Parcel and article sorting system and method with destination container removal

Abstract

System includes an article supply location that includes a plurality of articles to be sorted, first and second transport vehicles, each having a first position in which an article is stowed about the vehicle and a second position in which the article is deposited into a proximal container, and one or more removal devices that transport the container to a location of further processing. System further includes a control system configured to receive an order for a plurality of disparate articles, determine one destination container of a plurality of destination containers to direct the transport vehicle to deposit a selected article, direct the first transport vehicle to transport a selected article to the destination container, deposit the article in the destination container, and transport the destination container to a location for further processing by manipulation of the removal device.

What is claimed is: 
     
         1 . A system comprising:
 a first article supply location, wherein the first article supply location includes a plurality of articles to be sorted that have been pulled from batched orders from a first location in a distribution center,   a second article supply location, wherein the second article supply location includes a plurality of articles to be sorted that have been pulled from batched orders from a second location in the distribution center,   wherein a product type of each article is determined by interacting with an information acquisition device at a respective first article supply location and second article supply location;   first and second computer-controlled transport vehicles, each vehicle having a first position in which a selected article is stowed about the vehicle and a second position in which the selected article is deposited into a proximal container by manipulating a support of the vehicle that carries the selected article and deposits the selected article when in the second position;   a first platform elevated from a first surface, wherein the first computer-controlled transport vehicle traverses the first platform and the selected articles are deposited into a destination container positioned about the first surface;   a removal device configured to relocate a destination container from a position about the first surface to a location designated for further processing of at least one article contained within the destination container;   a control system configured to:
 receive an order for a plurality of disparate articles, wherein the disparate articles are found within the first or second article supply location after the articles have been pulled from the distribution center; 
 determine a first destination container of a plurality of destination containers to direct a first transport vehicle to deposit a selected article from the first or second article supply location based on a determined product type, wherein the first destination container corresponds with an order for a first business; 
 direct the first transport vehicle to transport the selected article to the first destination container and deposit the selected article by manipulation of the first transport vehicle from the first position to the second position for deposit of the selected article in the first destination container; 
 determine a second destination container of a plurality of destination containers to direct a second transport vehicle to deposit another article from the first or second article supply location based on a determined product type, wherein the second destination container corresponds with an order for a second business; 
 direct the second transport vehicle to transport a disparate article to the second destination container and deposit the disparate article by manipulation of the second transport vehicle from the first position to the second position for deposit of the disparate article in the second destination container; 
 determine a location that the destination container is to be delivered to for further processing of at least one article in the destination container; 
 determine when all of the articles required to complete at least one of the orders has been deposited in the destination container; 
 direct the removal device to remove the destination container from the position proximal to the platform and transport it to the location of further processing. 
   
     
     
         2 . The system of  claim 1 , wherein the control system is configured to indicate when the destination container is full or when the destination container has been removed whereby the control system directs at least one of the first and the second transport vehicles to cease delivery of articles to a removed destination container location; and
 wherein the control system is further configured to indicate when an empty destination container is positioned proximal to the platform whereby the control system directs the at least one of the first and the second transport vehicles to resume delivery of articles to the empty destination container.   
     
     
         3 . The system of  claim 1 , wherein the removal device is configured to replace destination containers that are full or that contain complete orders with empty destination containers. 
     
     
         4 . The system of  claim 1 , wherein the location of further processing comprises one or more of packaging, gift wrapping, labeling, and assembly. 
     
     
         5 . The system of  claim 1 , wherein the removal device is fully automated or semi-automated. 
     
     
         6 . The system of  claim 1 , wherein the removal device is one of an automatic guided vehicle, an automated mobile robot, and a rail robot. 
     
     
         7 . The system of  claim 1 , wherein the system comprises a plurality of locations of further processing. 
     
     
         8 . The system of  claim 1 , wherein the determined product type of the selected article or the disparate article is determined by interacting with an identifier of the selected article or the disparate article with the information acquisition device, wherein the identifier is a UPC or other product code associated with the selected article or the disparate article. 
     
