Abstract: Robotic carton loader or unloader incorporates three-dimensional (3D) and two-dimensional (2D) sensors to detect respectively a 3D point cloud and a 2D image of a carton pile within transportation carrier such as a truck trailer or shipping container. Edge detection is performed using the 3D point cloud, discarding segments that are two small to be part of a product such as a carton. Segments that are too large to correspond to a carton are 2D image processed to detect additional edges. Results from 3D and 2D edge detection are converted in a calibrated 3D space of the material carton loader or unloader to perform one of loading or unloading of the transportation carrier. Image processing can also detect jamming of products sequence from individually controllable zones of a conveyor of the robotic carton loader or unloader for singulated unloading.

Abstract: The present disclosure relates to a tray locator assembly for aligning one or more trays in a tray-based automated storage and retrieval system. The tray locator assembly may include one or more guide pin assemblies having one or more guide pins engaging with one or more slots formed in a surface of at least one tray of the one or more trays. The tray locator assembly may further include at least one translational actuator to move the one or more guide pins inserted into the one or more slots so as to translate the at least one tray, wherein the translation of the at least one tray separates a second group of trays having a second size from a first group of trays having a first size along the conveyance plane to a second position in order to reduce tolerance stack up associated with the first group of trays.

Abstract: A controller of a material handling system performs a method of creating a multidrop pattern of articles for robotic placement in layers on a pallet. A pattern is presented on a user interface of any currently positioned representations of articles on a pallet. A control affordance for inputting drag'n'drop and numeric inputs is presented on the user interface for robotic control operations to perform a multidrop of the more than one article in an end effector of a robotic arm for placement of the more than one article. User inputs are received that indicate placement position of a first subset of the more than one article. User inputs are received that indicate placement position of a second subset, which is mutually exclusive of the first subset, of the more than one article. The user inputs are converted into a place sequence of robotic control operations to perform a multidrop of the articles by the robotic arm.

Abstract: A vacuum coupling applies vacuum from a vacuum source to a rotating tool attached to a rotating end of a robotic arm. The vacuum coupling includes a rotating portion attaching the rotating tool to the rotating end of the robotic arm. The rotating portion communicates vacuum with the rotating tool. A fixed portion is positioned around the rotating portion such that the rotating portion is rotatable relative to the fixed portion. The fixed portion communicates vacuum to the rotating portion. At least one rotating vacuum seal is positioned between the fixed portion and the rotating portion.

Abstract: Methods, apparatuses, and systems for identifying and tracking products in a material handling system and/or for identifying and handling product defects in a material handling system are provided. An example method may include receiving one or more articles in the material handling system; capturing one or more images of the one or more articles; identifying at least one visual defect indicator on at least one article of the one or more articles; and determining an indication corresponding to at least one of a defect of the at least one article or a portion of the material handling system causing the defect.

Abstract: The present disclosure relates to a tote exchange module for handling totes. The tote exchange module includes a pick-up conveyor and an L-shaped pushing member. The L-shaped pushing member having a forward element and a side element. The forward element may be secured to the side element at the one end. Further, an actuator may move the L-shaped pushing member from a first position proximate a first side of the pick-up conveyor to a second position proximate a second side, opposite to the first side, of the pick-up conveyor. The second position defining a pick-up location.

Abstract: A material handling system has a vertical lift two vertically aligned carriages that are independently positionable on a vertical support structure by respective drive systems. A processor subsystem selects one of the two carriages to move an article from at least one in-feed conveyor to a selected level of an automated storage and retrieval system (AS/RS). The processor subsystem concurrently positions the other carriage to avoid a collision.

