MULTI-MODAL PACKAGE HANDLING TOOL AND SYSTEM

Abstract

The present invention is directed towards a multi-modal package handling tool. In accordance with one exemplary embodiment of the invention, the inventive tool includes a tool platform mounted to the end of a robotic arm. The tool further includes a plurality of package attachment systems mounted to the tool platform wherein each of the plurality of package attachment systems is configured to attach a package to the end of the robotic arm. The inventive tool is responsive to a controller that is operative to select at least one of the package attachment systems to be presented to the package for attaching the package to the end of the robotic arm.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-Part of currently-pending U.S. patent application Ser. No. 10/905,241 filed Dec. 22, 2004, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a tool which may be mounted upon a prime mover, such as an industrial articulating robot or gantry robot, for the purpose of handling a variety of different packages having different sizes and shapes, such as, for exemplary purposes only, those commonly used for consumer and pre-consumer packaging of various types of goods, to create “build to order” pallets, for example, comprising the goods packaged in the different sized and shaped packages.

BACKGROUND OF THE INVENTION

The distribution of various packages including, but not limited to food items, and particularly beverages, is rendered more difficult by the fact that beverage containers come in a variety of sizes and shapes. For example, beverages are marketed in 12 ounce cans, one liter bottles, smaller bottles, and larger containers having all sorts of sizes and shapes. Moreover, the packages used to hold such beverage containers, or any other packaged products for that matter, come in scarcely fewer number of sizes and shapes. It is often necessary for beverage distributors to break down pallets or subdivide pallets of beverages at a distribution point, because frequently the beverage retailer whose order is being filled does not desire to take delivery of a full pallet of one particular type of beverage. Thus, a full pallet having but one type of beverage packaged in a single type of package, will need to be broken down. Unfortunately, use of picker and packer employees to handle such packages results in considerable expense for labor.

The present invention uses an end of arm tool mounted on a robot, with the robot preferably mounted on a track, to pick a variety of different types of packages, for the purpose of loading the packages on a pallet for shipment to, for example, a retailer of packaged goods.

SUMMARY OF THE INVENTION

The present multi-modal package handling tool includes a tool platform with a plurality of package-carrying vacuum units arranged in a generally planar array, with tie vacuum units being attached to a first portion of the tool platform. A plurality of extensible package grippers is mounted to the tool platform, with extensible grippers having at least retracted position and an extended position. The tool platform may also have a slidingly deployable package platform mounted thereto, with the package platform having at least a retracted position and an extended position.

Each of the vacuum units mounted to the tool platform has a vacuum head powered by a dedicated vacuum generator. This offers the advantage that in the event that a vacuum leak occurs within any of the vacuum units, vacuum to will not be lost with respect to the remaining units because each of the vacuum heads has an independent source of vacuum. Moreover, minor air leads will not cause the vacuum power of any of the vacuum heads to be lost. Each of the vacuum heads extends through a port formed in a surface plate which is also attached to the tool platform, such that a package engaged by one or more of the vacuum heads will be drawn into contact with the surface plate. This advantageous result occurs because the vacuum units contract axially when the vacuum is applied and this causes the package being secured by the vacuum units to be pulled into contact with the surface plate, thereby stabilizing the package being carried.

Each of the previously mentioned extensible grippers comprises a package engaging tool mounted to the tool platform by means of a slidable carrier. The extensible grippers may include either hook-like members for engaging handholds formed in a tray of goods, or pincher members for engaging a tray of goods, whether the tray be of cardboard, plastics, metal, or other materials known to those skilled in the art and suggested by this disclosure.

Smooth-sided packages, such as closed cardboard cartons that contain, for example, food products, office supplies, apparel, and other similarly packaged goods, may be picked by the plurality of package-carrying vacuum units which are arranged in a generally planar array at one end of a space frame comprising the tool platform. Package grippers are mounted within space frame advanced to the generally planar array, with the package grippers having at lease a retracted position inboard of the planar array and extended position outboard of the planar array. Similarly, the package platform has at least a retracted position inboard of the planar array and an extended position outboard of the planar array.