     
         9 . The system of  claim 1 , wherein the destination container is positioned proximal an opening in the first platform, wherein the control system is further configured to direct the first transport vehicle to traverse the first platform proximal the opening, then manipulate from the first position to the second position to deposit the selected article or the disparate article into the destination container through the opening in the first platform. 
     
     
         10 . The system of  claim 1 , wherein each of the first transport vehicle and the second transport vehicle is configured to carry a respective single selected article at a time. 
     
     
         11 . The system of  claim 1 , further comprising a plurality of additional transport vehicles. 
     
     
         12 . The system of  claim 1 , wherein the control system is further configured to direct the first transport vehicle to return to a position proximal the first article supply location, wherein the first transport vehicle is configured to be in the first position upon being positioned proximal the first article supply location. 
     
     
         13 . The system of  claim 1 , wherein the control system is configured to direct a plurality of additional transport vehicles, wherein the control system is further configured to direct the plurality of additional transport vehicles such that the plurality of additional transport vehicles do not collide with one another. 
     
     
         14 . The system of  claim 1 , wherein the control system is configured to direct a plurality of additional removal devices, wherein the control system is further configured to direct the plurality of additional removal devices such that the plurality of additional removal devices does not collide with one another. 
     
     
         15 . A control system configured for use with material handling of a plurality of articles, the control system comprising a memory and a processor, the control system configured to:
 receive a plurality of orders for a plurality of disparate articles;   batch the plurality of orders over a period of time, wherein the plurality of disparate articles are received from a first article supply location that has been pulled from batched orders from a first location in a distribution center and from a second article supply location that has been pulled from batched orders from a second location in the distribution center;   interact with an identifier affixed to a selected article or packaging associated with the selected article to determine a product type of the selected article at the first article supply location or the second article supply location;   determine one destination container of a plurality of destination containers to deposit, with a transport vehicle, the selected article, wherein the destination container is determined based on at least one of the orders and a determined product type of the selected article;   direct a first transport vehicle to transport the selected article to the one destination container and deposit the selected article by manipulation of the first transport vehicle from a first position to a second position for deposit of the selected article in the one destination container;   determine another destination container of a plurality of destination containers to deposit, with a transport vehicle, a disparate selected article, wherein the another destination container is determined based on at least one of the orders and a determined product type of the disparate selected article;   direct a second transport vehicle to transport the disparate selected article to the another destination container and deposit the disparate selected article by manipulation of the second transport vehicle from the first position to the second position for deposit of the disparate selected article in the another destination container;   determine a location that the destination container is to be delivered to for further processing of at least one article in the destination container;   determine when all of the articles required to complete at least one order have been deposited into the destination container; and   direct a removal device to remove the destination container from a position proximal to a platform and transport it to the location of further processing.   
     
     
         16 . A system comprising:
 a first article supply location, wherein the first article supply location includes a plurality of articles to be sorted that have been pulled from batched orders from a first location in a distribution center;   a second article supply location, wherein the second article supply location includes a plurality of articles to be sorted that have been pulled from batched orders from a second location in the distribution center;   wherein a product type of each article is determined by interacting with an information acquisition device at a respective first article supply location and second article supply location;   a platform assembly that includes:
 a platform elevated from a proximal surface, wherein the platform defines an opening and a destination container that is positioned proximal the opening in the platform or proximal a location at an edge of the platform; 
   first and second computer-controlled transport vehicles, each transport vehicle having a first position in which a selected article is stowed about a transport vehicle and a second position in which the selected article is deposited into a proximal container by manipulating a support of the vehicle that carried the selected article and deposits the selected article when in the second position;   wherein each transport vehicle traverses the platform and positions proximal the opening to deposit the selected article in the destination container by manipulation from the first position to the second position;   a removal device configured to relocate the destination container from a position about the proximal surface to a location designated for further processing of at least one articles contained within a designation container;   a control system configured to:
 receive an order for a plurality of disparate articles, wherein the disparate articles are found within the first and second article supply location after the articles have been sorted and pulled at the distribution center; 
 determine a first destination container of a plurality of receiving destination containers to direct a first transport vehicle to deposit the selected article from the first or second article supply location based on a determined product type, wherein the first destination container corresponds with an order for a first business; 
 direct the first transport vehicle to transport the selected article to the first destination container and deposit the selected article by manipulation of the support of the first transport vehicle from the first position to the second position for deposit of the selected article in the first destination container; 
 determine a second destination container of a plurality of destination containers to direct a second transport vehicle to deposit a disparate selected article from the first or second article supply location based on a determined product type, wherein the second destination container corresponds with an order for a second business; 
 direct the second transport vehicle to transport the disparate selected article to the destination container and deposit the disparate selected article by manipulation of the support of the second transport vehicle from the first position to the second position for deposit of the disparate selected article in the destination container; 
 determine when all articles required to complete at least one order for purchase have been deposited in the destination container; 
 determine a location that the destination container is to be delivered to for further processing of at least one article in the container; 
 direct the removal device to remove the destination container from the position proximal to the platform and transport it to the location of further processing. 
   
