on the collector conveyor; 
     The defined zone on the collector conveyor may be defined between cleats on the collector conveyor. 
     The defined zone on the collector conveyor may comprises a logical accumulation zone on the collector conveyor, the logical accumulation zone lacking physical constraints on the collector conveyor. 
     According to one or more example embodiments, an electromechanical system is provided comprising a computer processor, a sensor and a robotic arm, wherein when a package group is conveyed for further processing including transferring into a container a plurality of the packages of the package group, the electromechanical system closes the container by a robotic arm or other automated closure system controlled by a computer processor based on stored or communicated information or commands, which can be based on input from the sensor. In an example implementation of one or more example embodiments the sensor can by indicative of fill amount of the container, or a position of the container, or both. One or more sensors, such as visual sensors, can be deployed in any of example configurations, and an associated image or video processing can be performed by the computer processor, or remotely and communicated to the computer processor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and/or other aspects will become apparent and more readily appreciated from the following description of example embodiments, taken in conjunction with the accompanying drawings, in which: 
         FIG.  1   , which is comprised of  FIGS.  1 A and  1 B , is a flow chart of an automated sortation method according to an example embodiment; 
         FIGS.  2 A and  2 B  illustrate a top view and a side view, respectively, of an automated sortation system according to an example embodiment; 
         FIG.  3 A  is a perspective view of an automated sortation system according to an example embodiment; 
         FIG.  3 B  is a schematic illustration of an automated sortation system according to an example embodiment,  FIG.  3 C  shows an enlarged view of a section of  FIG.  3 B , according to an example embodiment, and  FIG.  3 D  shows an enlarged view of another section of  FIG.  3 B , according to an example embodiment; 
         FIG.  4    is an enlarged perspective view of a section of  FIG.  3 A  and  FIG.  3 B , according to an example embodiment; 
         FIGS.  5 A- 5 C  are illustrate an enlarged schematic view, a side view, and a back view, respectively, of an end of a cleated conveyor, a hopper, and chutes of a system according to an example embodiment; 
         FIGS.  5 D- 5 G  are a perspective view, a top view, an end view, and a side view, respectively, of a cleated conveyor, a hopper, chutes, and carousels of a system according to an example embodiment; 
         FIGS.  5 H- 5 J  are a side view, a perspective view, and a bottom view of an example carousel according to an example embodiment; 
         FIGS.  6 A,  6 B, and  6 C  are different perspective views of a smart bin according to an example embodiment; 
         FIG.  6 D  is a plan view of the front of a smart bin according to an example embodiment; 
         FIG.  6 E  is a plan view of a side of the smart bin according to an example embodiment; 
         FIGS.  7 A,  7 B,  7 C,  7 D,  7 E, and  7 F  show different views of an example smart bin according to another example embodiment; 
         FIGS.  8 A,  8 B  8 C,  8 D, and  8 E , illustrate a perspective view, a side view, a front view, a detail of back view, and a back view, respectively, of an example hopper according to an example embodiment; 
         FIGS.  9 A and  9 B, and  9 C  illustrate an exploded view, an exploded view with the guard hidden of an example hopper according to an example embodiment; 
         FIG.  9 C  shows a detail of a portion of  FIG.  9 B ; 
         FIG.  10    is a schematic illustration of a main control panel according to an example embodiment. 
         FIGS.  11 A,  11 B,  11 C, and  11 D  illustrate, respectively, perspective, top, side and front views of a two-way linear rail assembly according to an example embodiment; 
         FIGS.  12 A,  12 B,  12 C, and  12 D  illustrate, respectively, perspective, top, side and front views of a three-way linear rail assembly according to an example embodiment; 
         FIGS.  13 A,  13 B,  13 C, and  13 D  illustrate, respectively, perspective, exploded perspective, side, and cross sectional (along cross section line of  FIG.  13 C ) views of a hopper assembly according to an example embodiment; 
         FIGS.  14 A,  14 B,  14 C,  14 D and  14 E  illustrate, respectively, plan view and four different cross section views (along labeled cross section lines of  FIG.  14 A ) of a system according to another example embodiment; 
         FIGS.  15 A,  15 B,  15 C,  15 D,  15 E,  15 F,  15 G and  15 H  illustrate, respectively, an isometric view, a plan view and six different cross section views (along labeled cross section lines of  FIG.  15 B ) of a system according to yet another example embodiment; 
         FIGS.  16 A,  16 B,  16 C,  16 D, and  16 E  illustrate, respectively, an isometric view, enlarged schematic plan view and various cross section and enlarged views, of a system according to yet another example embodiment; 
         FIGS.  17 A,  17 B, and  17 C  illustrate, respectively, an isometric view, a top view and a side view of a smart bin according to another example embodiment; and 
         FIG.  18    illustrates in a block format a system of any example embodiment implementing an auto bagging configuration according to an example embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to example embodiments which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. In this regard, the example embodiments may have different forms and may not be construed as being limited to the descriptions set forth herein. 