According to another aspect of the present invention, a machine vision unit is operatively connected with a controller which operates not only the robot to which the end of arm tool is attached, but also the vacuum units, package grippers, and sliding package platform. Using techniques which are known to those skilled in the art and beyond the scope of this invention, the machine vision unit provides the controller with an image of a package being handled, so as to permit the controller to select the use of either the vacuum units or package grippers or a combination of the vacuum units and the package platform. In the event that both the package platform and the vacuum units are used, the end of arm tool will be oriented such that the surface plate through which the vacuum units erupt will be suited in a generally vertical orientation, with the sequence of attaching the package to the end of arm tool following the steps of using the vacuum units and the robot to lift the package while deploying the sliding package platform under the lifted package. In this manner, the sliding package platform may be positioned under the package without pushing the package from its position on a supply pallet.

According to another aspect of the present invention, a method for picking up a package includes the steps of determining at least one characteristic of a package being picked up, communicating the determined characteristic to a controller, and using the controller to select from a plurality of package attachment systems carried upon an end of arm tool, with the controller making the selection based upon the previously described characteristic. Then, at least one selected package attachment system is presented to a package by means of a robot (i.e., such as an industrial robot or a gantry robot) having the end of arm tool attached thereto, with the robot being operated by the controller. The ultimate step is attachment of the package to the end of arm tool by means of the selected package attachment system.

It is an advantage of the present invention that a single end of arm tool may accommodate a large number of packages having different sizes, shapes, construction and configuration, ranging from plastic trays having multiple packages of bottles contained therein, to smooth sided cardboard or plastic packages, to cardboard tray packages.

It is a further advantage of the present invention that this invention allows the breaking down of homogeneous package pallets into mixed pallets without the need for human operators.

Other advantages, as well as features and objects of the present invention will become apparent to the reader of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a multi-modal package handling system according to the present invention.

FIG. 2 is an perspective view of a portion of the system in FIG. 1, showing the present handling system picking up a smooth-sided cardboard carton.

FIG. 3 is a segment of the illustration of FIG. 2, albeit from a different perspective, showing additional design elements of an end of arm tool according to the present invention.

FIG. 4 illustrates the present multi-modal package handling system picking up a tray of beverage bottles.

FIG. 5 is an enlarged portion of FIG. 4, showing additional details of construction of the present end of arm tool.

FIG. 6 is similar to FIG. 5, but depicts pincer type package grippers mounted to the end of arm tool.

FIG. 7 is similar to FIG. 1, but illustrates two end of arm tools mounted to a single robot arm.

FIG. 8 is a block diagram of a portion of a control system according to one aspect of the present invention.

FIG. 9 illustrates a multi-modal package pick up operation involving not only vacuum units, but also a sliding package platform.

FIG. 10 is a flow diagram illustrating an exemplary implementation of the multi-modal package handling tool and system shown in FIGS. 1 and 7, for example, in accordance with the present invention.

FIG. 11 is a perspective and diagrammatic view of an alternate preferred embodiment of the multi-modal package handling system illustrated in FIG. 1.

FIG. 12 is a flow diagram illustrating an exemplary implementation of the multi-modal package handling tool and system shown in FIG. 11, for example, in accordance with the present invention

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIG. 1, in a preferred embodiment, the present multi-modal package handling system 10 is used in conjunction with an industrial articulating robot 32 mounted upon a guideway 14, which is situated between adjacent rows of supply pallets 20. It should be noted however, that, as will be described in greater detail below, the present invention is not limited to use with an industrial articulating robot. Rather, the inventive tool and system to be described below can be implemented in any number of applications and arrangements that remain within the spirit and scope of the present invention.