     
     
         17 . The system of  claim 16 , wherein the control system is configured to direct the first transport vehicle to return to a position proximal the first article supply location, wherein the first transport vehicle is configured to be in the first position upon being positioned proximal the first article supply location. 
     
     
         18 . A system comprising:
 an article supply location;   a computer-controlled transport vehicle;   a removal device configured to relocate a destination container to a processing location designated for further processing of at least one article contained within the destination container;   a control system configured to:
 determine a destination container to direct the transport vehicle to deposit a selected article from the article supply location, wherein the destination container corresponds with a customer order; 
 direct the transport vehicle to transport the selected article to the destination container and deposit the selected article by manipulation of the transport vehicle from a first position to a second position for deposit of the selected article in the destination container; 
 determine a processing location that the destination container is to be delivered to for further processing of at least one article in the destination container; 
 direct the removal device to transport the destination container to the processing location for further processing. 
   
     
     
         19 . A system comprising:
 an article supply location, wherein the article supply location includes a plurality of articles to be sorted that have been pulled from batched orders from a location in a distribution center;   a computer-controlled transport vehicle having a first position in which a selected article is stowed about the vehicle and a second position in which the selected article is deposited into a proximal container by manipulating a support of the vehicle that carries the selected article and deposits the selected article when in the second position;   a removal device configured to relocate a destination container to a processing location designated for further processing of at least one article contained within the destination container;   a control system configured to:
 receive an order for a plurality of disparate articles, wherein the disparate articles are found within the article supply location after the articles have been pulled from the distribution center; 
 determine a destination container to direct the transport vehicle to deposit a selected article from the article supply location, wherein the destination container corresponds with a shipping order; 
 direct the transport vehicle to transport the selected article to the destination container and deposit the selected article by manipulation of the transport vehicle from the first position to the second position for deposit of the selected article in the destination container; 
 determine a processing location that the destination container is to be delivered to for further processing of at least one article in the destination container; 
 direct the removal device to transport the destination container to the processing location for further processing. 
   
     
     
         20 . A system comprising:
 an article supply location, wherein the article supply location includes a plurality of articles to be sorted that have been pulled from batched orders from a location in a distribution center;   wherein a product type of each article is determined by interacting with an information acquisition device at the first article supply location;   a computer-controlled transport vehicle having a first position in which a selected article is stowed about the vehicle and a second position in which the selected article is deposited into a proximal container by manipulating a support of the vehicle that carries the selected article and deposits the selected article when in the second position;   a removal device configured to relocate a destination container from a filling location to a processing location designated for further processing of at least one article contained within the destination container;   a control system configured to:
 receive an order for a plurality of disparate articles, wherein the disparate articles are found within the article supply location after the articles have been pulled from the distribution center; 
 determine a destination container of a plurality of destination containers to direct a transport vehicle to deposit a selected article from the article supply location based on a determined product type, wherein the destination container corresponds with an order for a first business; 
 direct the transport vehicle to transport the selected article to the destination container and deposit the selected article by manipulation of the transport vehicle from the first position to the second position for deposit of the selected article in the destination container; 
 determine a processing location that the destination container is to be delivered to for further processing of at least one article in the destination container; 
 determine when all of the articles required to complete at least one of the orders has been deposited in the destination container; 
 direct the removal device to remove the destination container from the filling location and transport it to the processing location of further processing.