Patent Description:
Generally, in material handling environments like, but not limited to, distribution centers, warehouses, inventories, or shipping centers, a material handling system, can convey, handle, sort, and organize various type of items (e.g. cartons, cases, containers, shipment boxes, totes, packages, and/or the like) at high speeds. Typically, in the material handling environments, items are conveyed on conveyors and are often collected into one or more chutes that are positioned alongside conveyors of the material handling system. Depending on a configuration of the material handling system, the items may travel through the material handling environment in an unregulated manner or may be repositioned, reoriented, and/or consolidated into a single stream of items as the items move on the conveyors and/or further collected into the chutes. For example, in some cases, items are sorted by sortation conveyor of the material handling system and upon sortation are collected into respective chutes.

Reference is made to <CIT> which discloses the preamble of claim <NUM> and <NUM> and relates to a method and apparatus for accumulating articles including a dispensing of the articles with a rotating, metering drum for movement to a first conveyor, wherein the metering drum has an entry end and an exit end, and in a particular aspect, the metering drum can be configured such that a rotation of the metering drum overcomes a static friction which would inhibit a movement of the articles downstream through the metering drum, wherein in another aspect the metering drum can include at least one lug member which is positioned and attached inside the metering drum at the exit end of the metering drum, wherein in further aspects, a ramp member can be configured to extend an operative distance into the volume of the metering drum, and can be spaced away from an inside wall surface of the metering drum by a selected offset distance.

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

Specific embodiments are defined in the dependent claims.

According to some example embodiments, the actuation unit can comprise, at least one drive roller and at least one idler roller. In this regard, the at least one drive roller and the at least one idler roller can be configured to rotate in a first direction cause rotation of the at least one tube in a second direction opposite to the first direction.

According to some example embodiments, the at least one tube can be positioned between the at least one drive roller and the at least one idler roller. Further, the at least one tube can abut with a surface of the at least one idler roller and a surface of the at least one drive roller respectively so that the rotation of the drive roller and the idler roller causes rotation of the at least one tube.

According to the invention, the at least one tube is configured to rotate at a variable rotational speed within a defined range of rotational speed.

According to some example embodiments, the conveyor is one of: a loop sorter, a tilt-tray sorter, a bomb-bay sorter, a shoe sorter, a singulation conveyor, or a line sorter.

In some example embodiments, the actuation unit can include a shaft assembly mechanically coupled to the at least one drive roller and at least one idler roller. In this regard, the rotation of the at least one drive roller and the at least one idler roller the shaft assembly to rotate a tube corresponding to each chute of the plurality of chutes.

According to the invention the material handling system further comprises a control unit. The control unit is configured to determine the physical characteristic of the item to be passed through the chute. Further, based on the determining, the control unit is configured to manipulate, via the actuation unit, the rotational speed of the at least one tube.

Some arrangements described herein relates to a chute of a material handling system. The chute comprises, an inlet of the chute configured to interface with a surface of a conveyor at a defined angle with respect to the surface. The chute also comprises an outlet of the chute configured to interface with an item accumulator. Further, the chute comprises, a tube portion of the chute between the inlet and the outlet. In accordance with said arrangements, the tube portion can be configured to be rotated about an axis at a defined rotational speed by an actuation motor. In this regard, the defined angle at which the inlet is configured to interface with the surface of the conveyor and the defined rotational speed at which the tube portion is configured to be rotated are based on at least one of: physical characteristic of an item to be passed through the chute, a rate of inflow of the item through the inlet, and a rate of outflow of the item through the outlet.

In accordance with some arrangements, the tube portion can be configured to be rotated at variable rotational speed within a defined range of rotational speed. Further, in some arrangements, the rotational speed of the tube portion can be based on at least: a physical characteristic of the item, a rate of inflow of the item through the inlet, and a rate of outflow of the item through the outlet.

According to some arrangements, the inlet comprises, a first end that can define a tapered surface and can be mechanically coupled to the conveyor. In this regard, the first end can be configured to receive a flow of items from the conveyor. In accordance with said arrangements, the inlet also comprises a second end having a curved surface that defines a curvature that matches a lateral surface defining a proximal end of the tube portion to facilitate movement of flow of the items from the inlet to the tube portion.

According to said arrangements, the outlet comprises a first portion defining a curved surface defining a curvature that matches a lateral surface defining a distal end of the tube portion to facilitate the movement of the flow of the item from the tube portion to the outlet.

In some arrangements, the inlet of the chute is mechanically coupled to one of: a loop sorter, a tilt-tray sorter, a bomb-bay sorter, a shoe sorter, a singulation conveyor, or a line sorter.

Some example embodiments described herein relate to a method of collecting items in a material handling environment. The method comprises, receiving, via an inlet of a chute, an item from a conveyor. In this regard, the inlet of the chute is positioned at a defined angle with respect to the conveyor. Further, the method comprises, receiving, via a tube defined at a portion of the chute, the item from the inlet. In this aspect, the tube defines a first end mechanically coupled to the inlet and a second end. Further, the method comprises, rotating, the tube at a defined rotational speed, to cause a further movement of the item into an outlet mechanically coupled to the second end of the tube. According to said arrangements, the defined angle of the inlet and the defined rotational speed at which the tube is to be rotated is based on a physical characteristic of the item.

