Patent ID: 12257604

DETAILED DESCRIPTION

Exemplary embodiments provide an automated sorting and relabeling system for one or more items. Items are received at a facility and processed. The items are processed using an automated sorting and transport system that includes a sorting apparatus having main conveyor system and multiple secondary conveyor systems each forming a transport section of the sorting apparatus. Each of the secondary conveyor systems can be associated with one or more specific item categories or types and/or one or more storage locations in a facility. The automated sorting and transport system can attempt to scan a label of each item being unloaded. The label can include information that can be used by the sorting and transport system to determine to which of the secondary conveyor systems to route the items. The labels are typically applied to the items prior to receipt at a facility and/or prior to receipt by the sorting and transport system. In some instances, a label may be missing from or unreadable on an item when it is received by the sorting and transport system and the sorting and transport system can be unable to determine to which of the secondary conveyor system to route the item.

A computing system executes a relabeling module which may include various circuits, circuitry and one or more software components, programs, applications, or other units of code base or instructions configured to be executed by one or more processors.

The relabeling module may be a hardware and/or software-implemented module configured to scan incoming items as they are unloaded and made ready for delivery or storage within a facility. The items that have labels are scanned using by a scan module reads and that label is used to identify the item and determine how the item should be handled. When an item is missing a label or the label unreadable, the relabeling module prints a label based on other information on the item and using real-time inventory information to identify the item and determine how the item should be handled.

Referring toFIG.1, a receiving system such as a sorting and transportation system100is used as an intake system to unload a delivery items from a vehicle into a facility, such as a retail environment. The system100can include sorting apparatus having one or more transport sections, a scanner104, a printing device106, a system controller108, a computing system110, a database112, and an inventory system114. The system controller108can be in communication with the computing system110and the inventory system114via a communications network105. The one or more transport sections can include a main conveyor102and/or secondary conveyors110-126. Items are loaded onto the main conveyor portion102of the system100at an inlet101and each item is routed to one of the outlets103of the system100. The outlets of the system100can be reached via the secondary conveyors110-126based on a sorting label affixed to each item. The main conveyor portion102transports the items passed the scanner104, which scans the items for sorting labels. Based on the scanned information from the labels, the system controller108determines to which of the secondary conveyors110-126the items are to be routed.

In some instances, it may be determined that a sorting label expected to be affixed to an item is missing or compromised such that the scanner104is unable to detect or read the label on the item. The system100is unable to route the item with the missing or comprised label to an appropriate or assigned one of the secondary conveyors110-126without the information included on the label. In such an instance, the scanner104attempts to scan the item for other indicia from which item identifying information can be detected. The other indicia may include a Universal Item Code (UPC), a manufacturer's item UPC, printed item information using text recognition, images, or a Digimark® image reading. Upon detection of other indicia, the scanner104, via the system controller108, can transmit the indicia to the computing system110, which can process the indicia and query a database112to identify the item based on the detected indicia.

Once an item that is missing a label or includes an unreadable label is identified by the computing system110based on an output of the scanner104, the computing system110can query the inventory system114to determine where the item is needed. The inventory system114can be a real-time inventory system that can dynamically allocate items based on real-time inventory requirements. Thus, the system100can determine at the time the item is identified that the item is needed in a location that is different the location that was previously assigned to the item.

The computing system110can generate a sorting label for the item and instruct the printer device106, via the system controller108, to print the label for the item being processed that does not have an expected label. The label identifies a location where the item should be stocked, which may include an aisle identifier, a section identifier, a shelf identifier, or a number. The printer device106prints the label and applies the label to the item. After the label is printed and applied to the item, the label can be re-scanned by scanning device104.

After the item is re-scanned and the label is detected, the outlet of the system to which the item is to be transported can be determined by the system controller108and the system controller108can control the main conveyor102and one of the second conveyors110-126to transport to the item to the assigned outlet. The system controller108can control different sets of rollers of the main conveyor102and/or the second conveyors110,112,114,116,118,120,122,124and126such that the item is directed to the appropriate location output location of the system100based on the scanned label of the item. For example, each one of the secondary conveyors110-126can be associated with a different category or type of item and/or with a different location in the retail facility to which the item will be delivered.

Referring now toFIG.2, a flow diagram of an example embodiment of a process200for relabeling unlabeled items is shown. In exemplary embodiments, an unlabeled item refers to an item that is missing a label or that has an unreadable label. The process200begins at operation202where an item is transported from an inlet of a sorting and transport system (e.g., an embodiment of the system100) towards one of the outlets of the sorting and transport system.

In operation204, as the item is being transported by towards the outlets by the transport sections of the sorting apparatus, an item is identified as missing an expected label by the scanning device. The expected label that is missing would have indicated a location where the item should be stocked in the retail facility and/or to which of the outlets of the sorting and transport system the item should be routed. For example, the item can be a box of footballs that should be routed to the outlet of the system corresponding to the sporting goods department.

