Patent Grant
12252357
The present disclosure relates to systems, apparatus and methods for sorting dunnage. More specifically, the present disclosure relates to systems, apparatus and methods for sorting dunnage based on a type or kind of dunnage.
In many instances, it may be desirable to transport large quantities of articles, such as empty bottles, to a location for filling. To reduce the amount of handling required and/or to reduce the amount of shipping material consumed, the articles may be arranged in a tight grouping, or array, of articles. Each empty article arrays are typically separated from each other by wrapping a plastic bag to form a loaded pallet and ready for shipment. The article arrays can also be arranged on (or overlay) a layer of articles, such as, a dunnage (e.g., slip sheets, top frames, pallets) having a footprint which can be accommodated by freight hauling compartments, e.g., for truck, rail, sea or air vessels. In most cases, the dunnage is an inexpensive or waste material used to load and secure the article arrays during transportation. In other terms, it refers to miscellaneous baggage, brought along during transport. In the context of depalletizing a loaded pallet, dunnage can refer to a layer that separates each article array, a top layer or top frame and/or a bottom pallet, each layer used to prevent the article arrays from being moved or damaged during shipment.
Once the articles are depalletized or unpackaged, the dunnage can be transported to a location to be stored, reused, or discarded, if damaged. One approach to handling dunnage requires personnel to manually remove the dunnage from the article arrays and transport the dunnage to be stored. However, this is inefficient and labor-intensive, as well as possibly injuring the personnel. Also, this approach can be potentially hazardous for the personnel, as access to the dunnage may require the personnel to handle dangerous tools and/or equipment. Additionally, there may be damage or breakage to the dunnage itself during the depalletizing process or transport, leading to costly replacement costs of damaged dunnage.
Further, while there are depalletizing systems that can remove dunnage from a loaded pallet, these systems are only a single-type system. That is, these depalletizing systems merely handles the dunnage and stacks them without determining the type or form of the dunnage. This creates additional time to determine and sort the various types of dunnage into an organized stacked manner, which can lead to the potential concerns as discussed above.
Accordingly, there is a need for improved apparatus and methods for sorting and storing dunnage that do not suffer from these shortcomings.
In an exemplary embodiment, a system for sorting dunnage of an article array having a programmable robot includes an arm for transferring a dunnage from a plurality of dunnage being of different types to a collection area. The programmable robot includes a head having a first clamping assembly for engaging with a first type of dunnage, a second clamping assembly for engaging with a second type of dunnage; and a plurality of grippers for engaging with a third type of dunnage. The first clamping assembly, the second clamping assembly and the plurality of grippers are independently operated and configured to engage the respective dunnage based on the type of dunnage.
In a further exemplary embodiment, a system for sorting dunnage of an article array, includes a dunnage receiving table, a programmable robot including an arm for transferring a dunnage based on a type of dunnage, wherein, in response to a dunnage of a first type, the programmable robot transfers the dunnage of the first type to a first collection area, wherein, in response to a dunnage of a second type, the programmable robot transfers the dunnage of the second type to a second collection area, and wherein, in response to a dunnage of a third type, the programmable robot transfers the dunnage of the third type to the dunnage receiving table, a conveyor for transporting the dunnage of the third type to an inspection area, and an inspection device for inspecting the dunnage of the third type for damage.
In yet a further exemplary embodiment, a method of sorting dunnage of a depalletized loaded pallet, includes scanning, via a sensor, a topmost dunnage from a stack of dunnage, determining a type of dunnage, selectively operating a corresponding gripper assembly associated with the determined type of dunnage, and transporting the dunnage to a predetermined stacking area.
Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
It should be noted that these Figures are intended to illustrate the general characteristics of methods, structure and/or materials utilized in certain example embodiments and to supplement the written description provided below. These drawings are not, however, to scale and may not precisely reflect the precise structural or performance characteristics of any given embodiment, and should not be interpreted as defining or limiting the range of values or properties encompassed by example embodiments. For example, the relative thicknesses and positioning of layers, regions and/or structural elements may be reduced or exaggerated for clarity. The use of similar or identical reference numbers in the various drawings is intended to indicate the presence of a similar or identical element or feature.