     It will be understood that the terms “include,” “including”, “comprise, 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 further understood that, although the terms “first,” “second,” “third,” etc., may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections may not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. 
     Expressions of relational orientation, such as “upper,” “lower,” “inside,” “outside,” etc. which are used for explaining the structural positions of various components as described herein, are not absolute but relative. The orientation expressions are appropriate when the various components are arranged as shown in the figures, but should change accordingly when the positions of the various components in the figures change. 
     In this description, position terms such as “upper,” “lower,” “inside,” and “outside” are defined according to the position of a ground pool during normal use. 
     As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list. 
     Various terms are used to refer to particular system components. Different companies may refer to a component by different names - this document does not intend to distinguish between components that differ in name but not function. 
     Matters of these example embodiments that are obvious to those of ordinary skill in the technical field to which these example embodiments pertain may not be described here in detail. 
       FIG.  1    is a flow chart of an automated sortation method according to an example embodiment. As shown in  FIG.  1   , various operations of an automated sortation method occur in an integration section  150 , at which packages from another sorter are received and diverted to a smart bin/slide gate section  160 . From the smart bin /slide gate section  160 , packages are transferred to a package group collection and transportation section  170 , then to a bag fill section  180 , and then to a bag transportation and processing section  190 . It should be noted that while the term “bag” is used in the descriptions of example embodiments, this term is not limiting, and any of the example embodiments described herein may be used in conjunction with any suitable container, including, but not limited to a bag. 
     According to the example embodiment shown in  FIG.  1   , packages enter a sorter in the integration section (S 102 ), and are diverted from the sorter into a smart bin (S 104 ), based on, for example an established sort criteria. In the smart bin /slide gate section  160 , packages may continue to accumulate in the smart bin (S 106 ). A determination of whether the smart bin is full (S 108 , S 110 ) may be made based on a number of packages that have accumulated therein; based on a signal from an optical device, such as a photocell or other optical sensor, which detects a full condition; and/or based on one or more volumetric calculations based on known or sensed volumes of the packages. For example, there may be a smart-bin controller, and data on dimensions of each received package may be transmitted to the smart-bin controller, such that a total volume of packages can be calculated and tracked, and when a threshold volume is reached, the smart bin may be considered full and ready for release. Alternately, a photocell may be disposed at a fixed location on the smart bin or with respect to the smart bin, and when a signal from the photocell indicates that the photocell has been blocked for a predetermined period of time, it may be determined that the smart bin is full and ready to release. 
     According to another example implementation, when a smart bin is determined to be full, the system can be configured to release the packages onto the collector conveyor according to one or more of various criteria including, but not limited to: a leading edge of a tracking window being a certain distance (for example, 18 inches) past a configured offset of chute of a smart bin (this distance being configured to prevent packages from overflowing into a next zone when they are released); and a tracking window being is available and not assigned to another chute of another smart bin. 
     If it is determined that a smart bin is full (S 110 -YES), packages in the smart bin are transferred to a zoned collector conveyor (S 112 ). 
     In an example implementation, the smart bin can include a gate, for example a high speed gate, at a bottom thereof, such that when the smart bin is full (S 110 ) the gate opens, enabling packages to be vertically transferred, or dumped via a gravitational straight drop from the smart bin through the open gate onto the zoned collector conveyor disposed below the smart bin (S 112 ). The zoned collector conveyor may comprise a plurality of dynamically established accumulation zones or windows. 
     Packages within an accumulation zone or window of a the zoned collector conveyor may be grouped and tracked together as they are transported as a group, for example down the collector conveyor (S 114 ). The collector conveyor can be configured and positioned to feed onto, for example, a cleated conveyor with the cleats bounding each package group zone or window (S 116 ). Packages from each package group zone or window can then be diverted or transferred for further processing as a group. 
     Upon a determination to deposit packages into a container fill chute (S 118 -YES), a package group can be diverted from the cleated conveyor into a hopper, and from the hopper, into a bag fill chute (S 120 ). A bag can then be filled with the packages of the package group, and the package group is logically linked with the bag (S 122 ). Upon a determination that a particular bag is full, or that the fill chute should not otherwise receive more packages (S 118 -NO), an additional incoming package group can be transferred to another collector conveyor in zones or windows within which the package group continues to be tracked (S 140 ). The package group can then be diverted from such other one or more collector conveyors to another container fill chute (S 138 ). A bag can then be filled with that package group and logically linked with the bag (S 122 ). 
