Merry-go-round storage conveyor system
Conventional automated fulfillment systems require complex technology, such as robots and autonomous guided vehicles. Accordingly, embodiments are disclosed for a conveyor system that can perform automated fulfillment with the simplicity of conveyor technologies. The conveyor system may comprise a plurality of concentric, circular, nested conveyors or parallel linear conveyors that each comprises a plurality of segments. The conveyor system may also comprise a chute along a radial or orthogonal axis. Each conveyor is configured to move, such that each segment of the conveyor is movable into the chute. A chute mechanism may be configured to move items in and/or out of a chute. Thus, for example, a control system may move items, stowed on the conveyors, into the chute, and utilize the chute mechanism to move all of these items out of the chute and off of the conveyor system with a single sweep operation.
1 . A conveyor system comprising:
a plurality of nested conveyors, wherein each of the plurality of nested conveyors comprises a circular disk that is concentric around a central axis, wherein the circular disk comprises a plurality of segments that are each configured to hold at least one item on a top surface;
a stationary circumferential wall between each adjacent pair of the plurality of nested conveyors, wherein each circumferential wall comprises a gap along the radial axis;
a chute along at least one radial axis that is orthogonal to the central axis, wherein each of the plurality of nested conveyors is configured to rotate around the central axis, such that each of the plurality of segments in the circular disk of each of the plurality of nested conveyors is rotatable into the chute;
a chute mechanism configured to radially move items, along the radial axis, across the top surfaces of all of the plurality of segments that are in the chute; and
at least one hardware processor configured to,
receive a list of one or more items stowed on the plurality of nested conveyors,
for each of the one or more items in the list, rotate a segment that is holding that item into the chute, and
control the chute mechanism to, in a single operation, move all items that are held by segments in the chute out of the chute.
2 . The conveyor system of claim 1 , wherein each of the plurality of segments of each of the plurality of nested conveyors has a same width, and wherein each gap has the same width.
3 . The conveyor system of claim 1 , wherein the at least one hardware processor is further configured to:
receive a list of one or more items held on the plurality of segments that are in the chute;
identify a location at which to stow each of the one or more items held on the plurality of segments that are in the chute; and
rotate a segment that is holding one of the one or more items, held on the plurality of segments that are in the chute, out of the chute to the identified location for that one item.
4 . The conveyor system of claim 1 , wherein the at least one hardware processor is further configured to maintain, in each of the plurality of nested conveyors, at least one empty segment that is rotatable into the chute, such that the at least one hardware processor can always clear the chute by rotating the at least one empty segment in all of the plurality of nested conveyors into the chute.
5 . The conveyor system of claim 1 , wherein each of the plurality of nested conveyors comprises, for each of the plurality of segments in the circular disk of the nested conveyor, a pair of fixed radial walls bounding that segment.
6 . The conveyor system of claim 5 , wherein in each pair of fixed radial walls, the radial walls are parallel to each other.
7 . The conveyor system of claim 6 , wherein the radial walls for each of the plurality of segments in each of the plurality of nested conveyors are spaced apart by a same distance, such that the radial walls of all segments within the chute align with each other to form a pair of parallel walls defining radial boundaries of the chute.
8 . The conveyor system of claim 1 , wherein the at least one hardware processor is further configured to independently control each of the plurality of nested conveyors to rotate independently from each other.
9 . The conveyor system of claim 8 , wherein each of the plurality of nested conveyors is configured to rotate in two directions.
10 . The conveyor system of claim 9 , wherein the at least one hardware processor is further configured to determine in which of the two directions to rotate each of the plurality of nested conveyors so as to minimize movement.
11 . The conveyor system of claim 1 , further comprising a central component that is encircled by the plurality of nested conveyors, wherein the central component comprises a central segment that is configured to hold at least one item on a top surface, and wherein the chute extends across an entire diameter of the plurality of nested conveyors and includes the central segment.
12 . A coordinated system comprising at least one level that includes a plurality of the conveyor system of claim 11 , arranged side-by-side, such that the top surface of each of the plurality of segments in each of the plurality of conveyor systems is in a same plane.
13 . The coordinated system of claim 12 , wherein the at least one level comprises a plurality of levels arranged along an axis that is orthogonal to the plane.
