Abstract: Described are automated systems and methods for the handling and processing of items at material handling facility. The exemplary systems and methods can receive the items from various upstream processes and systems and can process and handle the items so that they can be provided to various downstream processes and systems. The exemplary systems and methods can provide modular systems and methods that can perform automated singulation, sortation, retrieval, and packing of items without any manual handling.

Abstract: A device for manipulating items for facility operations is described. The device includes a first arm assembly that includes a first arm, a second arm parallel to the first arm, a first shaft disposed between the first arm and the second arm at a first location along the first arm and the second arm, and a first head attachment disposed between the first arm and the second arm at a second location along the first arm and the second arm. The device also includes a first driver coupled to the first shaft and configured to control movement of the first arm assembly about a first axis extending along a length of the first shaft. The device further includes a second driver coupled to first head attachment and configured to control movement of the first head attachment about a second axis extending along a length of the first head attachment.

Abstract: Systems and methods are disclosed for automatic item picking stations. In one embodiment, an example automated item picking station may include a first set of container slots configured to support a first set of containers, and a second set of container slots configured to support a second set of containers. The item picking station may include a first item handling device configured to transport a first item to a container in the first set of containers or the second set of containers, a first empty container shuttle disposed adjacent to the first set of container slots, and an optional second empty container shuttle disposed adjacent to the second set of container slots. The item picking station may include a takeaway conveyor disposed between the first set of container slots and the second set of container slots, the takeaway conveyor configured to transport full containers to a downstream processing station.

Abstract: Systems, methods, and computer-readable media are disclosed for detection of overfilled containers in sortation systems. In one embodiment, an example container capacity detection system for use with an item sortation machine may include a first sensor positioned to detect a remaining capacity of a first container in the item sortation system, and a controller. The controller may be configured to determine, using the first sensor, that the remaining capacity of the first container is less than or equal to a first threshold, and to send a signal.

Abstract: A robotic arm can clean an end-of-arm tool using a cleaning station. The end-of-arm tool can be positioned at an introduction position with a portion of the end-of-arm tool in contact with a cleaning agent contained within the cleaning station. The end-of-arm tool can be positioned at a scrubbing position with the end-of-arm tool in contact with a cleaning surface. And the end-of-arm tool can be positioned at a drying position for drying of the end-of-arm tool.

Abstract: A level compensator system may be configured to receive containers of different heights and position them at the same level. The level compensator system can include engagement platforms for engaging with the containers. The engagement platforms can move between an engagement configuration for engaging with the containers and a conveyance configuration for conveying of the containers relative to the level compensator.

Abstract: Systems, methods, and computer-readable media are disclosed for mesh flaps for container capacity detection in sortation systems. In one embodiment, an example system for use with an item sortation machine may include a rotatable flap comprising a mesh grid coupled to a frame, where the rotatable flap is disposed adjacent to a container of items in the item sortation machine, and a sensor disposed adjacent to the rotatable flap, where the sensor is configured to sense an item protruding out of the container. The mesh grid may have a set of metallic wires that intersect to form the mesh grid, where the set of metallic wires form a geometric pattern.

Abstract: Automated tray handling systems and methods may include robotic systems having various end effectors to move trays relative to item sortation systems. For example, the robotic systems may include robotic arms and gantry systems. In addition, the various end effectors may include dual end effectors and passthrough end effectors. The dual end effectors may lift, move, and place trays by engaging and clamping onto flanges of the trays. The passthrough end effectors may lift, move, and place trays through an interior of the end effectors by engaging and pulling or pushing flanges, edges, or other surfaces of the trays. The various automated tray handling systems and methods may increase the speed and efficiency of such processes while also reducing or minimizing the space required for such systems.

Abstract: A method of applying a label to a transport structure includes receiving the label from a label dispenser with an end effector, in which the label includes information related to a plurality of storage containers secured to the transport structure with a restraining member. The method further includes measuring a position of the end effector relative to an object, moving the end effector with the label to a target position based upon the measured position, and applying the label to the restraining member with the end effector. The method may further include moving the end effector away from the storage containers, and transporting the transport structure with the storage containers and the label based upon the information of the label.

Abstract: A movement device is moved along an X axis and a Y axis by providing a sensor configured to measure angle of rotation of at least one of a first and a second kinematic link about a respective axis of rotation. A force is imparted on the first and second kinematic links such that an angular displacement of the first and second kinematic links about the respective axis of rotation is achieved. The angular displacement of the first and second kinematic links about the respective axis of rotation is determined. The movement device is moved along the X axis and/or the Y axis in response to the determination of the angle of rotation of the first and second kinematic links about the respective axis of rotation until first and second kinematic links are vertical.

Abstract: A vehicle charging station includes a track configured to extend across a plurality of vehicle parking spaces and a movable charging apparatus supported by the track. The movable charging apparatus is translatable along the track between the plurality of vehicle parking spaces to charge one or more vehicles. The movable charging apparatus includes a base slidably coupled with the track, an end effector in mechanical communication with the base and configured to electrically couple with an electric vehicle disposed within one of the plurality of vehicle parking spaces, and a power delivery circuit configured to receive an electrical charge from a power source and to controllably provide the electrical charge to the electric vehicle.