In the preferred embodiment wherein articulating robot 32 is employed, however, robot 32 has robot arm 34 that is operable along a plurality of axes, to which multi-modal package handling tool 36 is mounted by way of, for exemplary purposes only, bolts or other known fasteners. In turn, robot 32 is mounted using, for example, bolts or other known fasteners, upon carriage 38, which is then mounted upon guideway 14 to provide a measure of movability to system 10, and more particularly, robot 32. System 10 generally, and robot 32 in particular, traverses guideway 14, picking various items or packages 26 from supply pallets 20, depositing them on a shipping pallet 24. In the illustrated embodiment, shipping pallet 24 is disposed on carriage 38 so as to move along guideway 14 with robot 32. In other alternate embodiments, however, pallet 24 may not be on carriage 38, but rather may be disposed elsewhere proximate robot 32. In the embodiment wherein shipping pallet 24 is disposed on carriage 38, when shipping pallet 24 is full, or the predetermined composition for shipping pallet 24 is complete, pallet 24 is removed from carriage 38 by, for example, a fork lift, an automated guided vehicle or laser guided vehicle, and placed in line for transport from the storage facility. As will be described in greater detail below, the operation of robot 32 and arm 34, and the movement of carriage 38 along guideway 14 is controlled by a controller included in the inventive multi-modal package handling system. It should be noted that system 10 is not limited to an application wherein the packages to be picked up are located on supply pallets. Rather, system 10 can be implemented in a number applications. For example, in one alternate embodiment, instead of picking up packages from supply pallets 20, robot 32 picks up packages disposed on a conveyor, and then deposits the picked up package on the supply pallet, which may or may not be mounted or otherwise disposed on carriage 38.

FIG. 2 shows certain details of a portion of a system according to present invention. Multi-modal package handling tool 36 includes end plates 46, between which four columns 48 are mounted by way of, for exemplary purposes only, bolts or other known fasteners. End plates 46 and columns 48 define a space frame to which various other components are mounted. The space frame is mounted to robot arm 34 using, for example, bolts or other known fasteners. FIG. 2 illustrates end of arm tool 36 picking up a smooth sided cardboard carton 26. This carton is being picked by means of vacuum units 76, which are described in greater detail later in this specification.

FIG. 2 additionally shows slidingly deployable package platform 54, which is mounted upon sliding mount 62. Columns 48 each have a plurality of mortises 56 which are engaged by mount 62. Slidingly deployable package platform 54, which in a preferred embodiment is controlled by a controller that will be described in greater detail below, is positioned by means of cylinder 60, which has a fixed end mounted to the space frame defined by columns 48 and end plates 46 using bolts or other known fasteners, for example. Usage of sliding platform 54 is further described in connection with the discussion of FIG. 9. FIG. 2 also shows gripper 70, which is positioned by means of cylinder 72. Gripper 70 is swung into deployment by means of a cylinder, 73 which is shown with greater specificity in FIG. 4. Those skilled in the art will appreciate in view of this disclosure that, as used herein, the term “cylinder” means either a conventional pneumatic cylinder, or a hydraulic cylinder, or an electrically driven device, or yet other types of linear actuators used within various types of machinery.

FIGS. 3 and 5 show the construction of surface plate 86, which has a plurality of ports 84, formed therein. As shown in FIG. 3, surface plate 86 is mounted to end plate 46 by way of an arrangement of bolts and standoffs 87, for example. Standoffs 87 provide clearance between end plate 46 and surface plate 86 for vacuum generators 82 that are disposed therebetween. Each of vacuum units 76 includes a multi-ribbed cup which is fed vacuum by means of a dedicated vacuum generator 82. In an exemplary embodiment, vacuum generators 82 are attached to endplate 46. It this particular embodiment, end plate 46 includes a plurality of apertures for receiving threaded studs of the vacuum generators 82. Once the studs are inserted through the apertures in end plate 46, a nut is threaded onto the threaded stud so as to hold vacuum generator 82 in place. It should be noted, however, that those skilled in the art will appreciate that other attachment methods exist that are suitable for mounting vacuum generators 82, which remain within the spirit and scope of the present invention. The present inventors have determined that a vacuum generator model VGS3010.AC.04.BH from the PIAB AB company of Täby, Sweden, is preferred for practicing the present invention. It should be noted, however, that other types and models of vacuum generators exist that could be used to practice the invention. Vacuum generators 82 are shown with greater specificity in FIG. 5.