14 . The coordinated system of claim 12 , wherein the chute in each of the plurality of conveyor systems is aligned with the chute in at least one adjacent one of the plurality of conveyor systems to form a composite chute that extends across two or more of the plurality of conveyor systems in the at least one level.
15 . The coordinated system of claim 14 , wherein the central component in each of the plurality of conveyor systems is configured to rotate, and wherein the at least one hardware processor in each of the plurality of conveyor systems is configured to rotate the central component in that conveyor system to thereby change a direction of the chute in that conveyor system.
16 . An enclosure that encloses the coordinated system of claim 14 , wherein the composite chute extends across all of the plurality of conveyor systems in the at least one level, and wherein the enclosure comprises a port at one end of the composite chute.
17 . The enclosure of claim 16 , wherein the enclosure is a portion of a delivery vehicle.
18 . A conveyor system comprising:
a plurality of nested conveyors, wherein each of the plurality of nested conveyors comprises a circular disk that is concentric around a central axis, wherein the circular disk comprises a plurality of segments that are each configured to hold at least one item on a top surface, wherein the top surface of each of the plurality of segments in each of the plurality of nested conveyors is textured;
a chute along at least one radial axis that is orthogonal to the central axis, wherein each of the plurality of nested conveyors is configured to rotate around the central axis, such that each of the plurality of segments in the circular disk of each of the plurality of nested conveyors is rotatable into the chute;
a chute mechanism configured to radially move items, along the radial axis, across the top surfaces of all of the plurality of segments that are in the chute; and
at least one hardware processor configured to,
receive a list of one or more items stowed on the plurality of nested conveyors,
for each item in the list, rotate a segment that is holding that item into the chute, and
control the chute mechanism to, in a single operation, move all items that are held by segments in the chute out of the chute.
19 . The conveyor system of claim 18 , further comprising a stationary circumferential wall between each adjacent pair of the plurality of nested conveyors, wherein each circumferential wall comprises a gap along the radial axis.
20 . A method comprising using at least one hardware processor, within a conveyor system that comprises a plurality of nested conveyors, each of the plurality of nested conveyors comprising a circular disk that is concentric around a central axis, the circular disk comprising a plurality of segments that are each configured to hold at least one item on a top surface, a stationary circumferential wall between each adjacent pair of the plurality of nested conveyors, wherein each circumferential wall comprises a gap along the radial axis, a chute along at least one radial axis that is orthogonal to the central axis, each of the plurality of nested conveyors configured to rotate around the central axis, such that each of the plurality of segments in the circular disk of each of the plurality of nested conveyors is rotatable into the chute, and a chute mechanism configured to radially move items, along the radial axis, across the top surfaces of all of the plurality of segments that are in the chute, to:
receive a list of one or more of the items stowed on the plurality of nested conveyors;
for each of the one or more items in the list, rotate a segment that is holding that item into the chute; and
control the chute mechanism to, in a single operation, move all items that are held by segments in the chute out of the chute.
21 . A conveyor system comprising:
a plurality of parallel linear conveyors, wherein each of the plurality of parallel linear conveyors comprises a plurality of segments along a longitudinal axis of that parallel linear conveyor, and wherein each of the plurality of segments is configured to hold at least one item on a top surface;
one or more chutes along an orthogonal axis that is orthogonal to the longitudinal axis of each of the plurality of parallel linear conveyors, wherein each of the plurality of parallel linear conveyors is configured to move along the respective longitudinal axis, such that each of the plurality of segments of the parallel linear conveyor is movable into at least one of the one or more chutes;
a stationary circumferential wall between each adjacent pair of the plurality of parallel linear conveyors, wherein each circumferential wall comprises a gap along the orthogonal axis of each of the one or more chutes;
a chute mechanism configured to orthogonally move items, along the orthogonal axis, across the top surfaces of all of the plurality of segments that are in the at least one chute; and
at least one hardware processor configured to,
receive a list of one or more items stowed on the plurality of parallel linear conveyors,
for each of the one or more items in the list, move a segment that is holding that item into the chute, and
control the chute mechanism to, in a single operation, move all items that are held by segments in the chute out of the chute.