     After a bag is filled with a package group, and the package group is logically linked with the bag, the bag can be transported to a processing area (S 124 ) where the bag is closed (S 126 ). For example a bag can be zipped closed, and a shipping label can be applied to the bag (S 128 ). Of course, zipping a bag closed is only one example, and the bag or other container can be closed in any of various other ways. A labeled bag containing the package group, can then be transferred for further processing (S 130 ). Additionally, the package group associated with the bag may be cleared, i.e. the package group and bag may be disassociated from a container, for example automatically or via a container release button, and the empty container can be returned (S 132 ), for example to a racetrack, and reloaded with one or more bags, for example to wait in a queue to be filled (S 134 ), and transported to queue area at container fill chute for processing (S 122 ) of another package group. 
       FIGS.  2 A and  2 B  illustrate a top view and a side view, respectively, of an automated sortation system  500  according to an example embodiment. As described herein, a bin according to one or more example embodiments may be referred to, for ease of explanation and without any limitation, as a “smart bin.”. Such a smart bin  202  can be configured to feed a collector conveyor  208 , for example located under each side of the sorter  220 , for example a sorter having sections. The smart bins  202  may be positioned within the integration section  150  to receive packages from the sorter  220  and to selectively release one or more packages (not shown) onto the collector conveyor  208 . As discussed above with respect to  FIG.  1   , the packages may be released based on any of various criteria and/or a signal from a sensor, such as an optical sensor. 
     The released packages form a package group, released for example directly below a chute of smart bin  202  onto the collector conveyor  208 . Each package group can then be logically tracked down the collector conveyor  208  in zones or windows of suitable dimensions. For example, a zone or window may be a section of the collector conveyor  208  having a width of the collector conveyor  208  and extending about 10 ft in length. The specific configurations of each of a smart bin  202  and a collector conveyor  208  can be optimized for efficiency and accuracy of package processing. This includes, without limitation, parameters such as, but not limited to, size, relative positions (vertically and/or horizontally) with respect to each other, and relative displacement (for example due to speed and/or direction of the conveyor  20   8 ). For example, for an essentially vertical drop of packages (e.g., due to gravity) from a smart bin  202  onto a conveyor  208 , a spread of packages on the collector conveyor  208  and, for example, a the size or dimensions of a zone or window, can be optimized by taking into account one or more of the height or distance from the chute of the smart bin  202  to surface of the collector conveyor  208 , the relative moving speed of the surface of the collector conveyor  208  with respect to the smart bin  202 , and the relative moving direction of the surface of the collector conveyor  208  with respect to the smart bin  202 . In addition, a speed of opening and/or a type of opening (such sliding, hinged, etc.) of a chute or opening of the smart bin  202  can be selectively implemented to facilitate deposition of packages onto the collector conveyor  208 . For example, a system can comprise a belt running at 150 fpm, and for such belt speed, a 10 foot windows can be defined in accordance with an example implementation. One or more of a texture, a material, a resilience, and a roughness of the surface or portions of the surface of the collector conveyor  208  can be selected to facilitate the deposition of packages on the collector conveyor  208  and/or the maintenance of packages on the collector conveyor  208 . Any combination of any or all of the above-noted parameters, features, and structures can be selectively adjusted and/or optimized to facilitate group tracking and/or processing of packages in accordance with one or more example embodiments described herein. 
     According to further example implementations, zones or windows can be created or defined on the collector conveyor  208  and/or the cleated conveyor  212  using an encoder pulse width from an optional encoder  215 , such that when a certain selected or predetermined number of pulses of the encoder are detected that correspond to a determine window size, a unique token may be created. The unique token can be tracked along the collector conveyor  208  and/or the cleated conveyor  212  using the encoder pulse. This sequence can be repeated for each zone or window. When a package group is released from a smart bin into a zone or window, a smart bin number of the smart bin can be associated with the unique token. When the window reaches the charge of the hopper  230 , the system will drop the load into the available hopper  230 . At this point the smart bin number is passed to the host system to initiate the printing of a label to be associated with that group of packages. 
     As shown in  FIGS.  2 A and  2 B , this example system  500  comprises the collector conveyor  208  which transfers packages to a conveyor  212 . The collector conveyor  208  may include a rising section  214  in which the collector conveyor  208  is at an inclined angle, with an upper end adjacent to a conveyor  212 . The conveyor  212  may be a cleated conveyor, and cleats may form boundaries for one or more zones or windows along the conveyor  21   2 . 