According to some example embodiments, the chute can be positioned at a defined angle relative to the conveyor. In this aspect, in some examples, the conveyor is one of: a loop sorter, a tilt-tray sorter, a bomb-bay sorter, a shoe sorter, a singulation conveyor, or a line sorter.

In some example embodiments, the method can comprise, rotating a drive roller and an idler roller, at a defined rotational speed in a first direction to cause rotation of the tube in a second direction opposite to the first direction.

The method further comprises, manipulating a rotational speed of the rotating of the tube based on the physical characteristic of the item.

According to some example embodiments, the chute is mechanically coupled to the conveyor and wherein the conveyor is one of a loop sorter (tilt-tray or cross-belt), a bomb-bay sorter, a shoe sorter, a singulation conveyor, or a line sorter.

The above summary is provided merely for purposes of summarizing some arrangements to provide a basic understanding of some aspects of the disclosure. Accordingly, it will be appreciated that the above-described arrangements are merely examples and should not be construed to narrow the scope of the disclosure in any way. It will be appreciated that the scope of the disclosure encompasses many potential arrangements in addition to those here summarized, some of which will be further described below.

Indeed, the disclosure may 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 satisfy applicable legal requirements. The terms "or" and "optionally" are used herein in both the alternative and conjunctive sense, unless otherwise indicated. The terms "illustrative" and "exemplary" are used to be examples with no indication of quality level.

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

Turning now to the drawings, the detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description comprises specific details for the purpose of providing a thorough understanding of various concepts with like numerals denote like components throughout the several views.

Typically, in material handling systems, chutes are installed alongside a conveyor at various positions to collect items into item accumulators and/or to transfer items to another conveyance equipment (e.g. secondary conveyors extending from a primary upstream or downstream conveyor). In this regard, as some items are diverted from a mail or flow of items flowing on the conveyor, the items flow through respective chutes identified for the items (e.g. based on item category, size etc.), and are further accumulated into item accumulators. For example, a flow of items on the conveyor may contain different types of items having varying shapes and sizes, moving on the conveyor. As these items flow on the conveyor, in some examples, depending on shape, size or category of the item, the items may be diverted (e.g. by a sortation system like a loop sorter, shoe sorter, etc.) onto different chutes positioned alongside the conveyor. Chutes are generally in a form of a slide onto which an item can fall based on gravitational and centrifugal forces experienced by the item, as the item is diverted from the conveyor towards the chute. Usually, the chutes can be positioned at an angle relative to a surface of the conveyor such that, a slope defined by the chute is sufficient enough to cause falling of an item through the chute into an item accumulator and/or to transfer items to another conveyance equipment (e.g. secondary conveyors extending from a primary upstream or downstream conveyor). Said differently, an angle at which the chute is installed against a surface of the conveyor (or relative to a ground surface) can be such that, it causes the item to experience a gravitational pull downwards towards the ground surface that overcomes a static friction force experienced by the item due to the surface of the chute. However, as items of various shapes and sizes flow on the conveyor in form of a bulk flow, it is desired, to give careful consideration while positioning or installing chutes alongside conveyor frames of the conveyor. For instance, a greater angle at which the chute may be installed with respect to the conveyor surface may often cause an increase in rate of flow /speed at which items may fall onto the chute. This may cause larger items to impact against smaller items, in the flow of items, resulting in damaging of items, or excessive noise, or sometimes personal injury to operators working in the material handling system. Alternatively, a smaller angle at which the chute may be installed relative to the conveyor surface may cause a decreased rate of flow or slow speed at which the items move onto the chute, thereby creating jams, and at times requiring manual intervention by an operator to clear the jams. Further, this jamming and manual intervention may lead to excessive downtime and system recirculation. Accordingly, installing chutes alongside conveyors in a material handling environment has associated challenges and limitations.

Various example embodiments described herein, relates to a chute of a material handling system comprising, a tube configured to rotate at a desired rotational speed to maintain a constant flow rate of items, as the items pass through the chute. The chute can comprise, (i) an inlet, (ii) at least a portion defining a tube that can be configured to be rotated at a desired rotational speed, and (iii) an outlet. In this regard, the inlet is mechanically coupled to a first end of the tube and the outlet is mechanically coupled to the second end of the tube. Further, the inlet can be mechanically coupled to a surface of a conveyor at a defined angle and the outlet can be mechanically coupled to an item accumulator (which may collect items that may fall through the chute). As mentioned, the inlet of the chute is positioned at a defined angle relative to the surface of the conveyor. In this regard, in accordance with various example embodiments described herein, (a) the defined angle at which the chute is positioned relative to the conveyor and (b) the desired rotational speed at which the tube can rotate, can be based on factors like physical characteristic of items to be passed through the chute, a rate of inflow of items through the inlet, and a rate of outflow of items through the outlet. In this aspect, irrespective of varying sizes and shapes of the items, by way of implementation of various example embodiments described herein, the chute based on rotation can maintains a constant flow rate at which the items pass through the chute, thereby can prevent any jamming or falling of items at an excessively faster rate that may cause damage to the items.