When the multi-ribbed vacuum cups incorporated within vacuum devices 76 are activated by providing compressed air for an air source to vacuum generators 82, the vacuum ribbed cups contract axially, causing the package being picked to be pulled up tightly to surface plate 86. This is shown specifically in FIG. 2. As noted above, each of vacuum generators 82 shown in FIG. 5 is independently powered. In other words, compressed air is supplied to each of the vacuum generators 82, but there is no manifolding for interconnecting the vacuum output side of vacuum generators 82. Each vacuum generator 82 provides vacuum to a single vacuum unit 76, and this is important because in the event that a vacuum cannot be pulled on any one or more of vacuum units 76, vacuum may still be pulled on the remaining units.

The drink bottles shown in FIG. 5 are pulled up tightly against surface plate 86, but this is due to the action of package grippers 70, which pull upon tray 26 of FIG. 5. Vacuum units 76 are normally not employed to pick bottles such as those illustrated in FIG. 5. FIG. 6 is similar to FIG. 5, but shows a pincer 90, which is used in a plurality of locations similar to those locations used with respect to package grippers 70. Pincers 90 are particularly useful for gripping cardboard shipping trays, either at the ends of such trays, or in certain cases, at the center of the tray. Pincers 90 may be actuated either by hydraulic or pneumatic cylinders, or by other types of linear force/motion devices known to those skilled in the art and suggested by this disclosure. The application of such devices is beyond the scope of this specification. It should be noted that one preferred application for the inventive tool and system is the beverage industry. However, the present invention is not limited to such as application. Rather, the inventive tool and method can be applied to any industry involving packages and/or palletizing.

FIG. 7 is similar to FIG. 1, but shows two end of arm tools 36 mounted on a single robot arm 34. This configuration may be pursued in an effort to increase the throughput of a system according to the present invention

FIG. 8 is a block diagram according to the present invention, and shows controller 100 as receiving inputs from sensors 102. A number of suitable controllers could be used, such as, for exemplary purposes only, a programmable computer or a programmable logic controller, that can receive inputs from the sensors 102, for example, and then causes robot 32 to respond accordingly (i.e., movement of arm 34, selection of one or more of the package attachment systems, etc.). A variety of different sensors such as regular, low light, or infrared cameras, radio frequency tagging, or other types of devices known to those skilled in the art and suggested by this disclosure may be employed for the purpose of locating and sensing the package, as well as determining a characteristic of the package being picked. This characteristic may, for example, be the amount of open area in the top surface of the package, which would indicate whether the package is a tray of bottles having a large amount of open area, or a smooth cardboard carton having little or no open areas.

In one preferred embodiment, sensors 102 take the form of a machine vision unit. The machine vision unit is operatively connected with controller 100 which, as described elsewhere herein, operates not only robot 32, but also vacuum units 76, package grippers 70, and sliding package platform 54. Using techniques which are known to those skilled in the art and beyond the scope of this invention, the machine vision unit provides controller 100 with an image of the package being handled, so as to permit controller 100 to select the use of either vacuum units 76 or package grippers 70 or a combination of vacuum units 76 and package platform 54. In the event that both package platform 54 and vacuum units 76 are used, the end of arm tool will be oriented such that the surface plate through which the vacuum units erupt will be suited in a generally vertical orientation, with the sequence of attaching the package to end of arm tool 36 following the steps of using vacuum units 76 and robot 32 to lift the package while deploying sliding package platform 54 under the lifted package. In this manner, sliding package platform 54 may be positioned under the package without pushing the package from its position on its respective supply pallet 20.

In any event, inputs from various sensors 102, which are disposed on and/or proximate to surface plate 86, are used by controller 100 to select which one or more package attachment systems are to used to lift the package, and to selectively operate vacuum units 76, robot 32, package grippers 70, and sliding platform 54 to pick a package having a detected characteristic.

FIG. 9 illustrates another multi-modal function according to the present invention in which end of arm tool 36 picks a package from one side by first attaching to the side of package 26 with at least one vacuum unit 76. Then, package 26 will be lifted by robot 32 so that cylinder 60 is able to extend slidingly deployable package platform 54 under package 26 without pushing package 26 from its immediately previous location.

