Automated unloading system for package stacks
Automated unloading systems and methods may include a preparation subsystem and a transfer subsystem. A package stack may be loaded into the preparation subsystem to open or enable access to individual packages of the stack, and the opened stack may be rotated to an unloading position. Then, conveyance mechanisms of the transfer subsystem may cause automated unloading of individual packages of the opened stack, thereby improving the safety, speed, and efficiency of such package unloading processes.
1 . An automated unloading system, comprising:
a base configured to tilt between at least two positions, the base including a first portion comprising a preparation subsystem and a second portion comprising a transfer subsystem;
a frame configured to slide within the base between the preparation subsystem and the transfer subsystem, the frame configured to receive a stack of packages at the preparation subsystem;
the preparation subsystem including at least one element configured to enable access to the stack of packages; and
the transfer subsystem including a plurality of belts configured to unload individual packages from the stack;
wherein the preparation subsystem enables access to the stack when the base is in a first position;
wherein the transfer subsystem unloads individual packages from the stack when the base is in a second position; and
wherein in the second position, each of the base and the frame includes respective open sides that are aligned with each other, and the plurality of belts of the transfer subsystem are aligned with and extend along the respective open sides of the base and the frame.
2 . The automated unloading system of claim 1 , further comprising:
a slide mechanism operatively coupled between the base and frame, and configured to slide the frame within the base between the preparation subsystem and the transfer subsystem.
3 . The automated unloading system of claim 1 , further comprising:
a tilt mechanism associated with the base and configured to tilt the base between the at least two positions.
4 . The automated unloading system of claim 1 , wherein the first position is an opening position that is rotated in a first direction relative to an upright, nominal position.
5 . The automated unloading system of claim 1 , wherein the second position is an unloading position that is rotated in a second direction relative to the upright, nominal position, the second direction being opposite of the first direction.
6 . A system, comprising:
a base configured to rotate between at least two positions;
a frame positioned within the base, the frame configured to receive a stack of packages; and
a transfer subsystem including at least one conveyance mechanism configured to unload individual packages from the stack;
wherein in an unloading position, each of the base and the frame includes respective open sides that are aligned with each other, and the at least one conveyance mechanism of the transfer subsystem is aligned with and extends along the respective open sides of the base and the frame.
7 . The system of claim 6 , wherein each of the base and the frame includes a floor, three closed sides, and the respective open side.
8 . The system of claim 6 , wherein the at least two positions of the base includes at least two of a nominal position, an opening position, and the unloading position.
9 . The system of claim 6 , further comprising:
a tilt mechanism associated with the base and configured to rotate the base between the at least two positions;
wherein the tilt mechanism includes at least one of a rotary actuator, linear actuator, pneumatic actuator, pulley, servo, or rack and pinion mechanism.
10 . The system of claim 6 , further comprising:
a preparation subsystem including an element configured to enable access to individual packages of the stack;
wherein the element includes at least one of an actuator, hinge, slide, or cutter.
11 . The system of claim 10 , wherein the preparation subsystem enables access to the stack of packages when the base is rotated to an opening position.
12 . The system of claim 10 , further comprising:
a slide mechanism operatively coupled between the base and the frame, and configured to slide the frame within the base between the preparation subsystem and the transfer subsystem;
wherein the slide mechanism comprises at least one of a linear actuator, rotary actuator, pneumatic actuator, pulley, servo, screw drive mechanism, rack and pinion mechanism, belt, conveyor, roller, wheel, robotic drive unit, or automated guided vehicle.
13 . The system of claim 6 , wherein the at least one conveyance mechanism of the transfer subsystem comprises a plurality of belts, conveyors, sorters, rollers, or wheels configured to cause unloading of individual packages from the stack.
14 . The system of claim 13 , wherein at least some of the plurality of belts, conveyors, sorters, rollers, or wheels are actuated at selected speeds, directions, or sequences to cause unloading of individual packages from the stack.
15 . The system of claim 6 , wherein the transfer subsystem unloads individual packages from the stack when the base is rotated to the unloading position.
16 . The system of claim 6 , further comprising:
at least one of a curtain or a crossbar associated with an upper portion of the base and configured to prevent uncontrolled unloading of individual packages from the stack.
17 . A method, comprising:
loading a stack of packages to a frame, the frame positioned within a base of an automated unloading system;
rotating, via a tilt mechanism associated with the base, the stack of packages to an unloading position; and
causing, via at least one conveyance mechanism of a transfer subsystem of the automated unloading system, unloading of individual packages from the stack;
wherein in the unloading position, each of the base and the frame includes respective open sides that are aligned with each other, and the at least one conveyance mechanism of the transfer subsystem is aligned with and extends along the respective open sides of the base and the frame.
18 . The method of claim 17 , further comprising:
rotating, via the tilt mechanism, the stack of packages to an opening position; and
enabling, via an element of a preparation subsystem of the automated unloading system, access to individual packages of the stack;
wherein rotating the stack to the opening position comprises rotating the base in a first direction relative to an upright, nominal position; and
wherein rotating the stack to the unloading position comprises rotating the base in a second direction relative to an upright, nominal position, the second direction being opposite of the first direction.
19 . The method of claim 18 , wherein enabling access comprises at least one of removing a plastic wrap around a pallet, opening a door or panel of a cart, or removing a side of a gaylord.
20 . The method of claim 18 , further comprising:
prior to rotating the stack to the unloading position, sliding, via a slide mechanism operatively coupled between the frame and the base of the automated unloading system, the stack of packages from the preparation subsystem to the transfer subsystem.