The present disclosure describes systems and methods for automatically sorting (i.e., arranging, grouping, organizing) dunnage from a depalletized loaded pallet based on a type of dunnage. This creates an efficient and time-saving process in organizing similar dunnage into respective individual orderly stack from a stack of different types of dunnage. There is also no need for an operator to handle and sort the dunnage from the stacked dunnage, unlike conventionally, tools and/or instruments were required or used, resulting in possible injuries to the operator and/or damage to the dunnage itself.
In one embodiment, a programmable robot is used to sort the different types of dunnage. The robot can be an industrial robot, such as an anthropomorphic robotic device, or other device capable of handling and transferring the dunnage to a stacking area. The robot includes a robot head that handles and transports the dunnage to its respective area. It is to be understood that the robot head can be dunnage specific, and easily and quickly operate various types of dunnage. As such, the present system requires only one robot head which can operate and transport different types of dunnage, e.g., slip sheets, top frames, pallets, etc. For example, after an initial scan of a topmost stacked dunnage by a sensor (via a controller) attached on the robot head, the robot transfers the dunnage to one of: a first collection stacking area of a first type of dunnage (e.g., top frames), a second collection stacking area of a second type of dunnage (e.g., pallets), or a third collection area of a third type of dunnage (e.g., slip sheets) for further inspection, which will be described later in detail.
For purposes herein, the term “dunnage” may refer to an article layer used to load and secure an article array during transportation. Such examples include slip sheets, top frames, pallet, and others. The terms “gripped,” “transported,” “moved,” “engaged” and the like in the context of the interaction between a robot and a dunnage may be used interchangeably. Finally, the terms “translated” and “moved” and “pushed” and the like in the context of the movements of the dunnage may be used interchangeably.
Referring to
The robot 20 is mounted on a rotary axis 22 (attached to a base 21) that is configured to rotate 360 degrees about its axis. As such, the robot 20 is a multi-axis robot having five axes of motion. The robot 20 includes a cantilevered arm 23 extending from the rotary axis 22 and supporting a robot head 30. At a distal end of arm 23, the robot head 30 is attached to a rotary axis 25 (
Referring to
Referring to
While the exemplary embodiments illustrated herein describe two pairs of grippers, it should be noted that this is not limited by herein and other numbers of grippers may be employed.
Referring to
While the exemplary embodiments illustrated herein describe two pairs of end grippers, it should be noted that this is not limited by herein and other numbers of grippers may be employed. For example, there may be only three or more end grippers at each end thereof.
In some implementations, in conjunction with the pair of end grippers 32, the two pairs of grippers 31 (used primarily for top frames 50a) also interacts to engage with the pallet 50b. For instance, as shown in
Referring to
While exemplary embodiments illustrated herein describe three pairs of suction grippers, it should be noted that this is not limited by herein and other numbers of suction grippers may be employed. For example, there may be more or less than three pairs of suction grippers thereof.
Referring now to
As shown in
Referring now to
Each of sensors 40c, 40d, 40e are creating scanning paths that are recorded in three dimensions (i.e., x,y,z). In some implementations, sensors 40c, 40d, 40e on the robot head 30 provide a z-measurement and the robot head 30 itself provides the x and y coordinates as the robot head 30 moves across the stacked dunnage 50. For example, the scanning provides a z-measurement with sensor 40c, 40d, sensor 40e. The scanning algorithm looks through each sensor path to identify the edge point of the dunnage 50, generating three coordinates in three dimensions that can compute a fourth dimensional pick point. It should be appreciated that the type of dunnage also contributes to the computation of the pick point. Hence, the present invention describes features and advantages that are for precision picking and placement of each dunnage.
While exemplary embodiments illustrated herein describe a pair of sensors 40, it should be noted that this is not limited by herein and other numbers of sensors may be employed. For example, there may be more than one pair of sensors 40 thereof. It should further be appreciated that the sensors 40 can be a device including at least a light source, a receiver, a signal converter, an amplifier, and an output, and will not be described in detail. It should further be appreciated that other sensors may be employed, such as, but not limited to, inductive, capacitive, magnetic and/or ultrasonic sensors.