One exemplary implementation of the inventive tool and system is illustrated, in part, in FIG. 10. It should be noted that this implementation is provided for exemplary purposes only and is not meant to be limiting in nature. Rather, the inventive tool and system can be implemented in other applications/arrangements while remaining within the spirit and scope of the present invention. In this implementation, the distributor of the goods being shipped enters a desired order into a warehouse management system 104. WMS 104 includes a software program that manages the overall operation of the warehouse, and among other things, also stores all orders placed, keeps track of inventory and stores various product information. WMS 104 also determines, for example, the mix and quantity of products required to meet the entered order (i.e., the number and composition of the shipping pallets, for example). If necessary, the required products (i.e., the source pallets 20 described above) are then retrieved—either by an automated storage and retrieval system, or manually using forklifts or automated/laser guided vehicles, for example—and placed in appropriate predetermined product slot locations along guideway 14 (i.e., supply pallets). WMS 104 then sends the order data to a coordinator system 106, which is essentially a software platform loaded on a personal computer, for example, that is capable of receiving information from WMS 104 relating to the desired order, and then communicating that information to multiple devices in the package handling system or systems in the warehouse, such as, for example, various conveyors, robots, and tools. WMS 104 communicates with coordinator system 106 using known communication methods and techniques, such as, for example, an Ethernet network, a PROFIBUS network (or other bus structure), a wireless network, or other similar methods and techniques that one of ordinary skill in the art will appreciate as being suitable for the desired purpose.

Coordinator system 106 is programmed with the corresponding coordinates of the individual product slots and the type of products in the respective slots. As will be described below, coordinator system 106 is therefore operative to take the information from WMS 104, correlate the composition of the order with the location of the respective goods making up the order (i.e., the coordinates of the respective product slots within which the products are located), and providing a converted form of the WMS order information to controller 100 of robot 32 that will allow robot 32 to assemble the desired order. In one exemplary embodiment such as that illustrated in FIG. 1, coordinator system 106 and controller 100 are located in a single control panel or enclosure 108. It should be noted, however, that the present invention is not so limited. Rather, those of ordinary skill in the art will appreciate that other arrangements exist in which coordinator system 106 and controller 100 are separate from each other, and these arrangements remain within the spirit and scope of the present invention. Additionally, coordinator system 106 and controller 100 may be located proximate to robot 32, as shown in FIG. 1, or may be remote to robot 32 in, for example, a supervisory station. As with the communication from WMS 104 to coordinator system 106 described above, coordinator system 106 and controller 100 likewise communicate using known communication methods and techniques, such as, for exemplary purposes, an Ethernet network, a PROFIBUS network (or other similar bus structure), a wireless network, or other similar methods and techniques that one of ordinary skill in the art will appreciate as being suitable for the desired purpose.

Once the order information is provided by coordinator system 106 to controller 100, controller 100 causes robot 32 to build the desired order in the correct quantity and order sequence. Accordingly, controller 100 is configured, in part, to move robot 32 along guideway 14 to the correct product slot where the next type of product in the order to be picked up is located, and to then pick up the correct quantity of the product and place it on shipping pallet 24. As described in greater detail above, in a preferred embodiment, robot 32 includes sensors 102, such as, for example, a vision unit, to determine and confirm the presence and type of product (including certain predetermined characteristics thereof), and the products location. Sensors 102 may be hardwired to controller 100 using known methods, or may also be connected to controller 100 over a wireless link. Using the information provided to controller 100 by sensors 102, controller 100, for example, positions tool 36 so as to be operative to pick up the desired product, and also selects one or more of the package attachments systems associated with tool 36 to be used to pick up the respective product. Accordingly, controller 100 moves robot 32 to the correct place along guideway 14 where the desired products is; manipulates the position of arm 34 such that tool 36 is situated over the respective product to allow for sensors 102 to verify the type and location of the product; and then causes robot 32, and tool 36 in particular, to pick up the product and deposit it on the shipping pallet 24. This operation is then repeated until the composition of shipping pallet 24 meets the desired order. The completed shipping pallet 24 is then removed from carriage 38, and replaced with an empty shipping pallet 24 to continue the cycle.