Further, the chute described according to various example embodiments herein, can handle a wider spectrum of items (i.e. items having varying sizes, shapes, weights, etc.) in the same volume without any limitations (like, product speed, damage, product jams, etc.). In other words, as the chute continually feeds the items forward at a controlled rate, items may progress toward the chute outlet with a reduced risk of getting stuck or travelling excessively fast. Furthermore, a descent of items through the chute can be controlled while maintaining continuous infeed of items through the chute. In this regard, in accordance with said example embodiments, larger/heavier items may move thought the chute at substantially similar rates as smaller lighter items. Further details of the material handling system comprising the chute and its associated operations are described hereinafter in reference to <FIG>.

"A flow of items" referred hereinafter throughout the description, refers to a set of items that can comprise at least one item, that may move along a surface of a conveyor or a chute, at a defined flow rate (e.g. items per second). In this regard, in some example embodiments, each item in the flow of items may move along the conveyor or the chute at same or varying speed relative to each other.

<FIG> illustrates a perspective view of a material handling system <NUM> comprising a sortation conveyor (referred hereinafter, as a conveyor <NUM>) and a plurality of chutes <NUM>, in accordance with various example embodiments described herein. For purpose of brevity, the material handling system <NUM> illustrated herein represents, an example material handling environment (e.g. but not limited to, a warehouse, a distribution center, an inventory, etc.) in which a chute described according to various example embodiments herein, may be installed. Illustratively, the material handling system <NUM> includes the conveyor <NUM> that can comprise a pair of left and right lateral side conveyor frames <NUM>, <NUM>, and an apron <NUM> of lateral slats <NUM>. The lateral slats <NUM> can be supported for longitudinal movement on the conveyor <NUM> to define a top conveying run <NUM> and a bottom return run (not shown).

Illustratively, the material handling system <NUM> also includes an induction conveyor <NUM> that can be positioned to deposit a plurality of items <NUM> onto the top conveying run <NUM>. As a flow of the plurality of items <NUM> moves on the top conveying run <NUM> of the conveyor <NUM>, some items from amongst the plurality of items <NUM> may be diverted and deposited onto one or more of the plurality of chutes <NUM> positioned along the left and right lateral side conveyor frames <NUM>, <NUM>. Furthermore, the items may be moved via the chutes <NUM>, into respective item accumulators <NUM> corresponding to the plurality of chutes <NUM> and/or can be transferred to another conveyance equipment (e.g. secondary conveyors extending from a primary upstream or downstream conveyor). According to said example embodiments, the induction conveyor <NUM> can be an offset induct belt that allows use of a single pusher on each flight that runs down towards center of the conveyor <NUM> and allows diverting of one or more items <NUM> off, both sides of the conveyor <NUM>, and further into the respective chutes <NUM>. In this regard, in some example embodiments, the chutes <NUM> may positioned on both left and right side of the conveyor <NUM>. As illustrated, the conveyor <NUM> can comprise more than one pusher (or shoe) <NUM> received for lateral movement across the apron <NUM>, and transverse to the longitudinal movement of the conveyor <NUM>. In this regard, each pusher <NUM> may be configured to cause diverting of the items from the conveyor <NUM> into respective chutes <NUM>.

Illustratively, the material handling system <NUM> also comprises, a controller referred hereinafter as, a control unit <NUM>, of the conveyor <NUM>. The control unit <NUM> can comprise a network interface <NUM> that can be configured to communicate with a warehouse management system (WMS) <NUM>. Further, the control unit <NUM> can also include a memory <NUM> containing parameters and other configuration settings. For example, the control unit <NUM> may access via the memory <NUM>, parameters and settings to identify one or more of: items or chutes selected from amongst the plurality of chutes <NUM> onto which one or more items from the flow of items <NUM> is to be diverted. In some example embodiments, the control unit <NUM> can include a device interface <NUM> that may control electrical communication with the conveyor <NUM> and an item scanner or vision system <NUM>.

In accordance with some example embodiments, a processor subsystem <NUM> of the control unit <NUM> can be in communication with the network interface <NUM>, the memory <NUM>, and the device interface <NUM>. In this regard, in some example embodiments, the processor subsystem <NUM> may receive a scanned identification from the item scanner or the vision system <NUM> of a flow of items <NUM>. Further, the processor subsystem <NUM> may receive, from WMS <NUM>, for each item from amongst the flow of items <NUM>, an identification of a chute <NUM> into which the item is to be diverted. Furthermore, based on the received identification, the processor subsystem <NUM> may assign one or more pushers <NUM> predicted to flank a selected item from amongst the flow of items <NUM> towards one of a chute (i.e. a selected chute from amongst the plurality of the chutes <NUM>). Accordingly, one or more items from amongst the flow of items <NUM> can be diverted into respective chutes <NUM> at a defined flow rate. In accordance with said example embodiments, the chutes <NUM> of the material handling system <NUM> are rotatable about its axis. In this regard, the chutes <NUM> can be configured to rotate at a desired rotational speed so as to facilitate a desired flow of items into item accumulators <NUM> respective to each chute and/or to another conveyance equipment, while at the same time, prevent jamming of items (which may occur during transition of items from the conveyor <NUM> onto a chute or item accumulator) or damaging of the items (which may occur due to high rate of falling of items onto the chute from the conveyor <NUM>). Details related to chutes <NUM> of the material handling system <NUM> and method of collecting items, are described hereinafter in reference to <FIG>.