In operation206, the unlabeled item is re-scanned by the scanning device as the item is transported by the sorting and transport system to detect other indicia, such as a machine-readable identifier on the item, is scanned, wherein the machine-readable identifier can be at least one of a package Universal Item Code® (UPC), a manufacturer's UPC, printed item information identified using text recognition and/or image recognition, or a Digimark image.

In operation208, the other indicia is transmitted from the scanner device to a computing system via the system controller of the sorting and transport system. The computing system determines the identity of the item based on the other indicia received from the scanner device and in operation210, queries the inventory system to determine a location in the retail facility for the item based on the determined identity of the item. In operation212, a label indicating a location where the item should be stocked in the retail facility is generated by the computing system214, which instructs the printing device to print the label211. The label can include a location where the item should be stocked, which can be dynamically allocated for the item based on real time inventory requirements216. For example, the item is identified as a soccer ball, and it may be determined that the sporting goods department is low on this type of soccer ball at the time the identity of the soccer ball is determined and the system can determine the soccer ball should be delivered to the sporting goods department area as opposed to a stocking area. In some embodiments, the label includes at least one of an aisle identifier, a section identifier, a shelf identifier, and a number218. The location where the item should be stocked comprises a storage area220.

In operation211, the printing device prints the label. In operation212, the printed label is applied to the item, wherein the item can be further processed based on the printed label. In operation206, the scanner device re-scans the item to detect the label and, in operation202, the system controller of the sorting and transport system controls the main conveyor and at least one of the secondary conveyors to transport the item to an outlet associated with the information included on the label.

FIG.3illustrates a network diagram depicting an embodiment of a system300for relabeling items, according to an example embodiment. The system300can include a network305, multiple computing devices, for example, client device310, client device320, a server330, and database(s)340. The system300can also include an embodiment of the sorting apparatus including the main conveyor102and secondary conveyors110-126, and can include the scanner device104and the printing device106. Each of the client devices310,320, server330, and database(s)340is in communication with the network305.

In an example embodiment, one or more portions of network305may be an ad hoc network, an intranet, an extranet, a virtual private network (VPN), a local area network (LAN), a wireless LAN (WLAN), a wide area network (WAN), a wireless wide area network (WWAN), a metropolitan area network (MAN), a portion of the Internet, a portion of the Public Switched Telephone Network (PSTN), a cellular telephone network, a wireless network, a WiFi network, a WiMax network, another type of network, or a combination of two or more such networks.

The client devices310,320and server330may comprise computing devices. The client devices can be, but are not limited to, mobile devices, hand-held devices, wireless devices, portable devices, wearable computers, cellular or mobile phones, portable digital assistants (PDAs), smart phones, smart watches, tablets, ultrabooks, netbooks, laptops, desktops, multi-processor systems, microprocessor-based or programmable consumer electronics, and the like. Each of client devices310,320and server330may connect to network305via a wired or wireless connection. In an example embodiment, the client devices310,320and/or the server330may perform one or more of the functionalities of the system for sorting and relabeling items described herein, or transmit data or signals to the system described herein to facilitate sorting and relabeling items. The client device310,320and/or the server330can include one or more components of computing device400ofFIG.4.

The database(s)340comprise one or more storage devices for storing data and/or instructions (or code) for use by the server330and/or the client devices310,320. Each of the database(s)340and the server330is connected to the network305via a wired connection. Alternatively, one or more of the database(s)340and server330may be connected to the network305via a wireless connection. The server330comprises one or more computers or processors configured to communicate with the client devices310,320via network305. The server330can include one or more components of device400ofFIG.4. Server330hosts one or more software systems, applications or websites, including one or more components of the system100described herein and/or facilitates access to the content of database(s)340.

In an example embodiment, the server330also includes various software services332,334,336,338that facilitate the functionalities of the system100for sorting and relabeling items. Database(s)340and server330may be located at one or more geographically distributed locations from each other or from client devices310,320. Alternatively, database(s)340,345may be included within server330.

FIG.4is a block diagram of an exemplary computing device400that can be used to perform one or more operations of the processes described herein. For example, the client device310,320and the server330, as described inFIG.3, may each be embodied as the computing device400. The computing device400includes one or more non-transitory computer-readable media for storing one or more computer-executable instructions or software for implementing exemplary embodiments. The non-transitory computer-readable media can include, but are not limited to, one or more types of hardware memory, non-transitory tangible media (for example, one or more magnetic storage disks, one or more optical disks, one or more USB flashdrives), and the like. For example, memory406included in the computing device400can store computer-readable and computer-executable instructions or software for implementing exemplary embodiments. The computing device400also includes processor402and associated core404, and optionally, one or more additional processor(s)402′ and associated core(s)404′ (for example, in the case of computer systems having multiple processors/cores), for executing computer-readable and computer-executable instructions or software stored in the memory406and other programs for controlling system hardware. Processor402and processor(s)402′ can each be a single core processor or multiple core (404and404′) processor.

Virtualization can be employed in the computing device400so that infrastructure and resources in the computing device can be shared dynamically. A virtual machine414can be provided to handle a process running on multiple processors so that the process appears to be using only one computing resource rather than multiple computing resources. Multiple virtual machines can also be used with one processor.