FIG. 11 illustrates a second preferred embodiment of a multi-modal package handling system 110. In this particular embodiment, system 110 includes a four-post gantry type robot system wherein a gantry robot 132 is employed in place of the industrial robot 32 described above and illustrated in FIGS. 1 and 7, and the overhead gantry 133 takes the place of guideway 14. Gantry robots, which are known generally in art, are stationary robots that may allow for linear motion in three or more axes. In the present invention, this includes movement along the x and y axes of a horizontal plane depicted in FIG. 11 (e.g., front and back, and left and right movement), which is parallel to the floor/platform on which the posts of the gantry system are mounted. In the inventive system, gantry robot 132 includes a telescoping arm 134 to the end of which a package handing tool 136 is mounted by way of bolts or other known fasteners. Arm 134 provides gantry robot 132, and therefore tool 136, with the ability to move not only along the x-y axes, but also along the z-axis, which is perpendicular to the aforementioned horizontal x-y plane. Accordingly, with the addition of arm 134, tool 136 can be moved in the front/back, left/right and up/down directions.

Generally speaking, the structure and functionality of tool 136 is the same as that of tool 36. As such, a full description of tool 136 will not be repeated here, but rather, the description of the function and structure of tool 36 set forth above applies with equal force to tool 136. Similarly, the general function served by multi-modal package handling system 110 is the same as that of system 10. Therefore, a full description of system 110 will not be repeated here, but rather, with the limited exceptions noted below, the description of system 10 set forth above applies with equal force to system 110.

Accordingly, gantry robot 132 moves along the x, y, and/or z axes as needed to pick up various packages 126 from supply pallets 120 located within the operating area of gantry robot 132, and deposits them on a shipping pallet 124 that is positioned at a predetermined location within the operating area of gantry robot 132. It should be noted that as with the description of system 10 above, in alternate embodiments, the packages to be picked up may not be disposed on supply pallets 120 located within the operating area of gantry robot 132. For example, in one exemplary embodiment, robot 132 picks up packages from a conveyor belt located within the operating area of the gantry and then deposits the package on supply pallet 124. Accordingly, one of ordinary skill in the art will appreciate that the inventive system can be implemented in a number of applications and arrangements.

As with system 10, system 110 includes one or more sensors 202 (not shown in FIG. 11) positioned on or proximate to tool 136 that locate and/or sense the presence of a package, as well as, in a preferred embodiment, to determine a characteristic of the package being picked up. This characteristic may, for exemplary purposes only, be the amount of open area in the top surface of the package, which would indicate the type of package.

As discussed above with respect to sensors 102, sensors 202 may take the form of one or more of any number of suitable sensors, such as, for example, regular, low light or infrared cameras, radio frequency tagging or machine vision units (which are described in greater detail above). Regardless of the sensors used, the information detected or sensed by sensors 202 is sent to a controller 200, which controls, among other things, at least the operation of both gantry robot 132 and tool 136. In one preferred embodiment, controller 200, which, as set forth above, may take on any one of a number of types of controllers, including but not limited to, for example, programmable computers or programmable logic controllers, moves gantry robot 132 to supply pallet 120, and then receives the information from sensors 202 relating to the presence and type of the package on supply pallet 120. Controller 200 then selects the type or types of package attachment system(s) mounted to the tool platform to present to the package, and then operates robot 132 and tool 136 accordingly in order to pick up the package and place it on shipping pallet 124.