It should be appreciated that, in some example embodiments, the control unit <NUM>, the processor subsystem <NUM>, and/or the WMS <NUM> may include circuitry that may comprise a separate processor, specially configured field programmable gate array (FPGA), or application specific interface circuit (ASIC) to perform various operations described herein.

Although, <FIG> illustrates an example of a sortation conveyor system, e.g. an in-line shoe sorter comprising the conveyor <NUM> against which the chutes <NUM> described in accordance with various example embodiments herein, can be installed. However, without limiting the scope of the present disclosure, the chutes <NUM>, <NUM> described hereinafter in accordance with various example embodiments can be installed against conveyors of various other types of sortation systems (e.g. but not limited to, a loop sorter (tilt-tray or cross-belt), a bomb-bay sorter, a shoe sorter, a singulation conveyor, and a line sorter. For example, in some example embodiments, the chutes <NUM> can be installed against sortation conveyor (representing a loop sorter) as described in <CIT>.

<FIG> illustrates a perspective view of a chute <NUM> of the material handling system <NUM> in accordance with various example embodiments described herein. The chute <NUM> illustrated herein may represent one or more of the plurality of chutes <NUM> illustrated in <FIG>. Referring to <FIG>, the chute <NUM> comprises, an inlet <NUM>, an outlet <NUM>, and a tube portion <NUM> defined between the inlet <NUM> and the outlet <NUM>. In this regard, the tube portion <NUM> defines a tube <NUM>. In this regard, in accordance with said example embodiments, the tube <NUM> can be configured to be rotated about an axis X. Although, in the illustrated <FIG>, the tube portion <NUM> comprises one tube, i.e. the tube <NUM>, however, without limiting the scope of the present disclosure, in alternate example embodiments, the tube portion <NUM> may define one or more than one similar tubes (i.e. the tube <NUM>) between the inlet <NUM> and the outlet <NUM>, where each of the tube can be configured to be rotated about its respective axis (e.g. axis X). Said differently, according to some example embodiments, there may be one or more than one such rotatable tubes, (i.e. the tube <NUM>) defined between the inlet <NUM> and the outlet <NUM> of the chute <NUM> each of which may be configured to be rotated at same or different rotational speeds. In some examples, the tube <NUM> may correspond to a corrugated style plastic drainage tube. In alternate example embodiments, the tube <NUM> may be made up of a same material as of the inlet <NUM> and outlet <NUM> of the chute <NUM>.

Illustratively, the inlet <NUM> is interfaced with a surface <NUM> of a conveyor <NUM>, at a defined angle Y. In some examples, the chute <NUM> may be positioned such that the inlet <NUM> is positioned at the defined angle Y with respect to the surface <NUM> of the conveyor <NUM>, thereby defining a slope, (in other words, in form of a slide) from the conveyor <NUM> and onto which items moving the conveyor <NUM> may fall through, as the items get diverted onto respective chutes. In another aspect, the chute <NUM> may be positioned at a defined angle relative to a ground surface.

According to said example embodiments, the inlet <NUM> can define a first end <NUM> and a second end <NUM>. The first end <NUM> of the inlet <NUM> can be mechanically coupled (for example, but not limited to, connected or in connection, by means such as, fastening unit, screws, bolt or nut arrangement, and/or, the like) to the surface <NUM> of the conveyor <NUM>. In this regard, the mechanical connection between the inlet <NUM> and the surface <NUM> of the conveyor <NUM> may be such that, it may not cause any obstruction or hindrance to the flow of items which may fall into item accumulators, through the chute <NUM>, from the conveyor <NUM>. Illustratively, the tube <NUM> defines a proximal end <NUM> and a distal end <NUM>. The proximal end <NUM> of tube <NUM> can be mechanically coupled to the second end <NUM> of the inlet <NUM>. Further, the distal end <NUM> of the tube <NUM> can be mechanically coupled to the outlet <NUM>, which can be further mechanically coupled to an item accumulator that collects items. In some examples, the outlet <NUM> can be mechanically coupled to another conveyance equipment (e.g. secondary conveyors extending from a primary upstream or downstream conveyor).

In accordance with said example embodiments, the tube <NUM> can be rotated about the axis X by an actuation unit to cause rotation of the tube <NUM>. For instance, in some example embodiments, the actuation unit can comprise a drive roller <NUM> and an idler roller <NUM> that can be configured to rotate about its respective axis, on actuation by the actuation unit (e.g. by a motor of the actuation unit). Illustratively, the tube <NUM> is positioned between the drive roller <NUM> and the idler roller <NUM> such that, a lateral surface <NUM> of the tube <NUM> abuts with surfaces of the drive roller <NUM> and the idler roller <NUM>, respectively. In this regard, an arrangement of the drive roller <NUM> and the idler roller <NUM> with respect to the tube <NUM> is such that, rotation of the drive roller <NUM> and the idler roller <NUM> in a first direction causes rotation of the tube <NUM> in a second direction opposite to the first direction. Said differently, if the drive roller <NUM> and the idler roller <NUM> rotates in a clockwise direction about X axis, the tube <NUM> rotates in a counterclockwise direction about X axis.