     From the conveyor  212 , package groups can be fed into one of one or more chutes  216  for filling into a respective closable bag  218 . Each package group ID may be logically linked to the corresponding bag  218 , and a label may be printed and placed on the bag  218 . The example system  500  may also include a diverting hopper  230  which receives packages from the conveyor  212  and diverts the packages into a chute  216 , 
     Regarding the cleated conveyor  212 , according to an example implementation, a speed of the cleated conveyor can be dynamically adjusted so that tracking zones or windows (for example, ten-foot windows) align with the physical cleat spacing. Such dynamic adjustment can be accomplished using a sensor to detect each cleat and using an encoder. 
       FIG.  3 A  is a perspective view of an automated sortation system  200  according to another example embodiment.  FIG.  3 B  is a schematic illustration of an automated sortation system  250  according to yet another example embodiment.  FIGS.  3 C and  3 D  are enlarged top and side views of sections B and C of  FIG.  3 B .  FIG.  4    is an enlarged perspective view of section A of  FIG.  3 A  and  FIG.  3 B . References numbers used in  FIGS.  3 A,  3 B, and  4    are the same as those used with respect to  FIGS.  2 A and  2 B , with respect to illustration of analogous elements. In contrast to the example embodiment of  FIGS.  2 A and  2 B ,  FIGS.  3 A,  3 B, and  4    illustrate example sections  221  of the sorter  220 , and illustrate example packages  206  within the systems  200  and  250 . 
       FIGS.  5 A- 5 C  illustrate an enlarged schematic view, a side view, and a back view, respectively, of an end of the cleated conveyor  212 , the hopper  230 , and the chutes  216  of an example system  500 ,  200 , or  250 .  FIGS.  5 D- 5 G  are a perspective view, a top view, an end view, and a side view, respectively, of the cleated conveyor  212 , the hopper  230 , the chutes  216 , and carousels of an example system  500 ,  200 , or  250 . As shown, the hopper  230  may be a diverting hopper  230  configured to receive packages from the conveyor  212  and direct the packages of each package group into one of the two chutes  216 .  FIGS.  5 H- 5 J  are a side view, a perspective view, and a bottom view of an example carousel configuration. An example carousel is shown in  FIGS.  5 H- 5 J  in which, for example: 1 is a formed angle stop; 2 is a center foot weldment; 3 is a flange bearing mount plate; 4 is a 4″ easy turn caster; 5 is a two bolt flange bearing for 2″ shaft diameter; 6 is a grip for 1-⅜″ OD; 7 is a ⅜″ anchor bolt; 8 is a steel hex head shoulder screw, ½″ shoulder diameter, 1-¾″ shoulder length, ⅜″-16 thread; 9 is a thin hex nut, nylon insert, ⅝″-11; 10 is a medium-strength steel nylon-insert locknut, grade 5, zinc-plated, ⅜″-16 thread size; 11 is a hexagon socket button head cap screw ¼″-20×½″ LG; 12 is a hexagon socket head cap screw ⅝″-11×1.75″ LG; 13 is a hexagon socket button head cap screw 5/16″-18 × ½″ LG; 14 is a ¼ plain washer (inch) type A and B; 15 is a ⅝″ plain washer (inch) type A and B; and 16 is a carousel weldment. 
     The diverting hopper  230  may comprise one or more flip gates  240  which selectively block or permit a package to flow into one of the chutes  216 . Alternately, the diverting hopper  230  may comprise air-operated, rodless cylinders mounted at 90 ° with respect to each other and at 45 ° with respect to a floor, such that the cylinders can be selectively retracted or extended to open and close a flip gate  240  which selectively blocks or permits a package to be diverted into one of the chutes  216 . Chutes  216  can be configured to deposit packages of a single package group into an open bag  218 , such that an operator may then close the bag, apply a label, remove the bag, and open a subsequent bag. 
     According to an example aspect, closable bags can be arranged at each of the chutes  216  in merry-go-round configurations  236  and  238 , such that, at each of the merry-go-round configurations  236  and  238 , a bag  218  can be staged on each one of a plurality of carts, for example four carts, such as carts  237  or  239 , below a respective chute  216 . The bags  218  can be mounted on a carousel  233 ,  235  which can be rotated to present a staged empty bag, as needed. Alternately, a linear shuttling system may be used in which shuttling carts with empty bags are moved from left to right, or a single cart can be in position and replaced once empty bags are all used. Once filled, a closable bag  218  can be labeled, closed, and placed onto a return conveyor to go back into the parcel sorting system. 