An exemplary implementation of the embodiment of the inventive tool and system illustrated in FIG. 11 is depicted, in part, in FIG. 12. It should be noted that this implementation is provided for exemplary purposes only and is not meant to be limiting in nature. Rather, the inventive tool and system can be implemented in other applications/arrangements while remaining within the spirit and scope of the present invention. In this implementation, the distributor of the goods being shipped enters a desired order into a warehouse management system 204. WMS 204 includes a software program that manages the overall operation of the warehouse, and among other things, also stores all orders placed, keeps track of inventory and stores various product information. WMS 204 also determines, for example, the mix and quantity of products required to meet the entered order (i.e., the number and composition of the shipping pallets, for example). If necessary, the required products (i.e., the source pallets 120 described above) are then retrieved—either by an automated storage and retrieval system, or manually using forklifts or automated/laser guided vehicles, for example—and placed in appropriate predetermined product slot locations within the operating area of gantry robot 132. WMS 204 then sends the order data to a coordinator system 206, which is essentially a software platform loaded on a personal computer, for example, that is capable of receiving information from WMS 204 relating to the desired order, and then communicating that information to multiple devices in the package handling system or systems in the warehouse, such as, for example, various conveyors, robots, and tools. WMS 204 communicates with coordinator system 206 using known communication methods and techniques, such as, for example, an Ethernet network, a PROFIBUS network (or other bus structure), a wireless network, or other similar methods and techniques that one of ordinary skill in the art will appreciate as being suitable for the desired purpose.

Coordinator system 206 is programmed with the corresponding coordinates of the individual product slots and the type of products in the respective slots. As will be described below, coordinator system 206 is therefore operative to take the information from WMS 204, correlate the composition of the order with the location of the respective goods making up the order (i.e., the coordinates of the respective product slots within which the products are located), and providing a converted form of the WMS order information to controller 200 of robot 132 that will allow robot 132 to assemble the desired order. In one exemplary embodiment such as that illustrated in FIG. 11, coordinator system 206 and controller 200 are located in a single control panel or enclosure 208. It should be noted, however, that the present invention is not so limited. Rather, those of ordinary skill in the art will appreciate that other arrangements exist in which coordinator system 206 and controller 200 are separate from each other, and these arrangements remain within the spirit and scope of the present invention. Additionally, coordinator system 206 and controller 200 may be located proximate to robot 132, as shown in FIG. 11, or may be remote to robot 132 in, for example, a supervisory station. As with the communication from WMS 204 to coordinator system 206 described above, coordinator system 206 and controller 200 likewise communicate using known communication methods and techniques, such as, for exemplary purposes, an Ethernet network, a PROFIBUS network (or other similar bus structure), a wireless network, or other similar methods and techniques that one of ordinary skill in the art will appreciate as being suitable for the desired purpose.

Once the order information is provided by coordinator system 206 to controller 200, controller 200 causes gantry robot 132 to build the desired order in the correct quantity and order sequence. Accordingly, controller 200 is configured, in part, to move gantry robot 132 in one or more of the x, y and z axes, to the correct product slot where the next type of product in the order to be picked up is located, and to then pick up the correct quantity of the product and place it on shipping pallet 124. As described in greater detail above, in a preferred embodiment, robot 132 includes one or more sensors 202, such as, for example, a vision unit, to determine and confirm the presence and type of product (including certain predetermined characteristics thereof), and the products location. Sensors 202 may be hardwired to controller 200 using known methods, or may also be connected to controller 200 over a wireless link. Using the information provided to controller 200 by sensors 202, controller 200, for example, positions tool 136 so as to be operative to pick up the desired product, and also selects one or more of the package attachments systems associated with tool 136 to be used to pick up the respective product. Accordingly, controller 200 moves robot 132 to the correct place within the operating area of the gantry where the desired products is; manipulates the position of arm 134 such that tool 136 is situated over the respective product to allow for sensors 202 to verify the type and location of the product; and then causes robot 132, and tool 136 in particular, to pick up the product and deposit it on the shipping pallet 124. This operation is then repeated until the composition of shipping pallet 124 meets the desired order. The completed shipping pallet 124 is then removed from the operating area of the gantry, and replaced with an empty shipping pallet 124 to continue the cycle.

Although the present invention has been described in connection with particular embodiments thereof, it is to be understood that various modifications, alterations, and adaptations may be made by those skilled in the art without departing from the spirit and scope of the invention set forth in the following claims.

Claims

1. A multi-modal package handling tool comprising:

a tool mounted to the end of a robotic arm, wherein said tool includes a tool platform;

a plurality of package attachment systems mounted to said tool platform wherein each of said plurality of package attachment systems is configured to attach a package to said end of said robotic arm;

wherein said tool is responsive to a controller that is operative to select at least one of said package attachment systems to be presented to said package for attaching said package to said end of said robotic arm.