Memory406can include a computer system memory or random access memory, such as DRAM, SRAM, EDO RAM, and the like. Memory406can include other types of memory as well, or combinations thereof. An individual can interact with the computing device400through a visual display device418, such as a touch screen display or computer monitor, which can display one or more graphical user interfaces422for receiving data from a user. The visual display device418can also display other aspects, elements and/or information or data associated with exemplary embodiments. The computing device400can include other I/O devices for receiving input from a user, for example, a keyboard or another suitable multi-point touch interface408, a pointing device410(e.g., a pen, stylus, mouse, or trackpad). The keyboard408and the pointing device410can be coupled to the visual display device418. The computing device400can include other suitable conventional I/O peripherals, such as image capture device432.

The computing device400can also include one or more storage devices424, such as a hard-drive, CD-ROM, or other computer readable media, for storing data and computer-readable instructions and/or software to facilitate one or more operations of the processes described herein for embodiments of the system100shown inFIG.1. For example, the storage devices424can store applications426(e.g., such as the relabeling module) that can be executed by the processing device(s)402,402′ to perform the processes described herein. Exemplary storage device424can also store one or more databases for storing suitable information required to implement exemplary embodiments. The databases can be updated by an individual or automatically at a suitable time to add, delete or update one or more items in the databases. Exemplary storage device424can store one or more databases426for storing provisioned data, and other data/information used to implement exemplary embodiments of the systems and methods described herein.

The computing device400can include a network interface412configured to interface via one or more network devices420with one or more networks, for example, Local Area Network (LAN), Wide Area Network (WAN) or the Internet through a variety of connections including, but not limited to, standard telephone lines, LAN or WAN links (for example, 802.11, T1, T3, 56 kb, X.25), broadband connections (for example, ISDN, Frame Relay, ATM), wireless connections, controller area network (CAN), or some combination of any or all of the above. The network interface412can include a built-in network adapter, network interface card, PCMCIA network card, card bus network adapter, wireless network adapter, USB network adapter, modem or another device suitable for interfacing the computing device400to a type of network capable of communication and performing the operations described herein. Moreover, the computing device400can be a computer system, such as a workstation, desktop computer, server, laptop, handheld computer, tablet computer (e.g., the iPad® tablet computer), mobile computing or communication device (e.g., the iPhone® communication device), or other form of computing or telecommunications device that is capable of communication and that has sufficient processor power and memory capacity to perform the operations described herein.

The computing device400can run an operating system416, such as versions of the Microsoft® Windows® operating systems, the different releases of the Unix and Linux operating systems, a version of the MacOS® for Macintosh computers, an embedded operating system, a real-time operating system, an open source operating system, a proprietary operating system, an operating systems for mobile computing devices, or another operating system capable of running on the computing device and performing the operations described herein. In exemplary embodiments, the operating system416can be run in native mode or emulated mode. In an exemplary embodiment, the operating system416can be run on one or more cloud machine instances.

The description is presented to enable a person skilled in the art to create and use a computer system configuration and related method and systems for modifying capacity for a new retail facility. Various modifications to the example embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Moreover, in the following description, numerous details are set forth for the purpose of explanation. However, one of ordinary skill in the art will realize that the invention may be practiced without the use of these specific details. In other instances, well-known structures and processes are shown in block diagram form in order not to obscure the description of the invention with unnecessary detail. Thus, the present disclosure is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

In describing exemplary embodiments, specific terminology is used for the sake of clarity. For purposes of description, each specific term is intended to at least include all technical and functional equivalents that operate in a similar manner to accomplish a similar purpose. Additionally, in some instances where a particular exemplary embodiment includes a plurality of system elements, device components or method steps, those elements, components or steps can be replaced with a single element, component or step. Likewise, a single element, component or step can be replaced with a plurality of elements, components or steps that serve the same purpose. Moreover, while exemplary embodiments have been shown and described with references to particular embodiments thereof, those of ordinary skill in the art will understand that various substitutions and alterations in form and detail can be made therein without departing from the scope of the invention. Further still, other aspects, functions and advantages are also within the scope of the invention.

Exemplary flowcharts have been provided herein for illustrative purposes and are non-limiting examples of methods. One of ordinary skill in the art will recognize that exemplary methods can include more or fewer steps than those illustrated in the exemplary flowcharts, and that the steps in the exemplary flowcharts can be performed in a different order than the order shown in the illustrative flowcharts.

Having described certain embodiments, which serve to illustrate various concepts, structures, and techniques sought to be protected herein, it will be apparent to those of ordinary skill in the art that other embodiments incorporating these concepts, structures, and techniques may be used. Elements of different embodiments described hereinabove may be combined to form other embodiments not specifically set forth above and, further, elements described in the context of a single embodiment may be provided separately or in any suitable sub-combination. Accordingly, it is submitted that the scope of protection sought herein should not be limited to the described embodiments but rather should be limited only by the spirit and scope of the following claims.