Abstract: A controller of a robotic material handling system performs a method that conveys articles from a pile within a confined space. One or more articles per operation are robotically moved onto a vertically-positionable nose conveyor surface conveys toward a narrower rearward conveyor. Controller detects a jammed article that is at least partially supported by the nose conveyor and that has failed to fully convey onto the rearward. The controller attempts to dislodge the jammed article by causing at least one of: (i) vertically repositioning the nose conveyor surface; and (ii) activating at least one of the two or more parallel conveyors of the nose conveyor surface to run in a forward direction. After the attempt to dislodge, the controller activates at least one parallel conveyor that is contact with the jammed article in a rearward direction.

Abstract: Various embodiments described herein generally relate to techniques for conveying articles on a conveyor system of a robotic material handling system in a material handling environment. In accordance with an embodiment, the robotic material handling system includes a front portion and a rearward conveyor. The front portion may be expandable to a first configuration and retractable to a second configuration. On detecting a jam on the front portion, the robotic material handling system may actuate expansion of the front portion to the first configuration, and attempt to dislodge the jammed articles by causing one or more of (i) separating the jammed articles by activating one or more of a plurality of zones of the front portion under the jammed articles, and/or (ii) activating one or more of the plurality of zones under the jammed articles in a reverse direction.

Abstract: The present disclosure relates to a method for replenishing containers with goods from stock keeping units (SKUs) arriving at a replenishment area in a distribution center. A central controller receives a first set of data comprising a plurality of first predefined threshold values, each indicative of a maximum capacity of goods in a corresponding SKU. The central controller associates the first set of data to a second set of data comprising one or more container identifiers having a second predefined threshold value indicative of a capacity of a corresponding container. Further, the central controller generates an ordered sequence of container identifiers indicative of the containers to be retrieved to the replenishment area for receiving goods from the plurality of SKUs based on the association of the first set of data with the second set of data.

Abstract: Various embodiments described herein relate to a method of predicting article dimensions and controlling release timing of upcoming articles from upstream conveyors and dynamically computing release times for the upstream conveyors. The method includes predicting a dimension of an upcoming article and creating empty spaces on an upstream conveyor between one or more upstream articles from among a set of upstream articles by controlling an operating speed of a set of drive motors of the upstream conveyor based on the predicted dimension for the upcoming article. Further, the release times of the set of upstream articles is dynamically computed based on a cumulative length of the set of upstream articles and an operating speed of the upstream conveyor.

Abstract: Various example embodiments described herein relates to a gripping device that includes a top plate, first side plate, a second side plate, a first arm, a second arm, and a driving pin. The first side plate and the second side plate are engaged to the top plate. The first arm is engaged to the first side plate and the second arm is engaged to the second side plate. The first arm defines a first cam slot, and the second arm defines a second cam slot and are constrained together, by the driving pin engaged to an actuation assembly. The driving pin is configured to move between a first position and a second position within the first cam slot and the second cam slot so as to drive movement of the first side plate and the second side plate between an open position and a closed position to grip a container.

Abstract: The present disclosure relates to a roller belt conveyor having an array of pivot rollers defining a conveyance surface that supports an article being conveyed in a first conveying direction, at least one drive plate pivotally coupled to at least a subset of the array of pivot rollers, and an actuator coupled to the at least one drive plate, such that, the actuator may manipulate the at least one drive plate to adjust an angular orientation of the at least one subset of the array of pivot rollers from the first conveying direction to a second conveying direction.

Abstract: Various embodiments described herein relate to a sortation conveyer system including a cart coupling assembly for coupling two adjacent carts. The cart coupling assembly includes a coupling disc having a control slot, a bearing slot, and one or more arcuately shaped mounting slots. The coupling disc is mounted on a cart such that, upon rotation of the coupling disc, a control slot cavity defined by the control slot slidably moves about a position register screw along the control slot cavity, and a cavity defined by a respective mounting slot slidably moves relative to a respective mounting pin received in the mounting slot. Cavities defined by the control slot facilitate a continual translation of a center of rotation of the coupling disc linearly, to adjust a gap between the two carts. The control slot includes position registers that restrict a sliding movement of the control slot cavity.

