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 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 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 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 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 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 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 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: In a system and method for identifying and transferring parcels from a first conveyor to a second conveyor aligned with the first conveyor, a camera of a vision and control subsystem is used to acquire image data of a bulk flow of multiple parcels on the first conveyor. The image data is processed by a computer of the vision and control subsystem to identify individual parcels in the bulk flow of multiple parcels. The computer then activates a robot to engage and transfer selected individual parcels in the bulk flow of multiple parcels in a predetermined sequence. After the robot has engaged and transferred the selected individual parcels, the computer communicates instructions to the first conveyor to advance remaining parcels in the bulk flow of multiple parcels on the first conveyor to the second conveyor.

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 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 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 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 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: An article removal conveyor includes first and second conveying lanes disposed in parallel alongside one another and driven in a manner imparting mutually divergent conveying forces. The first conveying lane has a conveying surface with a higher coefficient of friction than that of the second conveying lane so that any articles contacting the first conveying lane will be controlled by that lane.