Once the sensors 40 detect the type of dunnage (i.e., slip sheet, top frame, or pallet), the system 10 selects the appropriate grippers (e.g., 31, 32, 33) for engagement and transports the dunnage to the respective stacking area. For example, when a top frame 50a is detected, the system 10 controls the plurality of grippers 31 to engage and transports the top frame 50a to stacking area 51, as shown in
Referring to
In some implementations, a debris removal device (not shown) can be employed to remove and clean the surface of the slip sheet 50c in the staging area 63. For instance, the debris removal device can be a mechanism that is located on or adjacent to the conveying table 60 that tilts or lifts up the slip sheet 50c and cleans any debris using pressurized air. This ensures that the slip sheet 50c is free of debris prior to entering the inspection area 61 of table 60, for proper reading by the inspection device 70.
It is to be understood that the operation and movement of associated components, including the guide rails 66 and/or the pushing plate 68 can be controlled by a processor or control device or controller 105 (
In some implementations, the inspection device 70 can be a vision camera for inspecting the surface of the slip sheet 50c. When the inspection device 70 detects any anomalies or defects on the slip sheet 50c, the system 10 will transport the defected slip sheet 50c to a ‘failed’ stacked area 74 (
Referring to
The stacker 80 further includes an arm 83 extending from the elongated support 81 and supporting a stacker head 84 at a distal end thereof. The head 84 contains a plurality of suction grippers 85 for engaging slip sheets 50c. In one implementation, as shown in
In some implementations, the arm 83 of the stacker 80 can be further configured to move in a vertical direction (i.e., up-and-down) along the elongated support 81 in order to engage the slip sheet 50c. Some instances of the vertical movement include the function to retrieve the slip sheet 50c from the inspection area 61 of the table 60, place the slip sheet 50c into the stacking tray 76, or place the slip sheet 50c into the ‘failed’ stacked area 74.
While the example embodiments described herein relates to a rotary stacker, it should be understood that other types of stackers can be employed, such as, but not limited to, a linear stacker, a servo stacker, an electric stacker, a counterbalance stacker, a ride-on stacker, a manual stacker.
It is to be understood that the operation and movements of associated components of the stacker 80 is controlled by a microprocessor or control unit or controller 105 (
The sensor 40 is configured to measure a distance to a surface of the dunnage for determining a type of dunnage. In one example, the sensor 40 is a photoelectric sensor (or a photoeye sensor) that detects a change in light intensity by using laser scanners to measure a depth of various points in an image with infrared light, for example. This depth can be associated as the measured distance, which can be measured from the sensor 40 to the surface of the dunnage. In one implementation, the sensor 40 can include a light emitter 113 that produces the light to bounce off a targeted item and returned to a light receiver 115. Based on a time difference, via a timer (not shown), between the emission of the light and its return to the light receiver 115 after being reflected by the targeted item, the sensor 40 is able to measure the distance between the surface of the dunnage and the sensor 40. For example, the controller 105, via the sensor 40, can determine that the dunnage is either a slip sheet in response to the sensor 40 detecting a constant time (i.e., constant surface), a top frame in response to the sensor 40 detecting a substantial timing deviation near an end of the dunnage, or a pallet in response to the sensor 40 detecting multiple timing deviations of the dunnage.
In other implementations, the sensor 40 can use travel-time to determine distance (or depth), such as, for example, time pulses or phase shift of an amplitude modulated wave. This measured distance is then communicated to the computing system 105 to be process, which will be described herein.
The camera 70 is configured to inspect the surface of a slip sheet 50c. When the camera 70 detects any anomalies or defects on the slip sheet 50c, the computing system 105 will provide instructions to transport the defected slip sheet to a ‘failed’ stacked area 74. Such defects can include chips, cracks, dents, wrinkles, punctures, tears, blisters, foreign inclusions, etc. on the slip sheet 50c. However, when the camera 70 does not detect any defects, the computing system 105 will provide instructions to transport the slip sheet to a slip sheet stacking tray 76.