In accordance with said example embodiments, the conveyor <NUM> may correspond to the conveyor <NUM> illustrated in <FIG> that may support flow of items in a direction <NUM>. Thus, as the items flow on the surface <NUM> of the conveyor <NUM> and are diverted towards the chutes, as the inlet <NUM> of the chute <NUM> is positioned at an angle relative to the conveyor <NUM> (i.e. at a defined slope) some items, from the flow of items, which are diverted towards the chute <NUM> falls onto the inlet <NUM> of the chute <NUM>. In this regard, in some example embodiments, the angle Y at which the chute <NUM> is mechanically coupled to the conveyor <NUM> can be such that, it allows the items to fall onto the inlet <NUM> due to gravitational pull that may be experienced by the items. Said differently, the angle Y is enough that every item falling through the chute <NUM> can overcome a static component of sliding friction experienced by the item as it falls through a surface of the inlet <NUM>. In this regard, the angle Y at which the chute <NUM> is positioned relative to the conveyor <NUM> may be defined depending on various factors such as, but not limited to, at least one of: physical characteristic of items to be passed through the chute <NUM>, a rate of inflow of items through the conveyor <NUM>, a desired rate of flow of items through inlet <NUM>, and a desired rate of outflow of items through the outlet <NUM>. In some examples, the angle at which the chute <NUM> can be positioned relative to the ground surface can be within a range from about <NUM> degrees to about <NUM> degrees. However, in some example embodiments, the angle may not be consistent across the entire length of the chute <NUM> and can depend on the type of application desired.

<FIG> illustrates an end view <NUM> of the chute <NUM> of the material handling system <NUM>, in accordance with some example embodiments described herein. As illustrated, the chute <NUM> is mechanically coupled to the conveyor <NUM> comprising one or more chute interfacing units (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>. <NUM>-n) e.g. cross-belts of a cross-belt sorter or slats of a slat-shoe sorter as illustrated in <FIG>, , along which the pusher <NUM> may move across a width of the conveyor (<NUM>, <NUM>). In accordance with various example embodiments described herein, the chute <NUM> can be mechanically coupled, via the chute interfacing units (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>,. <NUM>-n) to any type of conveyor or sortation system, and/or a surface corresponding, but not limited to, one or more of: a loop sorter (tilt-tray or cross-belt), a bomb-bay sorter, a shoe sorter, a singulation conveyor, and a line sorter.

As shown, the inlet <NUM> of the chute <NUM> from its first end <NUM> is mechanically coupled to the conveyor <NUM>. In this regard, in accordance with some example embodiments, the inlet <NUM> towards its first end <NUM> may define a tapered surface that mechanically couples with the surface <NUM> of the conveyor <NUM>. The tapered surface towards the first end <NUM> of the inlet defines a smooth transition from the surface <NUM> of the conveyor <NUM> to a surface of the inlet <NUM> which prevents any bumping off the items, as the items flowing on the conveyor <NUM> are diverted and transitioned into the chute <NUM>. Further, according to said example embodiments, the inlet <NUM>, between its first end <NUM> and the second end <NUM>, defines a sloping surface, in form of a slide, that enables a smooth sliding down of the items, at a desired flow rate, as the items flow from the conveyor <NUM> in the chute <NUM>. In this aspect, in accordance with said example embodiments, the inlet <NUM> is positioned at the angle Y relative to the surface <NUM> of the conveyor <NUM>, <NUM> such that, in operation, a gravitational pull acting on each item that drives the item down in the chute <NUM> overcomes a frictional force experienced at each item by a surface <NUM> of the inlet <NUM>.

Further, according to said example embodiments, the second end <NUM> of the inlet <NUM> defines a shape having a curvature that matches with a lateral surface defining the proximal end <NUM> of the tube <NUM>. Thus, the shape of the second end <NUM> of the inlet <NUM> and of the proximal end <NUM> of the tube are so matched such that, as the items falls through the inlet <NUM>, the items make a smoother transition from the second end <NUM> of the inlet <NUM>, via the proximal end <NUM> into the tube <NUM> in rotation. In some example embodiments, the tube may rotate in a direction <NUM> about the axis X. According to some example embodiments, rotation of the tube <NUM> about the axis X may be by the actuation unit comprising the drive roller <NUM> and the idler roller <NUM>. As shown, the tube <NUM> is disposed between the drive roller <NUM> and the idler roller <NUM>. In said example embodiments, the drive roller <NUM> and the idler roller <NUM> may be mechanically coupled to a shaft of an electric motor that upon actuation may cause rotation of the drive roller <NUM> and the idler roller <NUM> in direction <NUM>. In this regard, according to said example embodiments, the idler roller <NUM> may support the rotation of the drive roller <NUM> in the direction <NUM> opposite to the direction <NUM> of rotation of the tube <NUM>.

In some example embodiments, there may be multiple pairs of drive rollers and idler rollers respective for each chute from amongst multiple chutes in the material handling system <NUM>. In this regard, the actuation unit can comprise a shaft assembly mechanically coupled a drive roller and an idler roller respective to each chute, from amongst plurality of chutes (e.g. chutes <NUM>) along the conveyor <NUM>, <NUM>. To this extent, the rotation of the at drive roller and the idler roller corresponding to each chute is by actuation of the shaft assembly which causes rotation of a shaft connecting each of the idler roller and the drive roller arrangement for each chute. Details related to material handling system <NUM> comprising multiple chutes and multiple pairs of drive rollers and idler rollers are described later in reference to <FIG> and <FIG>.

