Material handling apparatus for delivering or retrieving items
A method and apparatus are provided for sorting or retrieving items to/from a plurality of destinations areas. The items are loaded onto one of a plurality of independently controlled delivery vehicles. The delivery vehicles follow a track that guides the delivery vehicles to/from the destination areas, which are positioned along the track. Once at the appropriate destination area, an item is transferred between the delivery vehicle and the destination area.
1. A delivery vehicle operable with a material handling system having a plurality of destination areas and a guide system, wherein the delivery vehicle comprises:
a transfer mechanism for transferring an item onto or off the vehicle, wherein the transfer mechanism has a support surface configured to support the item when the item is on the vehicle;
a pair of opposing walls spaced apart from one another so that the support surface is between the opposing walls with the walls projecting upwardly relative to the support surface, wherein the opposing walls are positioned to form a first opening to facilitate transfer of items onto the support surface through the first opening, and wherein the opposing walls form a second opening to facilitate transfer of items onto the support surface through the second opening;
a drive system cooperable with the guide system to guide the vehicle to the destination areas,
a motor for driving the drive system;
an electric storage element for storing electricity and providing power to the transfer mechanism and the motor; and
a controller for receiving signals for controlling the motor and the transfer mechanism to control the movement of the vehicles along the guide system and to control transfer of items onto and off of the vehicles.
2. The delivery vehicle of claim 1 wherein the drive system is configured to maintain the orientation of the vehicle relative to the horizon as the vehicle changes from a horizontal direction of travel to a vertical direction of travel.
3. The delivery vehicle of claim 1 wherein the transfer mechanism is operable in a first direction to transfer items from the support surface through the first opening and wherein the transfer mechanism is operable in a second direction opposite the first direction to transfer items from the support surface through the second opening.
4. The delivery vehicle of claim 1 wherein the electric storage element comprises a rechargeable power source for powering the motor and the delivery vehicle comprises an electrical contact for contacting a charging rail along the guide system to recharge the rechargeable power source as the vehicle travels along the guide system to deliver an item.
5. The delivery vehicle of claim 1 wherein the delivery vehicle is configured to follow the guide system in first and second directions that are transverse one another and wherein the transfer mechanism is operable to displace items in a third direction that is transverse the first and second directions.
6. The delivery vehicle of claim 1 comprising a load sensor for detecting that an item is loaded onto the support surface.
7. The delivery vehicle of claim 6 wherein the load sensor comprises a pair of detectors wherein each of the detectors is operable to detect the presence of the item at a point along the support surface.
8. The delivery vehicle of claim 7 wherein the pair of detectors comprise a first sensor operable to detect a leading edge of the item when the item is moved in a first direction and a second sensor operable to detect a trailing edge of the item.
9. The delivery vehicle of claim 1 wherein the transfer mechanism comprises a conveyor belt.
10. A delivery vehicle operable with a material handling system having a plurality of destination areas, wherein the delivery vehicle comprises:
a drive system for driving the vehicle to one of the destination areas;
a motor for driving the drive system; and
a controller for receiving signals for controlling the motor to control the movement of the vehicle;
a transfer mechanism for transferring items between the vehicle and the destination areas wherein the transfer mechanism comprises a surface for receiving an item to be conveyed to one of the destination areas; and
a pair of opposing walls extending upwardly relative to the surface and spaced apart from one another so that at least a portion of the surface is between the opposing walls, wherein the opposing walls are dimensioned and arranged to facilitate transfer of items off the surface at a first end of the surface and to facilitate transfer of items off the surface at a second end of the surface.
11. The vehicle of claim 10 wherein the transfer mechanism comprises one or more conveyor belts and the surface comprises an upper surface of the one or more conveyor belts.
12. The vehicle of claim 10 wherein the transfer mechanism is operable in a first direction to transfer items off the surface at the first end and wherein the transfer mechanism is operable in a second direction opposite the first direction to transfer items off the surface at the second end.
13. The vehicle of claim 12 wherein the vehicle is configured to follow a guide system in first and second guide directions that are transverse one another and wherein the transfer mechanism is operable to displace items in a third direction that is transverse the first and second guide directions.
14. The vehicle of claim 10 wherein the surface is substantially horizontal.
15. A delivery vehicle operable with a material handling system having a plurality of destination areas and a guide system, wherein the delivery vehicle comprises:
a transfer mechanism for transferring items between the vehicle and the destination areas wherein the transfer mechanism comprises a platform for receiving an item to be conveyed to one of the destination areas;
a first wall projecting upwardly along a first side of the platform;
a second wall projecting upwardly along a second side of the platform, wherein the second wall is spaced apart from the first wall so that a first transfer opening is formed between the first and second walls at a third side of the platform and a second transfer opening is formed between the first and second walls along a fourth side of the platform, wherein the first and second transfer openings are configured to facilitate transfer of items onto and off of the platform through the first and second transfer openings;
a drive system cooperable with the guide system to guide the vehicle to one of the destination areas, wherein the drive system is configured to maintain the orientation of the vehicle relative to the horizon as the vehicle changes from a horizontal direction of travel to a vertical direction of travel;
a motor for driving the drive system; and
a controller for receiving signals for controlling the motor to control the movement of the vehicles along the guide system.
16. The vehicle of claim 15 wherein the transfer mechanism comprises one or more conveyor belts that form at least a portion of the platform.
17. The vehicle of claim 15 wherein the platform is substantially horizontal.
18. The vehicle of claim 14 wherein the transfer mechanism is operable in a first direction to transfer items off the platform through the first transfer opening and wherein the transfer mechanism is operable in a second direction opposite the first direction to transfer items off the platform through the second transfer opening.
19. The vehicle of claim 18 wherein the vehicle is configured to follow the guide system in first and second guide directions that are transverse one another and wherein the transfer mechanism is operable to displace items in a third direction that is transverse the first and second guide directions.