Abstract: Systems and methods are disclosed for induction of items directly onto shuttles. An example system for item induction onto a shuttle may include a track, a shuttle having a conveyor and a permanent magnet, the shuttle configured to move along the track, where the conveyor is configured to support an item thereon, and an electromagnet disposed along the track, where the shuttle is propelled via interaction between the electromagnet and the permanent magnet. The system may include an induction station disposed adjacent to the track, the induction station having a first sensor configured to detect a machine-readable code on the item, a second sensor configured to determine that the item is present on the conveyor of the shuttle, and a display configured to present a user interface, where the item can be manually placed onto the conveyor of the shuttle by an operator at the induction station.

Abstract: Systems and methods are disclosed for contactless direction of sortation shuttles along a track. An example system for contactless direction of sortation shuttles may include a track having a linear path, and a curved path that intersects the linear path. The system may include a shuttle with a first ferrous block and a second ferrous block, the shuttle configured to move along the track, and a first set of electromagnets disposed along a side of the curved path. Electromagnets of the first set of electromagnets may be configured to be individually energized. Energizing the first set of electromagnets may cause the shuttle to merge onto the curved path via interaction with at least one of the first ferrous block or the second ferrous block.

Abstract: Systems and methods are disclosed for a shuttle sortation system having a calibration shuttle for determining and adjusting shuttle coordinates for depositing items and/or loading totes at various tote receiving areas. The shuttle sortation system may include item tracks and tote tracks for sorting and/or distributing items, packages, and/or totes, and may move the shuttles about the shuttle sortation system via linear synchronous motors (LSMs). The calibration shuttle may include a base portion designed to interface with the track (e.g., with the LSMs). The base may support imaging systems having cameras and processors for capturing images of the tote receiving areas and processing the images to determine a centerline of such tote receiving areas and adjusting coordinates used to navigate the shuttle to the tote receiving areas. The calibration shuttle may be navigated to each tote receiving area to adjust coordinates where an offset from the centerline is detected.

Abstract: Systems and methods are disclosed for a shuttle track system for efficiently sorting items and packages by increasing a throughput of shuttles loaded with items. To increase item shuttle throughput, a shuttle track designated for shuttles that transport items (e.g., item track) may be positioned between on either side of a tote track designed for shuttles that transport totes (e.g., tote tracks). Tote receiving areas which may support totes for receiving the items may be positioned between each item track and the tote track. Shuttles designed to transport items (e.g., item shuttles) may deliver items to the totes in the tote receiving areas via the item tracks and shuttles designed to retrieve and/or receive totes (e.g., tote shuttles) may retrieve and/or receive totes via the tote track. Multiple sortation levels may be stacked and interconnected via ramps and/or shuttle lift systems to maximize and/or optimize item shuttle throughput.

Abstract: Systems and methods are disclosed for dynamic wheel assemblies for shuttles powered by linear synchronous motors. An example shuttle may include a frame having a front lateral portion, a rear lateral portion, and a central member. The shuttle may include a first wheel assembly coupled to a first end of the front lateral portion, the first wheel assembly having a first wheel configured to engage a first sidewall of the track, where the first wheel assembly is configured to rotate in a forward and rearward direction with respect to the front lateral portion. The shuttle may include a second wheel assembly coupled to a second end of the rear lateral portion, the second wheel assembly having a second wheel configured to engage a second sidewall of the track, where the second wheel assembly is configured to rotate in a forward and rearward direction with respect to the rear lateral portion.

Abstract: Systems and methods are disclosed for automated reorientation of sortation shuttles. An example system for automated shuttle reorientation may include a track having a first portion, a second portion, and a rotatable portion that a first end and a second end, where the rotatable portion is configured to rotate from a first position to a second position, and where the first end is adjacent to the first portion of the track in the first position, and the first end is adjacent to the second portion of the track in the second position. The system may include a shuttle configured to move along the track, where the rotatable portion of the track is configured to rotate the shuttle from a first orientation to a second orientation.

Abstract: Systems and methods are disclosed for systems and methods for container shuttle calibration. An example method for calibration of a shuttle coupled to a permanent magnet may include positioning the shuttle on a calibration table, energizing an electromagnet coupled to the calibration table, and determining a detected edge of the permanent magnet. Some methods may include determining a first location to position a connector of the shuttle along an X-axis based at least in part on the detected edge and a mechanical template coupled to the calibration table, and securing the connector in the first location.

Abstract: Systems and methods are disclosed for wireless powering and control of conveyors on shuttles. An example system may include a track, and a shuttle configured to move along the track, the shuttle having a conveyor, and a first induction coil. The system may include a second induction coil disposed at a first location along the track, where the second induction coil is configured to interact with the first induction coil to power the conveyor. The shuttle may not have an onboard power source coupled to the conveyor.

Abstract: Systems and methods are disclosed for structural rib assemblies for container shuttle rails. In one embodiment, an example system for a shuttle may include a rib assembly. The rib assembly may include a first plate with a first tab on a first lateral side, a second tab on a second lateral side, a first cutout disposed adjacent to the first tab, a second cutout disposed adjacent to the second tab, and a third cutout disposed along an upper portion of the first plate. The rib assembly may include a second plate coupled to the first plate, the second plate having a third tab on a first lateral side, a fourth tab on a second lateral side, a fourth cutout disposed adjacent to the third tab, a fifth cutout disposed adjacent to the fourth tab, and a sixth cutout disposed along an upper portion of the second plate.