<FIG> illustrates a top view <NUM> of the chute <NUM> of the material handling system <NUM> and a flow of items <NUM> through the chute <NUM>, in accordance with some example embodiments described herein. As illustrated, a flow of items <NUM> can pass through the tube <NUM> of the chute <NUM>. In this regard, the flow of items <NUM> may represent, a set of items, from amongst the flow of items <NUM> illustrated in <FIG>, which are being diverted towards the chute <NUM>. In accordance with some example embodiments, the flow of items <NUM> may represent items having common characteristics such as, but not limited to, item type, product category, item size, item handling property (fragile, consumable goods etc.), recipient container identifier, and/or the like. In this regard, the set of items <NUM> to be diverted towards the chute <NUM> may be identified based on similar characteristics associated with the items. According to said example embodiments, the flow of items <NUM> may move into the tube <NUM> at a defined flow rate (e.g. <NUM> items per minute, <NUM> items per minute, and/or the like). Further, the tube <NUM> can be rotated at a defined rotational speed to maintain a desired flow rate at which the flow of items <NUM> exits the tube <NUM>. In this regard, in some example embodiments, the rotational speed at which the tube <NUM> can be rotated may be within a range from about <NUM> revolutions per minute to about <NUM> revolutions per minute, or more specifically within a range from about <NUM> revolutions per minute to about <NUM> revolutions per minute. In some examples, the rotational speed at which the chute <NUM> can be rotated can be controlled by a variable frequency drive (VFD) coupled to the control unit <NUM>. In this regard, the rotational speed at which the chute <NUM> rotates can be configured depending of factors like, but not limited to, type of items being sorted by the conveyor <NUM>, a speed or frequency at which the items are being diverted by the conveyor <NUM>, the angle Y at which the chute <NUM> is installed relative to the conveyor <NUM>, and a desired overall handling of the items. In some example embodiments, the tube <NUM> can be rotated at a rotational speed that can ensure: (i) maintaining the desired rate of flow of the items <NUM> through the tube <NUM> and (ii) preventing any jamming of items as the items pass through the tube <NUM>. In some example embodiments, the tube <NUM> can be rotated at a rotational speed that maintains the desired rate of flow of the items <NUM> through the tube <NUM>. In this aspect, the rotational speed of the tube <NUM> may be based on factors like, but not limited to, physical characteristic of the items (e.g., but not limited to, size of items, dimensions of the items, weight of the items, material of the items, and a type associated with the items) or a rate of inflow of the items <NUM> onto the inlet <NUM> or a desired rate of outflow of the items <NUM> onto the outlet <NUM>. In some example embodiments, the rotational speed of the tube <NUM> may be varied within a defined range to ensure the flow of items <NUM> at the desired flow rate.

According to the invention, the control unit <NUM> of the material handling system <NUM> may determine, various parameters, for example, at least one of: the physical characteristic of items <NUM> to be passed through the chute <NUM>, the rate of inflow of items through the inlet <NUM>, and the rate of outflow of items through the outlet <NUM>. Based on the parameters the control unit <NUM> may cause to manipulate, via the actuation unit, the rotational speed of the tube <NUM>. In this regard, the control unit <NUM>, may cause to increase or decrease a rotational speed of the tube <NUM> to maintain a constant flow rate of the items.

<FIG> illustrates a top perspective view <NUM> of a material handling system <NUM> comprising a plurality of chutes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>), in accordance with some example embodiments described herein. <FIG> illustrates a bottom perspective view <NUM> of the material handling system <NUM> comprising the plurality of chutes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>), in accordance with some example embodiments described herein. As illustrated, each chute from amongst the plurality of chutes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) comprises inlets (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>), outlets (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>), and tubes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) respectively. In this regard, each tube from amongst the tubes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) can be configured to be rotated about a respective axis X1, X2, X3, and, X4. Rotation of the tubes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) can be caused by an actuation unit comprising, a drive motor <NUM>, a jackshaft <NUM>, a driving belt <NUM>, a drive wheel <NUM>, and multiple gear units (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>). As shown, the drive motor <NUM> is mechanically coupled to a jackshaft <NUM>, via a driving belt <NUM> that is pulleyed over a drive wheel <NUM> connected to the jackshaft <NUM>. The actuation unit further comprises drive rollers and idler rollers arrangement comprising pairs of drive rollers (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) and idler rollers (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>). In this regard, each of the tubes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>) is positioned respectively between each pair of the drive roller and the idler roller (<NUM>-<NUM>, <NUM>-<NUM>), (<NUM>-<NUM>, <NUM>-<NUM>), (<NUM>-<NUM>, <NUM>-<NUM>), and (<NUM>-<NUM>, <NUM>-<NUM>) such that, rotation of the drive rollers (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) and idler rollers (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) in a first direction causes the respective tubes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) to rotate about its axis in a second direction opposite to the first direction.