Abstract: Various embodiments described herein relate to a material handling system including a first conveyor and a second conveyor positioned such that a curved section of the second conveyor is substantially concentric with a curved section of the first conveyor. The speed of the first conveyor and the second conveyor are matched such that a loaded cross belt carriage may transfer an article on to an empty cross belt carriage at the curved sections of the first conveyor and the second conveyor. The speed of the first conveyor and the second conveyor are matched using a speed matching routine executed by a central controller such that the transfer of the article is facilitated at the curved sections of the first conveyor and the second conveyor.

Abstract: A material handling system comprising one or more sub-systems and one or more sensing panels is provided. Each sensing panel may determine whether a mode control token is within a vicinity of the respective sensing panel. When the mode control token is within the vicinity of the respective sensing panel, the sensing panel may generate a signal, and when the mode is outside of the vicinity of the respective sensing panel, the generation of the signal is halted. The material handling system may further include a processor that enables at least one of the one or more sub-systems of the material handling system in response to the generated signal and disables each of the one or more sub-systems of the material handling system in response to a halting of the generation of the signal.

Abstract: A material handling system includes a very high speed linear sortation conveyor that receives articles at an operating speed of 650 to 700 feet per second (fps) and up to 100 fps with gapping as small as one inch. In one or more embodiments, a recirculation sortation conveyor receives articles that are not diverted by the linear sortation conveyor with dynamic capacity sufficient to handle a high speed shutdown of the linear sortation conveyor. The recirculation sortation conveyor is itself a very high speed linear sortation conveyor having a pusher pre-sort feature that can distribute received articles at different lateral positions on an endless conveyor to align with more than one recirculation sortation conveyors that may be operating at a slower operating speed. In an exemplary embodiment, the recirculation sortation conveyor has a divert section for diverting articles to a divert target on a lateral side.

Abstract: A robotic carton unloader is configured for automatic unloading of cartons from a carton pile. In various embodiments, the robotic carton unloader may include a mobile body, a movable robotic arm attached to the mobile body and comprising an end effector, a conveyor system having a front portion, and a lift attached to the mobile body and the front portion of the conveyor system to move the front portion. In some embodiments, the conveyor system may comprise a front-end shelf conveyor configured to be moved (e.g., raised, lowered, laterally moved, tilted, etc.) relative to the body of the unloader. The front-end shelf conveyor may be moved separately for positioning below the robotic arm in order to receive cartons from a small distance. The front-end shelf conveyor may be moved via various mechanisms (e.g., scissor lifts, pedestal lifts, etc.).

Abstract: A material handling system automatically each picking orders using a put wall. A controller determines whether any of more than one removable intermediate holders in a put wall that are within the reach of a first robotic arm contain one or more articles that are ready for transporting away from the put wall. The controller directs the first robotic arm to: (i) engage the selected removable intermediate holder, (ii) move the selected removable intermediate holder to an empty order container, and (iii) reorient the selected removable intermediate holder to transfer the one or more articles from the selected removable intermediate holder to the empty order container. In one or more embodiments, the articles can be placed in the put wall by conveying donor totes to an each picking robotic arm that places picked articles into an end effector of a second robotic arm.

Abstract: The present disclosure relates to a conveyor carrier cart. The conveyor carrier cart includes a main body, a pair of pivoting arms, and a folding mechanism. The main body defines a load carrying surface to support one or more objects disposed thereon. The pair of pivoting arms include a proximal end and a distal end. The proximal end pivotally connects each pivoting arm with the main body through the folding mechanism and the distal end connects with a guide member of a conveyor assembly. Each pivoting arm is configured to pivot between a deployed position and a retracted position. In the deployed position, the distal end of each pivoting arm engages the guide member of the conveyor assembly. In the retracted position, the distal end of each pivoting arm pivots about the folding mechanism to disengage from the guide member of the conveyor assembly.