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 system for transferring parcels made in accordance with the present invention includes: a first conveyor for conveying a bulk flow of parcels; a second conveyor positioned adjacent to the first conveyor; a robot positioned adjacent to the first conveyor and the second conveyor; and a rejection member. The robot engages and transfers select parcels in the bulk flow of parcels on the first conveyor to the second conveyor. The rejection member is positioned as to receive parcels offloaded from the first conveyor and/or the second conveyor and directs such parcels out of the system. Parcels within the bulk flow of parcels with characteristics which make it difficult for one or more of the components of the system or downstream systems to handle or process can be directed to the rejection member by operation of the first conveyor and/or the second conveyor to reduce system processing delays and stoppages.

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 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 system for unloading parcels from a cargo area includes: an extendible conveyor; a transfer conveyor for conveying parcels to the extendible conveyor; and a mobile robot assembly configured to engage and transfer parcels in the cargo area onto the transfer conveyor. The mobile robot assembly repeatedly advances and transfers parcels in the cargo area to the transfer conveyor. As the mobile robot assembly advances within the cargo area, the transfer conveyor and the extendible conveyor follow to provide a pathway along which parcels transferred by the mobile robot assembly can be transferred out of the cargo area. The mobile robot assembly includes: a mobile base for repositioning the mobile robot assembly; a framework mounted to the mobile base; a first robot and a second robot, each mounted for vertical movement with respect to the framework and configured to engage and transfer parcels; and a vision and control subsystem.

Abstract: A vacuum cup damage detection system detects vacuum cup damage or absence in a robot singulator including a vacuum-based end effector with one or more vacuum cups. The system generally comprises a plate and a control subsystem. The plate provides a potential point of engagement for the one or more vacuum cups of the vacuum-based end effector when the robot singulator is moved to a predetermined position in which, if present, at least one of the one or more vacuum cups of the vacuum-based end effector is in contact with the plate. The control subsystem includes: one or more sensors configured to obtain readings indicative of the engagement of the one or more vacuum cups with the plate or lack thereof; and a controller configured to determine whether any one of the vacuum cups is damaged or missing based on the readings obtained by the one or more sensors.

Abstract: A conveyor system includes a first robot singulator, a second robot singulator, and a picking area from which parcels of a bulk flow of parcels can be engaged and transferred by the first robot singulator or the second robot singulator. The conveyor system further includes a first place conveyor positioned downstream of the picking area and configured to receive parcels transferred by the first robot singulator. The conveyor system further includes a second place conveyor positioned downstream of the picking area and the first place conveyor, the second place conveyor configured to receive parcels transferred by the second robot singulator and to receive parcels from the first place conveyor. A buffering conveyor is positioned between the first place conveyor and the second place conveyor for regulating a rate at which parcels offloaded by the first place conveyor are transferred to the second place conveyor.

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 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 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 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 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 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: In an extendible belt conveyor with a boom mounted for movement with respect to a penultimate section and a cable extending from user controls on the boom to the penultimate section, a cable management system may include a first pulley mounted to an underside of the penultimate section and a second pulley mounted to the underside of the penultimate section, with a distance between the first pulley and the second pulley adjusted to maintain tension in the cable. The cable management system may also include a first shoe mounted to an underside of the boom near the penultimate section and a second shoe mounted to the underside of the penultimate section near the boom. The first shoe defines a channel for receiving the cable and the second shoe defines a channel for receiving the cable, with the cable passing around the first shoe and then around the second shoe.

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 pivoting load chute includes one or more sections that define a conveying surface that is configured for rotation relative to a support stand about a substantially horizontal axis between a lowered position and a raised position. The pivoting load chute further includes at least one linkage assembly having (i) a first linkage arm, with a first end of the first linkage arm operably connected to the support stand, (ii) an actuator that is operably connected to and extends between the support stand and the first linkage arm, and (iii) a second linkage arm, with a first end of the second linkage arm operably connected to the one or more sections that define the conveying surface, and with a second end of the second linkage arm operably connected to a second end of the first linkage arm.

Abstract: An extendible belt conveyor includes a penultimate section, a boom mounted for pivotal movement with respect to the penultimate section, and a transfer plate spanning between the belt of the boom and the belt of the penultimate section. The transfer plate includes a plurality of first components and a plurality of second components that each include a base member mounted on and rotatable with respect to a rod, and a flange member extending from the base member and positioned adjacent to one of the belts of the boom or penultimate section, with a distal edge of the flange member extending over the belt. As the boom pivots, an upper surface of the plurality of first components remains substantially parallel to the belt of the boom, and an upper surface of the plurality of second components remains substantially parallel to the belt of the penultimate section.

Abstract: A pivoting load chute includes one or more sections that define a conveying surface that is configured for rotation relative to a support stand about a substantially horizontal axis between a lowered position and a raised position. The pivoting load chute further includes at least one linkage assembly having (i) a first linkage arm, with a first end of the first linkage arm operably connected to the support stand, (ii) an actuator that is operably connected to and extends between the support stand and the first linkage arm, and (iii) a second linkage arm, with a first end of the second linkage arm operably connected to the one or more sections that define the conveying surface, and with a second end of the second linkage arm operably connected to a second end of the first linkage arm.