Abstract: A conveyor sortation system includes a frame and two or more carriages riding along the frame in a travel direction. Each carriage includes a belt and an electric motor. The belt is oriented at a direction that is transverse to the travel direction of the carriage. The electric motor is configured to drive the belt. In one form, the belt has a width that is at most 8 inches (20.32 cm) wide. In another form, the carriages have a vertical recirculation pattern along the frame.

Abstract: An automated flow buffer system includes infeed and discharge shuttle systems. A buffering system is disposed between the infeed shuttle system and the discharge shuttle system. The buffering system includes buffer conveyors arranged in an array to buffer one or more items. The infeed shuttle system and the discharge shuttle system each include a shuttle frame disposed proximal to an end of the buffering system and one or more shuttles independently moveable along the shuttle frame. Each of the shuttles include a drive system configured to move the shuttle in horizontal and vertical directions along the shuttle frame so that the shuttle is able to service the conveyors in the buffering system. The shuttle includes a conveyance mechanism upon which one or more of the items are transported. The conveyance mechanism is configured to convey the items to and/or from the buffer conveyors of the buffering system.

Abstract: A conveyor sortation system includes a frame and two or more carriages riding along the frame in a travel direction. Each carriage includes a belt and an electric motor. The belt is oriented at a direction that is transverse to the travel direction of the carriage. The electric motor is configured to drive the belt. In one form, the belt has a width that is at most 8 inches (20.32 cm) wide. In another form, the carriages have a vertical recirculation pattern along the frame.

Abstract: An automated flow buffer system includes infeed and discharge shuttle systems. A buffering system is disposed between the infeed shuttle system and the discharge shuttle system. The buffering system includes buffer conveyors arranged in an array to buffer one or more items. The infeed shuttle system and the discharge shuttle system each include a shuttle frame disposed proximal to an end of the buffering system and one or more shuttles independently moveable along the shuttle frame. Each of the shuttles include a drive system configured to move the shuttle in horizontal and vertical directions along the shuttle frame so that the shuttle is able to service the conveyors in the buffering system. The shuttle includes a conveyance mechanism upon which one or more of the items are transported. The conveyance mechanism is configured to convey the items to and/or from the buffer conveyors of the buffering system.

Abstract: A cargo handling system includes a gantry and a robot arm. The gantry is configured to move from a retracted position to an extended position. The robot arm hangs from the gantry. The robot arm is configured to move along the gantry at least when the gantry is in the extended position. The robot arm is configured to handle one or more cargo items. A conveyor is configured to move from a retracted position to an extended position. The conveyor is configured to transport the cargo items to and/or from the robot arm.

Abstract: A conveyor sortation system includes a frame and two or more carriages riding along the frame in a travel direction. Each carriage includes a belt and an electric motor. The belt is oriented at a direction that is transverse to the travel direction of the carriage. The electric motor is configured to drive the belt. In one form, the belt has a width that is at most 8 inches (20.32 cm) wide. In another form, the carriages have a vertical recirculation pattern along the frame.

Abstract: An autonomous robotic transport system has been developed in which the individual robot vehicles are able to move in multiple directions, such as vertically as well as around curves. Through the use of a unique rail system, the vehicle is able to move around corners and turns without the need for expensive modifications. This eliminates the need for various differentials or multiple electric motors to provide the difference between inner and outer wheels in a turn. Moreover, a number of switches have been developed that allow the vehicles to move not only vertically but also horizontally as well as transition between vertical and horizontal movement. A technique for operating the robotic vehicles is also described.

Abstract: A conveyor roller includes a roller body that defines a fill cavity. A concrete material at least partially fills the fill cavity in the roller body. A bearing assembly is coupled to the roller body. The bearing assembly is configured to facilitate rotation of the roller body. The roller body acts as a mold to allow curing of the concrete material to occur even after final assembly of the conveyor roller. In one example of the manufacturing method, the concrete material is poured into one or more fill cavities inside the roller body, and bearing assemblies are attached to the opposite ends of the roller body. The concrete material can continue to cure even after the bearing assemblies are attached. In one example, the bearing assemblies act as plugs, thereby sealing the concrete material within the fill cavities of the roller body.

Abstract: A robotic automated storage and retrieval system (AS/RS) mixed pallet build system includes a rack that includes two or more verticals levels upon which items are stored. The system includes a three-dimensional robotic AS/RS that includes a carriage, robot arm, vertical lift, and horizontal propulsion system. The items from the rack are loaded upon the carriage to create a pallet. The robot arm is configured to stack the items from the racks onto the pallet. The vertical lift is configured to move the carriage vertically between the vertical levels of the racks. The horizontal propulsion system is configured to move the carriage horizontally along the rack so that the carriage is able to service the entire length of the rack. The three-dimensional robotic AS/RS also includes a stretch wrapper that progressively secures the layers of items on the pallet to prevent the items from falling off the pallet.

Abstract: A conveyor roller includes a roller body that defines a fill cavity. A concrete material at least partially fills the fill cavity in the roller body. A bearing assembly is coupled to the roller body. The bearing assembly is configured to facilitate rotation of the roller body. The roller body acts as a mold to allow curing of the concrete material to occur even after final assembly of the conveyor roller. In one example of the manufacturing method, the concrete material is poured into one or more fill cavities inside the roller body, and bearing assemblies are attached to the opposite ends of the roller body. The concrete material can continue to cure even after the bearing assemblies are attached. In one example, the bearing assemblies act as plugs, thereby sealing the concrete material within the fill cavities of the roller body.

Abstract: A robotic automated storage and retrieval system (AS/RS) mixed pallet build system includes a rack that includes two or more verticals levels upon which items are stored. The system includes a three-dimensional robotic AS/RS that includes a carriage, robot arm, vertical lift, and horizontal propulsion system. The items from the rack are loaded upon the carriage to create a pallet. The robot arm is configured to stack the items from the racks onto the pallet. The vertical lift is configured to move the carriage vertically between the vertical levels of the racks. The horizontal propulsion system is configured to move the carriage horizontally along the rack so that the carriage is able to service the entire length of the rack. The three-dimensional robotic AS/RS also includes a stretch wrapper that progressively secures the layers of items on the pallet to prevent the items from falling off the pallet.

Abstract: A robotic automated storage and retrieval system (AS/RS) mixed pallet build system includes a rack that includes two or more verticals levels upon which items are stored. The mixed pallet build system further includes a three-dimensional robotic AS/RS that includes a carriage, robot arm, vertical lift, and horizontal propulsion system. The items from the rack are loaded upon the carriage to create a pallet. The carriage has a length that is shorter than the length of the rack. The robot arm is configured to stack the items from the racks onto the pallet. The vertical lift is configured to move the carriage vertically between the vertical levels of the racks. The horizontal propulsion system is configured to move the carriage horizontally along the rack so that the carriage is able to service the entire length of the rack. The three-dimensional robotic AS/RS also includes a stretch wrapper that progressively secures the layers of items on the pallet to prevent the items from falling off the pallet.

Abstract: A vertical storage rack system includes a vertically moveable transport conveyor and one or more vertical feed conveyors that vertically extend between the various rack levels so that items can be loaded and/or unloaded at any of the levels without the need for the vertically moveable transport to return to a loading/unloading level. This vertical rack system can be used to load and unload items from the racks as well as rearrange items in the racks. This system and technique allows items to be continuously moved in a vertical direction as well as sorts or merges the items at high speeds. In other words, this arrangement minimizes the vertical positioning of the vertically moveable transport conveyor, such as a cross-belt conveyor, before it can discharge (and/or load) items, thereby improving throughput.