Abstract: A parcel cart loading system includes: a conveyor; parcel carts for receiving parcels offloaded from the conveyor; a loading station where parcels are offloaded to the parcel carts; and a vision and control subsystem that is operably connected to a plurality of mobile robots. The vision and control subsystem acquires one or more images of parcel carts within a loading area of the loading station and determines if any of the parcel carts are fully loaded based on the image data. Each parcel cart determined to be fully loaded is autonomously transported out of the loading area and to its intended destination by one of the mobile robots within the system. Each parcel cart transported out of the loading area is replaced by another parcel cart from a queue area of the loading station by another mobile robot of the system.

Abstract: A parcel transfer system transfers a parcel or a similar article directly between a conveyor and a self-driving vehicle (“SDV”) while the conveyor and SDV are moving. The conveyor, SDV, or both may be configured to initially transport a parcel in a first direction of travel and then subsequently offload the parcel in a second direction of travel. The SDV is configured to travel alongside of the conveyor in the first direction of travel and either receive the parcel as it is offloaded from the conveyor or offload the parcel onto the conveyor in the second direction of travel. The parcel transfer system further includes a vision and control subsystem, which regulates movement of the SDV and offloading of the parcel from the conveyor or SDV.

Abstract: A trapdoor rejection subsystem includes one or more trapdoor rejection mechanisms. Each trapdoor rejection mechanism is configured to be selectively transitioned between a closed position to support parcels and an open position to allow parcels identified as unconveyable to pass through the trapdoor rejection mechanism. Each trapdoor rejection mechanism includes a first door, a second door, and one or more actuators which can be selectively actuated to rotate the first door and the second door and transition the trapdoor rejection mechanism between the closed position and the open position. The trapdoor rejection subsystem can be utilized in a conveyor system in combination with one or more robot singulators, an upstream conveyor, a place conveyor, and a vision and control subsystem. Detection of unconveyable parcels and the transition of each trapdoor rejection mechanism of the trapdoor rejection subsystem is controlled by the vision and control subsystem.

Abstract: A vacuum-based end effector for selectively engaging parcels includes a base plate to which a plurality of vacuum cups are mounted and configured to be placed in fluid communication with a vacuum source. Each vacuum cup includes a bellows having a distal end connected to a lip. The vacuum-based end effector further includes a linear actuator that is mounted to the base plate and includes an extendible arm to which at least one vacuum cup is operably connected. The linear actuator can be selectively actuated to extend the extendible arm and move the lip of the vacuum cup operably connected to the extendible arm below a common plane defined by the lips of vacuum cups which maintain a fixed position relative to the base plate to individually address a target parcel. The vacuum-based end effector can be combined with a robot to provide an improved system for selectively engaging parcels.

Abstract: A system for preventing debris buildup in vacuum sensor lines includes: a manifold, including a positive air pressure source and a controller; and one or more positive air pressure lines. Each positive air pressure line is in fluid communication with the manifold and can be placed in fluid communication with a vacuum sensor line. The controller is operably connected to and selectively activates the positive air pressure source to emit a positive flow of air, which can be directed into the one or more positive air pressure lines, and then into and through the associated vacuum sensor lines to evacuate debris. In some embodiments, a positive flow of air can also be directed through one or more vacuum lines of the end effector to promote the release of a parcel engaged with the end effector and/or clear the vacuum lines of debris.

Abstract: A conveyor system includes multiple carts that move along a rail. The rail includes a top panel upon which a vertical wheel of the cart is supported, along with a first side panel defining a channel within which a horizontal wheel of the cart is retained. One or more connector rails extend along the rail, and the cart is electrically connected to the one or more connector rails.

Abstract: A conveyor system includes: a pick conveyor defining a picking area for a bulk flow of parcels; a place conveyor positioned downstream of the picking area; a first robot singulator and a second robot singulator, which work in parallel to transfer parcels within a picking area of the pick conveyor to the place conveyor; and a vision and control subsystem that communicates instructions to control operation of some or all of the foregoing components. The vision and control subsystem includes a target camera for acquiring one or more images of the picking area, which are processed within the system to determine the location of parcels positioned within the picking area. The vision and control subsystem can execute one or more routines or subroutines to reduce system downtime associated with image acquisition and processing, parcel transfer to the place conveyor, and/or parcel delivery to the picking area.