Abstract: Systems and methods are disclosed for automated self-calibration and maintenance for container shuttles. An example system for automated repairs may include a track, a shuttle coupled to a permanent magnet, the shuttle configured to move along the track, and an electromagnet disposed along the track, where the shuttle is propelled via interaction between the electromagnet and the permanent magnet. The system may include a maintenance area accessible via the track, and a set of robotic manipulators disposed about the maintenance area, the set of robotic manipulators configured to perform automated maintenance actions on the shuttle. The system may include a first controller configured to determine that the shuttle is in need of maintenance, and automatically direct the shuttle to the maintenance area.

Abstract: Systems and methods are disclosed for wheel wear monitoring systems for shuttles powered by linear synchronous motors. An example system may include a first rail segment that forms a first side of the track, the first rail segment having a first aperture, a second rail segment that forms a second side of the track, the second rail segment having a second aperture, and a first camera disposed adjacent to the first aperture. The system may include a second camera disposed adjacent to the second aperture, and a controller configured to determine a first set of images of a first wheel of the shuttle using the first camera, determine a second set of images of a second wheel of the shuttle using the second camera, and determine a wear status of the first wheel based at least in part on the first set of images.

Abstract: Systems and methods are disclosed for a shuttle track system having a calibration shuttle for determining portions of the track having non-conforming geometry for optimum use of the shuttle track system. For example, the shuttle track system may include a track having an electromagnetic propulsion system (e.g., linear synchronous motor) embedded between two sides of the track. The calibration shuttle may move to various locations on the track and may use imaging systems for generating image data of a portion of the track. A trained model may process the image data to determine edges and surfaces of the components of the track and may determine distances between reference points on the track. The distances may be compared to threshold values to determine if they are in conformity with desired track geometry.

Abstract: Systems and methods are disclosed for elevators for material handling shuttles. In one embodiment, an example system configured to change elevation of a shuttle may include an elevator track disposed between a loading zone and an unloading zone, and a platform coupled to the elevator track and configured to move between the loading zone and the unloading zone. The platform may be configured to engage with a lower surface of the shuttle at the loading zone. The platform may be configured to lift the shuttle off a first set of rails at the loading zone, and to position the shuttle onto a second set of rails at the unloading zone.

Abstract: Systems and methods are disclosed for automated lateral transfer and elevation of sortation shuttles. An example system may include a track having a first portion arranged in a first direction, a shuttle configured to move along the track, and a shuttle carriage system configured to move in a second direction transverse to the first direction, where the shuttle is configured to move from the track to the shuttle carriage system. The shuttle carriage system may include a first frame configured to support the shuttle, a first electromagnet configured to propel the first frame, and a second electromagnet coupled to the first frame, the second electromagnet configured to propel the shuttle off the first frame.

Abstract: Systems, methods, and computer-readable media are disclosed for flexible rail switching components for container shuttles. In one embodiment, an example system for a shuttle may include an elongated spring steel plate, a first rail track component coupled to the elongated spring steel plate, a second rail track component coupled to the elongated spring steel plate and disposed adjacent to the first rail track component, and a third rail track component coupled to the elongated spring steel plate and disposed adjacent to the second rail track component. The elongated spring steel plate may be configured to be actuated from a first position to a second position. A distance between the first rail track component and the second rail track component when the elongated spring steel plate is in the second position may be less than when the elongated spring steel plate is in the first position.

Abstract: Systems and methods are disclosed for passive braking systems for container shuttles. An example system may include a track having a first portion and a ramp portion disposed at an angle, a first electromagnet disposed along the first portion, a shuttle with a permanent magnet that is configured to interact with the first electromagnet to propel the shuttle along the track, and a first metal block disposed along the ramp portion. The shuttle may enter the ramp portion at a first speed and exit the ramp portion at a second speed due to an eddy current induced in the first metal block by the permanent magnet.

Abstract: Systems and methods are disclosed for container shuttles having omnidirectional wheels. In one embodiment, an example system for shuttle transportation may include a first linear synchronous motor arranged in a first orientation, a second linear synchronous motor arranged in a second orientation that is offset with respect to the first linear synchronous motor, and a shuttle having a permanent magnet and a plurality of omnidirectional wheels. The shuttle may be configured to be propelled in a first direction via the first linear synchronous motor and the permanent magnet, and to be propelled in a second direction via the second linear synchronous motor and the permanent magnet.

Abstract: Systems, methods, and apparatuses are disclosed for automated securing and releasing of items on shuttles. In one embodiment, an example item sortation system may include a shuttle having a conveyor, a first gate portion having a second width that is about half a first width of the conveyor, a second gate portion having the second width, an optional third gate portion having the second width, and an optional fourth gate portion having the second width, wherein the third gate portion and the fourth gate portion are disposed at a second side of the conveyor. The first gate portion, the second gate portion, the third gate portion, and the fourth gate portion may be configured to: (i) secure the at least one item on the conveyor during transport, and (ii) guide the at least one item along the conveyor when the item is unloaded.

Abstract: Systems and methods are disclosed for contactless powering and control of conveyors on shuttles. An example system may include a track, a first transmitter disposed at a first location along the track, the first transmitter configured to transmit power and data wirelessly, and a shuttle configured to move along the track. The shuttle may include a conveyor, and a first receiver configured to wirelessly receive the power and the data from the first transmitter, where the power is used to power the conveyor. The shuttle may not have an onboard power source coupled to the conveyor.

Abstract: Systems and methods are disclosed for transition components for gaps in shuttle rails. An example system configured to transport items may include a shuttle configured to support an item, where the shuttle includes a first wheel. The first wheel may have a first side surface, a second side surface, and a middle portion that together form a v-groove. The system may include a first rail configured to engage the first side surface and the second side surface, a second rail configured to engage the first side surface and the second side surface, where the second rail is separated from the first rail, and a first transition block coupled to the first rail. The first transition block may be configured to transfer a load of the shuttle from the first side surface and the second side surface to the middle portion of the wheel.