Material handling apparatus with delivery vehicles and recirculation

Abstract

A method and apparatus are provided for sorting items to a plurality of sort destinations. The items are fed into the apparatus at an input station having a scanning station. The scanning station evaluates one or more characteristics of each item. The items are then loaded onto one of a plurality of independently controlled delivery vehicles. The delivery vehicles are individually driven to sort destinations. Once at the appropriate sort destination, the delivery vehicle ejects the item to the sort destination and returns to receive another item to be delivered. A re-induction conveyor may be provided for receiving select items from the vehicles and conveying the items back to the input station for re-processing. Additionally, a controller is provided to control the movement of the vehicles based on a characteristic each item being delivered by each vehicle. The system may also include vehicles having edge-detection assemblies for detecting items being loaded onto or discharged from the vehicles.

1 . An apparatus for sorting a plurality of items, comprising:
 a plurality of sort destinations;   a plurality of delivery vehicles for delivering items to the sort destinations;   a controller for providing signals for controlling operation of the vehicles;   a database for storing a plurality of vehicle movement profiles;   wherein in response to a characteristic determined for an item the central controller retrieves a vehicle movement profile and wherein the central controller controls the movement of the vehicle in response to the retrieved vehicle movement profile   wherein the vehicle movement profile comprises one or more of the following: acceleration, deceleration and cornering speed.   
     
     
         2 . The apparatus of  claim 1  comprising a track system for guiding the delivery vehicles to the sort destinations, 
     
     
         3 . The apparatus of  claim 1  comprising a scanner for scanning the items to detect a characteristic of each item, wherein the detected characteristic is the characteristic determined for an item that the controller uses to retrieve a vehicle movement profile. 
     
     
         4 . The apparatus of  claim 1  wherein the detected characteristic is a product identification code for the item. 
     
     
         5 . The apparatus of  claim 2  wherein the detected characteristic is one of the length, width, height, weight or shape of the item. 
     
     
         6 . An apparatus for sorting a plurality of items, comprising:
 a plurality of sort destinations;   a plurality of delivery vehicles for delivering items to the sort destinations;   a controller for providing signals for controlling operation of one of the vehicle carrying one of the items to one of the sort destinations;   wherein in response to a characteristic determined for the item the central controller controls the operation of the vehicle so that the position of the vehicle relative to the sort destination varies in response to the determined characteristic.   
     
     
         7 . The apparatus of  claim 6  comprising a track system for guiding the delivery vehicles to the sort destinations. 
     
     
         8 . The apparatus of  claim 6  wherein the sort destination comprises an output bin having a rearward end through which the item is discharged into the output bin. 
     
     
         9 . The apparatus of  claim 8  wherein the output bin comprises an open rearward end. 
     
     
         10 . The apparatus of  claim 9  wherein the output bin comprises a displaceable or collapsible rearward wall. 
     
     
         11 . A method for sorting a plurality of items, comprising the steps of:
 loading an item onto a vehicle to be delivered to an output bin;   driving the vehicle to the output bin;   discharging the item from the vehicle into the output bin;   monitoring the position of the item on the vehicle;   controlling operation of the vehicle based on the step of monitoring the position of the item, wherein the step of controlling operation of the vehicle comprises controlling the vehicle to attempt to move the item to a desired location on the vehicle.   
     
     
         12 . The method of  claim 11  wherein the step of driving the vehicle comprises driving the vehicle along a guide. 
     
     
         13 . The method of  claim 11  wherein the guide comprises a surface and the vehicle comprises a rotatable element, wherein the step of driving a vehicle along a guide comprises driving the rotatable element along the surface of the guide. 
     
     
         14 . The method of  claim 11  wherein the step of driving the vehicle comprises driving the vehicle in a vertical direction. 
     
     
         15 . The method of  claim 11  wherein the step of controlling operation of the vehicle comprises controlling the acceleration or deceleration of the vehicle to control the position of the item on the vehicle. 
     
     
         16 . The method of  claim 11  wherein the step of controlling operation of the vehicle comprises driving a conveyor belt of the vehicle to displace the item on the vehicle. 
     
     
         17 . The method of  claim 11  wherein the step of monitoring the position of the item comprises continuously monitoring the position of the item on the vehicle as the vehicle travels to the output bin.