       FIGS.  6 A- 6 E  illustrate a smart bin  202 , according to an example embodiment:  FIGS.  6 A,  5 B, and  6 C  are different perspective views of the smart bin;  FIG.  6 D  is a plan view of the front of the smart bin; and  FIG.  6 E  is a plan view of a side of the smart bin. As shown in  FIGS.  6 A- 6 E , the smart bin  202  includes a bottom  504 , and a side wall  502  extending upward from each edge of the bottom  504 , such that the bottom  504  and side wall  502  together define a cavity  506 , therewithin. The cavity  506  can have any of a variety of dimensions, including cross-section X-Y, height H, width W, and length L, sufficient to accommodate a plurality of packages  204  that can be transferred or released to zones or windows  210  of collector conveyor  208 . The bottom  504  comprises a gate  508 , which is moveable between an open position and a closed position. When the In the gate  508  is in the open position, a passage  510  is defined by lower edges of the side wall  502 , and a rear edge of the bottom  504 /gate  508 , as shown in  FIGS.  5 B and  6 C . The passage  510 , thus open, enables packages  204  to be released from the cavity  506 , for example onto a collector conveyor  208 . The side wall  502  may comprise four adjoining sections  511 ,  512 ,  513 , and  514 , which together to define sides of the cavity  504  having an essentially rectangular bottom with a cross-section X-Y. One or more of the sections  511 ,  512 ,  513 , and  514  may slant outward from their respective bottom edges, such that one or more of the sections  511 ,  512 ,  513 , and  514  may have a rectangular shape or a trapezoidal shape. The cavity  504  may have a height H, a width W, and a length L, as shown in  FIGS.  6 D and  6 E . The gate  508  can be a slide gate having a linear guide system  530  and a linear actuator  520 . The guide system  530  may include two or more guide rails, as shown in  FIGS.  6 A,  6 B,  6 C, and  6 E . Further components may be included in the smart bin  202 , such as a strip bush holder  522 , a strip bush  524 , and a pillow block  526 , which may facilitate operation of the smart bin  202 . 
     According to example implementations, Ultra High Molecular Weight Polyethylene (UHMW), or other types of low-friction material, can be used for manufacturing and/or for lining of chutes, hoppers, bins and other wear surfaces. 
       FIG.  7    illustrates another example smart bin  602  according to an example implementation in which:  1  is a frame assembly;  2  is a cylinder assembly;  3  is a smart bin assembly;  4  is a frame connector plate;  5  is a slide gate;  6  is a smart bin-right;  7  is a smart bin-left;  8  is a smart bin-sorter side;  9  is a smart bin-operator side;  10  is a smart bin-belt retainer plate;  11  is a smart bin-belt wiper;  12  is a smart bin-belt return plate with weldnuts;  13  is a slide gate mounting angle;  14  is a slide gate end mount plate;  15  is a smart bin-UIHMW wiper;  16  is a t-bolts for extrusion slots;  17  is a t-bolt lock nuts for extrusion slots;  18  is a side rails estruction x 69.5 1 g (1×3 slots);  19  is an intermediate strut extrusion × 25.375 1 g (1×1 slots);  20  is an intermediate struts extrusion × 25.375 1 g (1×3 slots);  21  is a bearing rail igus size  16  rail × 1346 mm 1 g; and  22  is a bearing igus drylin with bearings size  16 . 
       FIGS.  8 A,  8 B,  8 C,  8 D, and  8 E  illustrate a perspective view, a side view, a front view, a detail view of portion A of  FIG.  8 E , and a back view, respectively, of a hopper  230  according to an example implementation; while  FIGS.  9 A,  9 B, and  9 C  illustrate an exploded view, an exploded view with the guard hidden, and a detail B, respectively, of an example hopper, in which:  1  is a ACB-02 temporary ship weldment;  2  is a cylinder weldment;  3  is a front panel weldment;  4  is a lower center support;  5  is a flange bearing mount bracket;  6  is a support angle;  7  is a rear steel panel;  8  is a side panel;  9  is a triangle bracket  2 ;  10  is a triangle bracket;  11  is a polycarb. panel;  12  is an actuator plate;  13  is a gate weldment;  14  is an angle to cleated conveyor;  15  is a cylinder guard;  16  is a 2-hold flange bearing and clamp for 1.5″ diameter shaft;  17  is a bronze brushing - 5.0 ID × 8.0 OD × 8 mm LG;  18  is a flanged shaft clamp for 1.5″ diameter shaft with keyway;  19  is a hex nut, nylock, 5/16-18; 20 is a hex nut - ½″-13; 21 is a hex nut - ¼-20; 22 is a ¼ - 20 UNC - 2 ¼ HS HCS; 23 is a ¼ - 20 UNC - ⅞, HS HCS; 24 is a 5/16 - 18 ×⅞, HSBHCSI25 is a ½″ washer; 26 is a ¼″ washer; 27 is a ½-13 UNC - 1.5, HBI;  28  is a pneumatic cylinder - 25 mm bore x 305 mm (12″) stroke; and  29  is a shock absorber with ¾-16 UNF thread-body. 