The computing system 105 provides control instructions to be executed by the motor controller 120 which controls a motor(s) (not shown) for operating the robot 20, the robot head 30 and/or the grippers 31, 32, 33. The control instructions may be individually configured for each component. In one implementation, the control instructions provide instructions to a position module 122 and a gripper module 124 of the motor controller 120. For example, the position module 122 determines a position(s) of a rotary axis (e.g., 22) and a cantilevered arm (e.g., 23), creating a multi-axis robot with five axes of motion (i.e., an anthropomorphic robotic device). The position module 122 may also determine a position(s) of the robot head 30 for proper alignment above the stacked dunnage 50 and placement of the grabbed dunnage to its respective area. The gripper module 124 may determine which grippers (e.g., 31, 32, 33) to operate based on the determined type of dunnage and its position(s) thereof. For example, gripper module 124 controls and operates grippers 31 when a top frame 50a is determined, controls and operates grippers 32 when a pallet 50b is determined, and controls and operates grippers 33 when a slip sheet 50c is determined.
The motor controller 120 includes a processing system 125 and a storage 126. The storage 126 may house software, such as control software to execute control instructions for managing the movement system and/or the sensor 40. For example, the control functionality of the motor controller 120 may be programmable, such as programmable via the computing system 105. Control software stored in the storage 126 of the motor controller 120 is executable by the processor 126 in order to carry out certain aspects of the dunnage management methods and system controls described herein.
The computing system 105 further provides control instructions to be executed by the motor controller 140 which controls a motor(s) (not shown) for operating the rotary stacker 80. In one implementation, the control instructions provide instructions to a position module 142 to control movement of the rotary stacker 80 and a gripper module 143 of the motor controller 140. For instance, the position module 142 determines and operates a position(s) of a rotary arm 83 with respect to an elongated support 81. As an example, the position module 142 provides instructions to the rotary arm 83 to move in a vertical direction to engage the dunnage (i.e., slip sheet). The position module 142 also provides instructions to the rotary arm 83 to rotate in either direction to place the dunnage at its respective location. For example, the rotary arm is configured to rotates clockwise (e.g., 45 degrees) to transport the slip sheet to a failed’ stacked area 74 or counter-clockwise (e.g., 45 degrees) to transport the slip sheet to the stacking tray 76. The gripper module 143 provides instructions to the grippers (e.g., 85) to engage the slip sheet and release the slip sheet.
The motor controller 140 includes a processing system 144 and a storage 145. The storage 145 may house software, such as control software to execute control instructions for managing the movement system and/or the camera 70. For example, the control functionality of the motor controller 140 may be programmable, such as programmable via the computing system 105. Control software stored in the storage 145 of the motor controller 140 is executable by the processor 144 in order to carry out certain aspects of the dunnage management methods and system controls described herein.
The computing system 105 includes a processor 115 and a storage system 110. The storage system 110 includes software, including a dunnage type management module 111, and stored data 112, including data in database structure. The processor 115 loads and executes software, including the dunnage type management module 111, which is a software application stored in the storage system 110. The processor 115 can also access data stored in the database 112 in order to carry out the methods and control instructions described herein. Although the computing system 105 is depicted in
The storage system 110, which stores database 112, may comprise any storage media, or group of storage media, readable by processor 115, and capable of storing software and data. The storage system 110 can include volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules, or other data. As described above, storage system 110 may be implemented as a single storage device, but may also be implemented across multiple storage devices or subsystems located at disparate locations and communicatively connected, such as in a cloud computing system. Examples of storage media include random access memory, read only memory, optical discs, flash memory, virtual memory, and non-virtual memory, or any other medium which can be used to store the desired information and may be accessed by a processor 115.