In accordance with said example embodiments, the drive motor <NUM> upon initialization (e.g. by the control unit <NUM>) can cause a shaft <NUM> of the drive motor <NUM> to rotate about an axis Y, which can further cause movement of the driving belt <NUM> (disposed over the shaft <NUM>) about the drive wheel <NUM>. Movement of the driving belt <NUM> over the drive wheel <NUM> causes the drive wheel <NUM> to rotate about its axis Z. As shown, the jackshaft <NUM> through passes from the drive wheel <NUM>. Thus, the rotation of the drive wheel <NUM> about the axis Z, can cause the jackshaft <NUM> to follow rotation of the drive wheel <NUM>. Referring to <FIG>, each drive roller (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) is mechanically coupled to the jackshaft <NUM> via the gear units (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) comprising respective Power Take-Off (PTO) belts (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>). In this regard, the gear units (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) can comprise a gear mechanism (e.g. but not limited to a bevel gear type mechanism) that can be configured to cause rotation of the jackshaft <NUM> about Z axis to be translated into rotation of each of the drive rollers (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) about respective axis (P1, P2, P3, and P4). In accordance with said example embodiments, as the drive rollers (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) rotates, the idler rollers (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) supports rotation of the drive rollers thereby causing the tubes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) to rotate in a direction opposite to direction of rotation of the drive rollers (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>).

In some example embodiments, rotation of the tubes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) may be such that, each tube can be configured to rotate at a rotational speed different from each other, depending on factors like, physical characteristic of items to be passed through the respective chutes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>), a rate of inflow of items through the respective inlets (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>), and a rate of outflow of items through the respective outlets (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>). Alternatively, in some example embodiments, each tube from amongst the tubes (<NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>) can be configured to rotate at a same rotational speed.

<FIG> illustrates an example flowchart representing a method for collecting items, via the chute <NUM> of the material handling system <NUM>, as described in <FIG>, in accordance with various embodiments described herein. It will be understood that each or some blocks of the flowcharts, and combinations of blocks in the flowcharts, may be implemented by various means, such as hardware, firmware, one or more processors, circuitry and/or other devices associated with execution of software including one or more computer program instructions, and/or in conjunction with operations of various mechanical components like tube <NUM>, inlet <NUM>, outlet <NUM>, and/or the like as described in <FIG>. For example, some blocks of one or more of the procedure described above may be embodied by computer program instructions. In this regard, the computer program instructions which embody the procedures described above may be stored by a memory of an apparatus employing an embodiment of the present invention and executed by a processor in the apparatus. As will be appreciated, any such computer program instructions may be loaded onto a computer or other programmable apparatus (e.g., hardware) to produce a machine, such that the resulting computer or other programmable apparatus provides for implementation of the functions specified in the flowcharts' block(s). These computer program instructions may also be stored in a non-transitory computer-readable storage memory that may direct a computer or other programmable apparatus to function in a particular manner, such that the instructions stored in the computer-readable storage memory produce an article of manufacture, the execution of which implements the function specified in the flowcharts' block(s). The computer program instructions may also be loaded onto a computer or other programmable apparatus to cause a series of operations 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 operations for implementing the functions specified in the flowcharts' block(s). As such, the operations of <FIG> when executed, convert a computer or processing circuitry into a particular machine configured to perform an example embodiment of the present invention. In some examples, the operations of <FIG> can define an algorithm for configuring a computer or processor, to perform some blocks of the method described hereinafter, in accordance with some example embodiments. In some cases, a general-purpose computer may be provided with an instance of the processor which performs the algorithm of <FIG> to transform the general-purpose computer into a particular machine configured to perform an example embodiment.

Accordingly, blocks of the flowchart support combinations of means for performing the specified functions and combinations of operations for performing the specified functions. It will also be understood that one or more blocks of the flowcharts, and combinations of blocks in the flowchart, can be implemented by special purpose hardware-based computer systems which perform the specified functions, or combinations of special purpose hardware and computer instructions.

<FIG> illustrates an example flowchart representing a method for collecting items, via the chute <NUM> of the material handling system <NUM>, in accordance with some example embodiments described herein. According to various example embodiments, the method <NUM> for collecting items may start at step <NUM>. At step <NUM>, the material handling system <NUM> can include means such as, the chute <NUM> for receiving the flow of items <NUM> from the conveyor <NUM>, <NUM>. In this regard, at step <NUM>, the inlet <NUM> of the chute <NUM>, may receive at an item of the flow of items <NUM> from the conveyor <NUM>. As described earlier, the inlet <NUM> of the chute <NUM> can be positioned at a defined angle Y with respect to the conveyor <NUM> that ensures falling off the item from the surface <NUM> of the conveyor <NUM> towards the chute <NUM> due to gravitational and/or centrifugal forces acting on the item as it is diverted towards the chute <NUM>. The item herein, may correspond to an item from the flow of items <NUM> diverted towards the chute <NUM> from the conveyor <NUM>, <NUM>. According to said example embodiments, the flow of items <NUM> including the item may be received onto the inlet <NUM> at a defined flow rate (e.g., but not limited to, <NUM> items per second or <NUM> items per minute, and/or the like). In this regard, as the item falls onto the inlet <NUM> from the conveyor <NUM>, <NUM>, the item may gain speed due to gravitational pull experienced by the item. Moving to step <NUM>, the tube <NUM> defined at the tube portion <NUM> of the chute <NUM> may further receive the item from the inlet <NUM>. In this regard, the tube <NUM> may be rotating at a defined rotational speed while it receives the item from the inlet <NUM>. In this regard, in accordance with some example embodiments, as the tube <NUM> rotates and the flow of items <NUM> is inflowed into the tube <NUM>, various items in the flow of items <NUM> may move along a helical path along with the rotating tube <NUM>, thereby causing the items in the flow of the items <NUM> to continuously move towards the outlet <NUM> without experiencing any jam.