     According to an example embodiment, a turnkey solution may include the provision and installation of conveyor systems, as described herein, as well as all motors and control devices.  FIG.  10    is a schematic illustration of a main control panel according to an example embodiment. Such a main control panel can be installed to control an automatic sortation system, such any of those as described herein. The main control panel may include a plurality of input/output (I/O) modules, field devices, and implement variable frequency drive (VFD) technology. One or more main control panels may be networked together and may control coordinated operations. If a new main control panel is networked with an existing main control panel in an existing system, Human Machine Interface (HMI) and programmable logic controller (PLC) program development can be performed for the new main control panel and modifications, if any, may be made to programs in the existing main control panel to accommodate any new system elements. 
     According to an example embodiment, a two-way linear rail assembly can be provided as a replacement for merry-go-round configurations  236  and  238 , such that, for example, a two-way linear rail assembly can be installed at each or any of the merry-go-round configurations  236  and  238  and/or carousel  233 ,  235  shown in an example of  FIGS.  5 A- 5 I .  FIGS.  11 A- 11 D  illustrate an example implementation of a two-way linear rail assembly  110   0  comprising a support  112   0  and a carriage  1110 . 
     In an example implementation, one or more bag carts, such as for example two surepost bag carts (TSK-03), can be loaded into respective position of carriage  111   0  and located underneath a hopper, such as hopper  230 . When a bag is full the operator can remove the bag, and for example take it to a collector conveyor. When the bag cart is empty of bags, carriage  111   0  can be rolled over so that a bag cart full of empty bags can be placed underneath the hopper and the bags continue to be filled. While an operator is filling bag at a current position another operator can remove an empty bag cart and replace it with a cart full of bags. 
     According to an example embodiment, a three-way linear rail assembly can be provided as a replacement for merry-go-round configurations  236  and  238 , such that, for example, a two-way or a three-way linear rail assembly can be installed at each or any of the merry-go-round configurations  236  and  238  and/or carousel  233 ,  235  shown in an example of  FIGS.  5 A- 5 I .  FIGS.  12 A- 12 D  illustrate an example implementation of a three-way linear rail assembly  120   0  comprising a support  122   0  and a carriage  1210 . 
     In an example implementation, one or more bag carts, such as for example three surepost bag carts (TSK-03), can be loaded into respective position of carriage  121   0  and located underneath a hopper, such as hopper  230 . When a bag is full the operator can remove the bag, and for example and take it to a collector conveyor. When the bag cart is empty of bags, carriage  121   0  can be rolled over so that a bag cart full of empty bags can be placed underneath the hopper and the bags continue to be filled. While an operator is filling bag at a current position another operator can remove an empty bag cart and replace it with a cart full of bags. 
     Referring to  FIGS.  13 A- 13 D , in an exemplary embodiment, a hopper  130   0  can be used in place of hopper  230 , for example when using a linear rail assembly, such as assembly  110   0  or  120   0 , for two loading positions, which can be referenced as positions A and B. In an exemplary implementations, a three-position linear rail assembly, such as assembly  120   0 , can be placed under both sides of the chutes. A cleated conveyor assembly, such as assembly  212 , can be configured to feed packages between side plates  131   2  and  131   4  of hopper  130   0 , and based on a predetermined or desired destination of a slug of packages, a gate assembly  131   0  can be turned, for example to 90 degrees, if packages need to go to chute  132   2 , or for example to 45 degrees if packages need to go to chute  1324 . In an example implementation, gate  131   0  can be actuated by a pneumatic cylinder  133   0  which can be configured on one side, or both sides, of the hopper assembly  1300 . Hopper assembly  130   0  can be used for example when less packages per hour are needed, and less space is available since it can be implemented to have two positions to feed two linear rail assemblies, such as assemblies  110   0  and/or  1200 . 