2. A tool in accordance with claim 1 wherein said plurality of package attachment systems includes a plurality of package carrying vacuum units.

3. A tool in accordance with claim 2 wherein each of said vacuum units comprises a vacuum head powered by a dedicated vacuum generator.

4. A tool in accordance with claim 2 wherein said tool platform comprises a surface plate configured such that said package is drawn against and in contact with said surface plate when said package is engaged with one or more of said vacuum units.

5. A tool in accordance with claim 4 wherein each of said vacuum units comprises a vacuum head and said surface plate includes a plurality of ports therein configured such that each of said vacuum heads extends through a corresponding port.

6. A tool in accordance with claim 1 wherein said plurality of package attachment systems includes a plurality of extensible package grippers, said grippers having at least a retracted position and an extended position.

7. A tool in accordance with claim 6 wherein at least one of said grippers comprises a hook-like member for engaging a tray of goods.

8. A tool in accordance with claim 6 wherein at least one of said grippers comprises a pincer member for engaging a tray of goods.

9. A tool in accordance with claim 1 further comprising at least one sensor configured to sense the type and location of said package, said controller operative to select at least one of said package attachment systems to be presented to said package for attaching said package to said end of said robotic arm in response to said type and location of said package.

10. A tool in accordance with claim 9 wherein said at least one sensor comprises a machine vision system.

11. A tool in accordance with claim 1 wherein said plurality of package attachment systems includes a slidingly deployable package platform, said platform having at least a retracted and an extended position.

12. A tool in accordance with claim 1 wherein said robotic arm and said tool platform are operable along a plurality of axes.

13. A tool in accordance with claim 1 wherein said robotic arm is part of a gantry robot.

14. A multi-modal package handling system, comprising:

a robot having a moveable arm and configured for reciprocating movement in at least a first and second direction;

a tool attached to the end of said arm having a plurality of package attachment systems mounted thereon;

a controller configured to select at least one of said plurality of package attachment systems to be presented to a package to be picked up, and to control said movement of said robot, the operation of said arm, and the operation of said at least one selected package attachment system.

15. A system in accordance with claim 14 wherein said movable arm is operable along a plurality of axes, said system further comprising a guideway upon which said robot is mounted to allow for said reciprocating movement in at least said first and second directions.

16. A system in accordance with claim 15 wherein said robot further includes a carriage upon which said robot is mounted, said carriage being mounted to said guideway.

17. A system in accordance with claim 16 wherein said carriage includes a platform upon which a shipping pallet can be placed, said shipping pallet configured to receive said package attached to said at least one package attachment system.

18. A system in accordance with claim 14 wherein said robot further includes a platform upon which a shipping pallet can be placed, said shipping pallet configured to receive said package attached to said at least one attachment system.

19. A system in accordance with claim 14 wherein said robot is configured to assemble a shipping pallet comprising at least one package picked up by said at least one of said plurality of package attachment systems from a supply pallet disposed proximate said robot.

20. A system in accordance with claim 14 further comprising at least one sensor configured to sense the type and location of said package, said controller operative to select at least one of said package attachment systems to be presented to said package for attaching said package to said end of said robotic arm in response to said type and location of said package.

21. A tool in accordance with claim 20 wherein said at least one sensor comprises a machine vision system.

22. A tool in accordance with claim 13 wherein said robot is a gantry robot and said arm is a telescoping arm to which said tool is attached.

23. A multi-modal package handling system comprising:

a warehouse management system operative to receive an order comprising at least one package;

a coordinator system configured to receive information from said warehouse management system relating to said order, wherein said coordinator system is programmed with the coordinates of the location of said at least one package;

a robot having a moveable arm, said robot configured for reciprocating movement in at least a first and second direction;

a tool attached to the end of said arm having a plurality of package attachment systems mounted thereon; and

a controller configured to receive information from said coordinator system about said order and the location of said at least one package, and to control the movement of said robot, the operation of said robotic arm and the operation of said tool in response to said order information, and further wherein said controller is configured to select at least one of said plurality of package attachment systems to be presented to said package to be picked up.