Abstract: A cable management system for managing one or more cables extending from a robot singulator includes: an upper bracket assembly for mounting the cable management system to a robotic framework of the robot singulator; a cable carrier that is configured to receive and hold the one or more cables in a grouped configuration; and one or more leashes. Each leash of the cable management system is of a predetermined length and includes a distal end that is mounted to the cable carrier and a proximal end that is configured to be mounted to the robotic framework. When mounted to the robotic framework, each leash restricts the lateral movement of the cable carrier and the one or more cables received therein, thus reducing the extent to which the one or more cables can whip about the robotic framework while the robot singulator is in use.

Abstract: A sorting device for packages includes a fifth wheel mounted on a support structure and rotatable around a vertical axis; a conveyor belt mounted on the fifth wheel and able to rotate therewith about the vertical axis; and at least one sliding surface placed below the plane of the conveyor belt, to close the openings which, during the rotation of the fifth wheel and of the conveyor belt around the vertical axis, are created between the sorting device and the conveyor belts adjacent to it.

Abstract: A vacuum-based end effector for engaging parcels includes a base plate, one or more vacuum cups of a first type, and one or more vacuum cups of a second type. Each vacuum cup of the vacuum-based end effector is configured to be placed in fluid communication with a vacuum source to provide the vacuum cup with a suction force which can be used to engage and grasp parcels. Each vacuum cup includes a bellows defining a pathway for a flow of air and a lip connected to the bellows. Each lip of the one or more vacuum cups of the first type comprises a foam lip, and each lip of the one or more vacuum cups of the second type comprises an elastomeric lip. The vacuum-based end effector can be combined with a robot to provide an improved system for engaging parcels.

Abstract: A parcel cart for transporting parcels comprises a substructure, with a frame mounted to and supported by the substructure. The frame defines an internal volume in which parcels are received and stored for transport. The frame also includes: a base; a first end wall; a second end wall; a first side wall; and a second side wall. To facilitate loading or unloading of the parcel cart, the frame can include at least one end wall configured to transition between an upright position and a lowered position. To facilitate autonomous transport of the parcel cart, the substructure and the frame can define a cavity for receiving a mobile robot. To avoid occlusion of the field of view of one or more cameras associated with the mobile robot, the frame can include at least one end wall that is in a non-perpendicular orientation relative to the base.

Abstract: An end effector for engaging flexible packaging materials includes a frame, along with a first and second wheel mounted for rotation with respect to the frame. The first wheel and the second wheel are mounted to the frame relative to each other so that the outer surfaces of the two wheels are positioned opposite of each other. The first wheel and the second wheel can be driven in opposing directions to effectively define a roller intake which can be used to draw the flexible packaging materials of a target parcel between the first wheel and the second wheel. The end effector of the present invention can be combined with a robot to provide an improved system for engaging the flexible packaging materials of a parcel.

Abstract: A dual-material vacuum cup for a vacuum-based end effector includes a bellows having a proximal end configured for connection to the end effector and a distal end. The bellows also defines a pathway for a flow of air. A lip is connected to the distal end of the bellows, the lip defining an opening in fluid communication with the pathway for the flow of air. An insert is then connected to a distal end of the lip, and the insert is in fluid communication with the opening defined by the lip. To engage parcels of various dimension and construction, the lip is composed of a first material (such as silicone rubber or another elastomeric material), while the insert is comprised of a second material (such as a foam material).

Abstract: A system for managing parcel flow includes: an upstream conveyor for receiving and conveying a bulk flow of parcels; and a damming conveyor positioned to receive parcels offloaded from the upstream conveyor. The system may also include: a destacking conveyor positioned to receive parcels offloaded from the damming conveyor and configured to separate vertically stacked parcels; and a downstream conveyor positioned to receive parcels offloaded from the destacking conveyor. The damming conveyor can be selectively activated and deactivated to offload parcels in discrete batches, instead of a continuous flow. Selective activation and deactivation of the damming conveyor and/or destacking conveyor can be based on instructions communicated from a control subsystem in accordance in a prearranged sequence or based on data from one or more sensors configured to acquire data corresponding to the positioning of parcels within the system.