       FIGS.  14 A- 14 E  illustrate in an enlarged schematic plan view and various cross sectional views, respectively, example embodiment of a system, such as system  500 ,  200 , or  250 , implementing hopper  130   0  and linear rail assemblies  110   0  and/or  1200 . Example implementations shown in  FIGS.  14 A- 14 E  illustrate how a hopper  130   0  integrates with a cleated conveyor  212  and three-way linear rail assemblies  1200 . As illustrated in  FIG.  14 A , packages feed from a cleated conveyor  212  to either side to each operator A and B. In an exemplary implementation, a flip gate  141   0  can be provided on the end of a chute of hopper  130   0  that the operator flips up or down to hold each bag in place while packages are dropping into them. In yet further exemplary implementation, a hopper curtain  141   2  can be provided to slow down packages as they fall down the chute of hopper  1300 . 
       FIGS.  15 A- 15 H  illustrate in an isometric view, enlarged schematic plan view and various cross sectional views, respectively, another example embodiment of a system, such as system  500 ,  200 , or  250 , implementing hopper  140   0  and linear rail assemblies  110   0  and/or  1200 . Exemplary implementations shown in  FIGS.  15 A- 15 H  illustrate how a hopper  140   0  integrates with the cleated conveyor  212  and the two-way linear assemblies and three-way linear assemblies. In an exemplary implementation, hopper  140   0  has similar function to that of hopper  1   30   0 ; however, in addition to the two positions A and B of hopper  130   0 , hopper  140   0  implements an added third position, C,  1406 . According to an exemplary implementation, a first gate assembly  140   2  of hopper  140   0  flips up or down to either feed the A position or B position, and a secondary gate  140   4  can implemented at the B position that flips up or down to continue down the B position or feed onto a conveyor that takes the slug of packages on a belted conveyor  142   0  to the C position. In a further exemplary implementation, A and B positions can be configure to feed a three-way linear rail assembly  120   0  and the C position feed a two-way linear rail assembly  1100 . An exemplary configuration of  FIGS.  15 A- 15 H  can be used when, for example, more packages per hour are needed and/or the floor space is sufficient. 
       FIGS.  16 A- 16 E  illustrate in an isometric view, enlarged schematic plan view and various cross section and enlarged views, respectively, another example embodiment of a system, such as system  500 ,  200 , or  250 , implementing cleated conveyor  1600 . Exemplary implementations shown in  FIGS.  16 A- 16 E  illustrate how cleated conveyor  160   0  can be configured with hopper  140   0  and linear rail assemblies  110   0  and/or  1200 . 
     More generally,  FIGS.  16 A- 16 E  illustrated an example of the cleated conveyor assembly  160   0  that can feed either hopper  130   0  or hopper  140   0 , and the processing using conveyor  160   0  can also be performed as in the example of  FIG.  5 D  5E 5F and 5G.  FIG.  16 A  example shows cleated conveyor  160   0  and the hopper  140   0  along with three-way linear rail assembly  120   0  and two-way linear rail assembly  1100 . 
     Referring further to  FIGS.  16 A- 16 E , details of example implementations can include custom belting  160   4  that takes slugs of packages up an incline  160   2  in section  1608 . In an exemplary implementation, belting  160   4  can include cleats  160 5 configured at intervals  160   7  on belting  1604 . In an exemplary implementation, incline  160   2  can be about 20 degrees from horizontal. 
     In yet further exemplary implementations, custom flags (for example, metal) can be embedded in the belting to trigger a proximity sensor  161   0  and keep the belting tracked so that the location of essentially each slug of packages is the conveyor  160   0  can be determined. In an example implementation, proximity sensors  161   0  can be installed on both sides of belting  160   4 , for example on an outside edge thereof. In a further example implementation outside sprockets  161   1  on head and tail are installed so that they will not interfere with the proximity blocks. 
       FIGS.  17 A- 17 C  illustrate in an isometric view, top view and side view, respectively, another example embodiment of a smart bin  170   0  that can be deployed in any one of systems  500 ,  200 , or  250 , implementing cleated conveyor  212  or  160   0 , and any one of hopper configurations such as hopper  230 , hopper  130   0 , or hopper  140 , and either a carousel or linear rail assembly. 
     In an example implementation, smart bin  170   0  can have at least the functionality similar to that of a smart bin  202  described with reference to  FIGS.  6 A- 6 E  above. According to further example implementations, smart bin  170   0  can comprise hold-down tabs  170   6  on the front of bin body  170   4 , so that package weight does not shift the bin for example with respect to frame assembly  1702 . According to yet further exemplary implementations, smart bin  170   0  can comprise proximity flags and one or more sensor added to for example slide cylinder  170   8  for a more accurate readings when the gate is opened or closed. 
     Another example embodiment, which can be implemented independently of, or complimentary to, an automated sortation system embodying various features described with reference to  FIGS.  2 A- 17 C  capable of performing the automated sortation method as described with reference to  FIG.  1   , provides an auto bagging or auto packaging system and methodology. 