Abstract: A movement device is moved along an X axis and a Y axis by providing a sensor configured to measure angle of rotation of at least one of a first and a second kinematic link about a respective axis of rotation. A force is imparted on the first and second kinematic links such that an angular displacement of the first and second kinematic links about the respective axis of rotation is achieved. The angular displacement of the first and second kinematic links about the respective axis of rotation is determined. The movement device is moved along the X axis and/or the Y axis in response to the determination of the angle of rotation of the first and second kinematic links about the respective axis of rotation until first and second kinematic links are vertical.

Abstract: A movement device is moved along an X axis and a Y axis by providing a sensor configured to measure angle of rotation of at least one of a first and a second kinematic link about a respective axis of rotation. A force is imparted on the first and second kinematic links such that an angular displacement of the first and second kinematic links about the respective axis of rotation is achieved. The angular displacement of the first and second kinematic links about the respective axis of rotation is determined. The movement device is moved along the X axis and/or the Y axis in response to the determination of the angle of rotation of the first and second kinematic links about the respective axis of rotation until first and second kinematic links are vertical.

Abstract: Fixtureless self-alignment and orientation of components during an assembly process, and self-aligning/self-orienting components for assembly. Self-alignment and self-orientation are provided by integrating complementary spatially-modulated magnetic arrays into components requiring alignment and/or orientation during an assembly process. In addition to providing self-alignment/self-orientation, the spatially-modulated magnetic arrays also provide selective component placement and/or assembly order. Final assembly can involve permanent mechanical or adhesive fasteners.

Abstract: A system includes a first camera defining a first camera coordinate system (C1) and configured to acquire a first image of a scene. A range sensor is spaced a first distance from the first camera and defines a range sensor coordinate system (R). A controller is operatively connected to the first camera and range sensor. The controller has a processor and a tangible, non-transitory memory device on which is recorded instructions for executing a method for obtaining a two-dimensional region of interest (u1*, v1*) in the first image, which is a two-dimensional intensity image. The first image is represented by a plurality of first points (u1, v1) in a first image plane. The controller is configured to acquire a range image of the scene with the range sensor. The range image is represented by a plurality of second points (u2, v2, d) in a second image plane.

Abstract: Fixtureless self-alignment and orientation of components during an assembly process, and self-aligning/self-orienting components for assembly. Self-alignment and self-orientation are provided by integrating complementary spatially-modulated magnetic arrays into components requiring alignment and/or orientation during an assembly process. In addition to providing self-alignment/self-orientation, the spatially-modulated magnetic arrays also provide selective component placement and/or assembly order. Final assembly can involve permanent mechanical or adhesive fasteners.

Abstract: A system includes a robotic gripper and a grasp controller. The gripper, which has a sensory matrix that includes a plurality of sensors, executes selected grasp poses with respect to a component in the corresponding method to thereby grasp the component in response to a grasp command signal from the controller. The controller has a touch-screen or other interactive graphical user interface (GUI) which generates a jog signal in response to an input from a user. Sensory maps provide calibrated limits for each sensor contained in the sensory matrix for the selected grasp pose. The controller transmits the grasp command signal to the gripper in response to receipt of the jog signal from the GUI. The GUI may display a jog wheel having icons, including a hub corresponding to a neutral pose of the robotic gripper and icons corresponding to grasp poses arranged around a circumference of the jog wheel.

Abstract: A system includes a first camera defining a first camera coordinate system (C1) and configured to acquire a first image of a scene. A range sensor is spaced a first distance from the first camera and defines a range sensor coordinate system (R). A controller is operatively connected to the first camera and range sensor. The controller has a processor and a tangible, non-transitory memory device on which is recorded instructions for executing a method for obtaining a two-dimensional region of interest (u1*, v1*) in the first image, which is a two-dimensional intensity image. The first image is represented by a plurality of first points (u1, v1) in a first image plane. The controller is configured to acquire a range image of the scene with the range sensor. The range image is represented by a plurality of second points (u2, v2, d) in a second image plane.

Abstract: A reconfigurable end-effector assembly includes a master boom, a limb, and branches. The branches extend radially outward from the limb. Tandem branch joint assemblies connect the branches to the limb, and include a first and a second branch joint each having a cam lock. Tool modules mounted to the branches are translatable and rotatable with respect to the branches. The joint assemblies rotate and slide with respect to the longitudinal axis of the limb only when the cam lock is released. A configuration tool has an actuator and fingers. The branch joints define openings that are engaged via the fingers. The tool includes a latch which engages the cam lock, and clamps and unclamps the cam lock. A flexible dress package is mountable to the limb and configured to route lengths of conduit to each of the tool modules.

Abstract: Malfunction or failure of mechanical, electrical and electro-mechanical equipment, for example equipment used in manufacturing operations, is often preceded by an increase in the operating temperature of at least some portion of the equipment. Some pre-determined temperature, greater than the highest normal operating temperature of the equipment, is presumed or known to be indicative of impending equipment failure if no remedial action is taken. A resettable, temperature-sensitive device, containing a shape memory alloy actuator, pre-selected to operate at the pre-determined temperature, is disclosed. The device is placed in thermal contact with the equipment. If the equipment achieves the pre-determined temperature, the shape memory alloy actuator causes the device to display a flag or provide some other passive visual indication. Alternatively, or additionally, the actuator may trigger an electrically-powered alert including visual or audible alerts or a wireless communication.