Abstract: A singulating system for parcels comprises: an inner wall; a first section comprised of a series of driven rollers, which are skewed relative to a longitudinal direction of travel, so that the parcels are conveyed not only in the longitudinal direction of travel, but also toward the inner wall; a second section for receiving the parcels from the first section, and then identifying and moving parcels in a side-by-side arrangement and/or parcels with an irregular shape; and a third section for receiving the parcels from the second section. In some embodiments, the singulating system also includes a visioning subsystem, including a camera for acquiring image data of the parcels as the parcels move toward or into the second section, and a computer to receive and analyze the image data from the camera to identify parcels in a side-by-side arrangement and/or parcels with an irregular shape.

Abstract: A rejection chute for a conveyor system, which receives and redirects rejected parcels, includes: a conduit defined by a plurality of side walls; a door; and an actuator operably connected to the door. The conduit includes an enclosed upper portion defining a first opening for receiving parcels into the rejection chute and a lower portion defining a second opening for discharging parcels from the rejection chute. The door is mounted proximate to the first opening and is configured to transition between a first position to cover the first opening and a second position to uncover the first opening. The rejection chute can be integrated into a walking surface alongside of a conveyor to receive and redirect parcels transferred off of the conveyor to a location below the walking surface. An enclosure can be combined with the rejection chute to regulate access and guide parcels into the rejection chute.

Abstract: A rejection mechanism for a conveyor system, which pushes parcels across a surface, includes a linear actuator and a paddle mounted to the linear actuator for movement between a first position and a second position. The paddle includes a bracket portion, an upright portion, and a lateral wall portion. The lateral wall portion is configured to push parcels across a surface positioned below the lateral wall portion as the paddle is moved from the first position to the second position. In some embodiments, the rejection mechanism can further include a way cover which expands and contracts with movement of the paddle. In some embodiments, the lateral wall portion can be configured to rotate about an axis of rotation defined by a hinge to transition between an engaged and a disengaged position.

Abstract: A system for identifying and transferring parcels includes a robot singulator configured to engage and transfer individual parcels in a bulk flow of multiple parcels on a first conveyor to a singulated stream of parcels on a second conveyor. The system further includes a vision and control subsystem, with a first camera for acquiring image data of the bulk flow of multiple parcels, and a computer that receives and processes the image data to identify and segment individual parcels, and then communicates instructions to the robot singulator to engage and transfer each of the individual parcels to the second conveyor. The system may further include a second camera for acquiring image data of the individual parcels to confirm placement on the second conveyor. The system may further include first and second indexing conveyors controlled by the vision and control subsystem for delivering parcels to the robot singulator.

Abstract: A system for identifying and transferring parcels includes a robot singulator configured to engage and transfer individual parcels in a bulk flow of multiple parcels on a first conveyor to a singulated stream of parcels on a second conveyor. The system further includes a vision and control subsystem, with a first camera for acquiring image data of the bulk flow of multiple parcels, and a computer that receives and processes the image data to identify and segment individual parcels, and then communicates instructions to the robot singulator to engage and transfer each of the individual parcels to the second conveyor. The system may further include a second camera for acquiring image data of the individual parcels to confirm placement on the second conveyor. The system may further include first and second indexing conveyors controlled by the vision and control subsystem for delivering parcels to the robot singulator.

Abstract: A battery movement, storage, and charging system for large size batteries used in lift trucks includes spaced, parallel storage racks, each of which have multiple storage and charging bays. A battery transport tower is positioned in an aisle between the storage racks and is moveable horizontally between the two rows of racks. The tower includes an extendable fork lift mounted which may rotate around the axis of the tower as well as move vertically upwardly or downwardly on the tower. A battery exchanger loads a discharged battery from a lift truck, places it on a pallet and then transfers the pallet and battery to a transfer bay in a storage rack where the tower forklift moves a pallet and battery to a selected charging bay.