According to some example embodiments described herein, the tube <NUM> of the chute <NUM> can be positioned at angle which can be much flatter as necessary to facilitate overcoming static friction which the items experiences from surface of the tube <NUM>. In this regard, in accordance with various example embodiments described herein, as the tube <NUM> rotates at a selected or desired rotational speed, the items entering from the inlet <NUM> will begin climbing a wall defined by lateral surface of the tube <NUM> as depicted in <FIG>. Further, as the items begin climbing the wall of the tube <NUM>, the items will reach a height where the static friction can be overcome and the items start sliding back down from the wall of the tube <NUM>. To this extent, as the angle Y at which the chute <NUM> is installed relative to the conveyor <NUM> is below horizontal by some degree, the items will also index forward through the tube <NUM>. Furthermore, as tube <NUM> is continually rotating, a process of items climbing against the wall and sliding forward will repeat until the item reaches the outlet <NUM>. Any subsequent flow of items entering the chute <NUM> will follow a same process.

Moving to step <NUM>, the material handling system <NUM> can include means such as the control unit <NUM> that can cause, via the actuation unit, rotation of the tube <NUM> at a defined rotational speed, to cause a further movement of the item into the outlet <NUM>. The outlet <NUM> can be mechanically coupled to the distal end <NUM> of the tube <NUM>. Further, in accordance with said example embodiments, the defined angle Y of the inlet <NUM> and the defined rotational speed at which the tube <NUM> is to be rotated is based on a physical characteristic of the item, and optionally on at least one of a rate of inflow of the item through the inlet <NUM>, and a rate of outflow of the item through the outlet <NUM>. Thus, by way of implementation of the said method, the flow of items <NUM> diverted towards the chute <NUM> may move down through the chute <NUM> at a constant flow rate and can be safely collected into the accumulator without being damaged. Further, as the flow of items <NUM> move through the chute <NUM>, the items may not be jammed or piled up over each other which may disrupt continuity in the operation of the material handling system <NUM>.

According to the invention, the control unit <NUM> via the actuation unit, may also cause manipulation of the rotational speed at which the tube <NUM> rotates. Said differently, the control unit <NUM> causes the tube <NUM> to rotate at varying rotational speed within a defined range based on a physical characteristic of the item to be passed through the chute <NUM>.

It may be noted that, as used in this specification and the appended claims, the singular forms "a," "an" and "the" comprise plural referents unless the content clearly dictates otherwise.

References within the specification to "one embodiment," "an embodiment," "embodiments", or "one or more embodiments" are intended to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is comprised in at least one embodiment of the present disclosure. The appearance of such phrases in various places within the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, various features are described which may be exhibited by some embodiments and not by others.

It should be noted that, when employed in the present disclosure, the terms "comprises," "comprising," and other derivatives from the root term "comprise" are intended to be open-ended terms that specify the presence of any stated features, elements, integers, steps, or components, and are not intended to preclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.

Detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims.

Claim 1:
A material handling system (<NUM>, <NUM>) comprising:
a conveyor (<NUM>, <NUM>);
an actuation unit; and
a chute (<NUM>, <NUM>) mechanically coupled to the conveyor (<NUM>, <NUM>) at a defined angle (Y) with respect to a surface of the conveyor (<NUM>, <NUM>), the chute (<NUM>, <NUM>) comprising:
an inlet (<NUM>) defining a first end (<NUM>) and a second end (<NUM>), where the first end (<NUM>) of the inlet (<NUM>) is mechanically coupled to the surface of the conveyor (<NUM>, <NUM>);
at least one tube (<NUM>) defining a proximal end (<NUM>) and a distal end (<NUM>),
wherein the proximal end (<NUM>) of the tube (<NUM>) is mechanically coupled to the second end (<NUM>) of the inlet (<NUM>), wherein the at least one tube (<NUM>) is configured to be rotated about an axis (X) by the actuation unit at a defined rotational speed; and
an outlet (<NUM>) mechanically coupled to the distal end (<NUM>) of the at least one tube (<NUM>), wherein the defined angle (Y) at which the chute (<NUM>, <NUM>) is mechanically coupled to the conveyor (<NUM>, <NUM>) and the defined rotational speed at which the at least one tube (<NUM>) is configured to rotate are based on a physical characteristic of an item (<NUM>, <NUM>) to be passed through the tube (<NUM>),
wherein the at least one tube (<NUM>) is configured to rotate at a variable rotational speed within a defined range of rotational speed,
characterised in that
the material handling system (<NUM>, <NUM>) further comprises a control unit (<NUM>) configured to:
determine the physical characteristic of the item (<NUM>, <NUM>) to be passed through the tube (<NUM>); and
based on the determining, manipulate, via the actuation unit, the rotational speed of the at least one tube (<NUM>).