     In an example implementation of an auto bagging system complimentary to the automated sortation, steps S 124  and S 126  of  FIG.  1    are further automated such that: (1) the packages that were logically tracked by the automated sortation system are dropped into a large bag, which can be configured either in a carousel  233 , 235  or a linear rail system  110   0 , 120   0 , as described above with reference to  FIGS.  2 A- 17 C ; (2) the large bag determined to be full of packages is presented for closure (zipping); (3) the bag is automatically closed (zipped), for example by a robotic system with a custom end-effector; and (4) the closed bag exits the system while a new (empty) bag is placed into the rotation to be filled. 
     In an example implementation, an empty bag can be placed on into the system, for example on a carousel  233 ,  235  or a linear rail system  110   0 ,  120   0 , manually. Alternatively, the system can be configured such that multiple bags, for example a couple of hundred bags, can be loaded into the system before beginning operation and an operator could then tend to several such systems at one time to add additional bags as needed. 
     In an example implementation of closure with an automatic zipping component, a robot with a vision system to zip each bag can be deployed. As illustrated in an example of  FIG.  18   , such a system can include an electromechanical system and components  180   0  comprising mechanical devices that are actuated by electricity, including without limitation pneumatics and/or magnetics, such as robotic arm  180   2  in communication with one or more sensors  180   4  and/or a computer processor  1806 . In example embodiments, such system is configure to ensure that smaller items or parcels enter a bag or container, that such bag or container is closed by either zipping the bag or through other means (e.g., zip tie) for example by a robotic arm  180   2  controlled by the processor  180   6  based on stored and/or communicated information and/or command (including, without limitation, input from sensor  180   4 ), and such bag or container is transported from the filling station to downstream processing. 
     In an example implementation, such a system  180   0  can be capable of executing commands stored or transmitted by wire or wirelessly including specific routines and/or subroutines which execute to control the auto bagging process including the actions and timing of the electromechanical devices to, without limitation, ensure smaller items or parcels enter a bag or container, that such bag or container is closed by either zipping the bag or through other means, and such bag or container can be moved from the filling station to downstream processing. 
     While example of  FIG.  18    illustrates an auto bagging system components  180   0  deployed to complement an automated sortation system, system  180   0  can also be deployed in a stand-alone configuration adapted to automate bag closure in any system where a large quantity of bags or other containers need to be filled and closed. 
     One or more example embodiments described herein may provide various modes of operation for a conveyor system implementing smart bin technology including, but not limited to: manual or automated release of packages into package groups. A manual release can be based on, for example a visual inspection of the smart bin. A fully automated release can employ any of a variety of hardware and/or software configurations. such as, but not limited to: a proximity sensor, a volume sensor, a weight sensor, a photo sensors, and the like, in order to automate the release based on an output and/or control thereof. One or more of the example embodiments described herein may be used in conjunction with any of a variety of package group tracking techniques, such as using zone and/or window sensors arranged on the conveyor  208  or in proximity thereof. All electronic sensing components can be integrated into an operation monitoring system and/or an automated system such as a learning computer system. 
     One or more exemplary embodiments provide an electromechanical system comprising a computer processor, a sensor and a robotic arm, wherein when said package group is conveyed for further processing including transferring into a container the plurality of the packages of the package group, said electromechanical system closes the container by the robotic arm controlled by the computer processor based on stored or communicated information or commands based on input from the sensor. 
     One or more exemplary embodiments provide an electromechanical system wherein the input from the sensor comprises an indication of the container being full to a predetermined level. 
     One or more exemplary embodiments provide an electromechanical system wherein the container is a bag with a zipper closure. 
     One or more exemplary embodiments provide an electromechanical system, wherein the robotic arm comprises a plurality of movement axis. 
     One or more exemplary embodiments provide an electromechanical system, wherein the robotic arm comprises and end effector configure to close the zipper closure. 
     One or more exemplary embodiments provide an electromechanical system, wherein the electromechanical system further comprises means for position the container to facilitate the closure of the container. 
     While example aspects have been shown and described with reference to certain example embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein. For example, any of various communication protocols can be deployed in combination with any of various electronic sensors, and/or any of various visual and/or audio user interfaces can be implemented to facilitate processing and/or displaying information and/or controlling hardware and/or software components of example systems. 
     It may be understood that example embodiments described herein may be considered in a descriptive sense only and not for purposes of limitation. Descriptions of features or aspects within each example embodiment may be considered as available for other similar features or aspects in other example embodiments. 
     While example embodiments have been described with reference to the figures, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope as defined by the following claims.