The dunnage type management module 111 operates to control and produce the functionality of the dunnage management system 100. For example, the dunnage type management module 111 determines where to place the dunnage based on the type of dunnage measured by the sensor 40 in conjunction with analyzing information about which grippers to use. Additionally, the dunnage type management module 111 may access control instructions to a movement system, as described herein, and may transmit such program instructions from receiver/transmitter 121 to the motor controller 120 and/or receiver/transmitter 141 to the motor controller 140 for execution. Additionally, the dunnage type management module 111 may determine when a scanning by the sensor 40 should occur. For example, the dunnage type management module 111 may instruct scanning the dunnage once a position of the stack of dunnage is determined. For example, the dunnage management system 100 may include the sensor 40 that measures a distance from an edge of the stack of dunnage to the robot 20.
The dunnage type management module 111 may further determine which gripper to operate for manipulating the dunnage based on the type of dunnage detected by the sensor 40. Depending on the type of detected dunnage (i.e., a top frame, a pallet, or a slip sheet), the dunnage type management module 111 determines which grippers to use for engaging the dunnage. For example, gripper module 124 controls and operates grippers 31 when a top frame 50a is determined, controls and operates grippers 32 when a pallet 50b is determined, and controls and operates grippers 33 when a slip sheet 50c is determined.
Further, the computing system 105 includes a display device 150 in communication to display the information executed by the dunnage type management module 111. The display device 150 may be a display on a device, such as a computer monitor, a laptop, a television, a smart phone, etc.
The aspects and embodiments of the invention can be used alone or in combinations with other systems and methods. For example, the aspects and embodiments of this invention can be added to a bulk palletizer, more specifically, to a back of the bulk palletizer. This enables operators to load a single stack of unsorted dunnage instead of loading in three sorted, organized stacks.
In the description of the present application, it is to be noted that terms such as “mounted”, “joined”, and “connected” are to be understood in a broad sense unless otherwise expressly specified and limited. For example, the term “connected” may refer to “securely connected” or “detachably connected”; may refer to “mechanically connected” or “electrically connected”; or may refer to “connected directly”, “connected indirectly through an intermediary”, or “connected in two components”. For those of ordinary skill in the art, the specific meanings of the preceding terms in the present application may be understood based on specific situations.
The articles “a” and “an,” as used herein, mean one or more when applied to any feature in embodiments of the present disclosure described in the specification and claims. The use of “a” and “an” does not limit the meaning to a single feature unless such a limit is specifically stated. The article “the” preceding singular or plural nouns or noun phrases denotes a particular specified feature or particular specified features and may have a singular or plural connotation depending upon the context in which it is used. The adjective “any” means one, some, or all indiscriminately of whatever quantity.
“At least one,” as used herein, means one or more and thus includes individual components as well as mixtures/combinations.
The transitional terms “comprising”, “consisting essentially of” and “consisting of”, when used in the appended claims, in original and amended form, define the claim scope with respect to what unrecited additional claim elements or steps, if any, are excluded from the scope of the claim(s). The term “comprising” is intended to be inclusive or open-ended and does not exclude any additional, unrecited element, method, step or material. The term “consisting of” excludes any element, step or material other than those specified in the claim and, in the latter instance, impurities ordinarily associated with the specified material(s). The term “consisting essentially of” limits the scope of a claim to the specified elements, steps or material(s) and those that do not materially affect the basic and novel characteristic(s) of the claimed disclosure. All materials and methods described herein that embody the present disclosure can, in alternate embodiments, be more specifically defined by any of the transitional terms “comprising,” “consisting essentially of,” and “consisting of.”
Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It will be understood that, if an element is referred to as being “connected” or “coupled” to another element, it can be directly connected, or coupled, to the other element or intervening elements may be present. In contrast, if an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.).
Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper” and the like) may be used herein for ease of description to describe one element or a relationship between a feature and another element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, for example, the term “below” can encompass both an orientation that is above, as well as, below. The device may be otherwise oriented (rotated 90 degrees or viewed or referenced at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.
Example embodiments are described herein with reference to cross-sectional illustrations that are schematic illustrations of idealized embodiments (and intermediate structures). As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, may be expected. Thus, example embodiments should not be construed as limited to the particular shapes of regions illustrated herein but may include deviations in shapes that result, for example, from manufacturing.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
While the disclosure has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
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