Systems and methods for processing objects including space efficient distribution stations and automated output processing
A space efficient automated processing system for processing objects is disclosed. The processing system includes an input conveyance system for moving objects from an input area in at least an input conveyance vector that includes an input conveyance horizontal direction component and an input conveyance vertical direction component, a perception system for receiving objects from the input conveyance system and for providing perception data regarding an object, a primary transport system for receiving the object from the perception system and for providing transport of the object along at least a primary transport vector including an primary transport horizontal component and a primary transport vertical component that is generally opposite the input conveyance horizontal direction component, and at least two secondary transport systems, each of which receives the object from the primary transport system and moves the object in either of reciprocal directions.
1 . A conveyor system, comprising:
a buffer conveyor including a front side and a back side, the buffer conveyor configured to receive a plurality of containers, the plurality of containers biased to an end of the buffer conveyor,
an output conveyor adjacent the buffer conveyor on the front side;
a track adjacent the buffer conveyor on the back side; and
a box kicker on the track and movable over the track length, the box kicker including a displacement mechanism; wherein the box kicker is aligned on the track to one of the plurality of containers, and the displacement mechanism ejects the one of the plurality of containers onto the output conveyor.
2 . The conveyor system according to claim 1 , wherein the displacement mechanism comprises a rotatable arm, the rotatable arm including a roller at a distal end.
3 . The conveyor system according to claim 1 , wherein the buffer conveyor and the output conveyor are coplanar.
4 . The conveyor system according to claim 1 , further comprising a transition roller between the buffer conveyor and the output conveyor, the orientation of the transition roller being perpendicular to a direction of the buffer conveyor, the transition roller activated to pull the one of a plurality of containers onto the output conveyor as the one of the plurality of containers is ejected by the rotatable arm.
5 . The conveyor system according to claim 1 , wherein the plurality of containers are biased to the end of the buffer conveyor by gravity.
6 . The conveyor system according to claim 2 , wherein each of the plurality of containers includes a box tray assembly, the box tray assembly comprising a box and a box tray, the box tray including a flat surface upon which the roller engages.
7 . The conveyor system according to claim 6 , wherein the box tray includes a recessed area with identifying indicia.
8 . The conveyor system according to claim 6 , wherein the box includes top flaps and the system further comprises a box cover on the box, the box cover constraining the top flaps.
9 . The conveyor system according to claim 8 , wherein the box cover further comprises a recessed area with identifying indicia.
10 . An object processing system comprising:
an in-feed area at which a plurality of objects are indiscriminately received;
a perception system for providing perception data regarding the plurality of objects;
a control system for assigning each of the plurality of objects a selected destination container of a plurality of destination containers based on the perception data;
a processing conveyor for moving each of the plurality of destination containers;
a buffer conveyor, the processing conveyor being selectively linked to the buffer conveyor for holding a subset of the plurality of destination containers, the buffer conveyor including a front side and a back side, the buffer conveyor being configured to bias the subset of the plurality of destination containers to an end of the buffer conveyor;
an output conveyor adjacent the buffer conveyor on the front side;
a track adjacent the buffer conveyor on the back side; and
a box kicker on the track and movable over the track length, the box kicker including a displacement mechanism, wherein the box kicker is aligned on the track to one of the subset of the plurality of destination containers, and the displacement mechanism ejects the one of the subset of the plurality of destination containers onto the output conveyor.
11 . The object processing system according to claim 10 , wherein the displacement mechanism comprises a rotatable arm, the rotatable arm including a roller at a distal end.
12 . The object processing system according to claim 10 , wherein the buffer conveyor and the output conveyor are coplanar.
13 . The object processing system according to claim 11 , wherein the object processing system further comprises a transition roller between the buffer conveyor and the output conveyor, the orientation of the transition roller being perpendicular to a direction of the buffer conveyor, the transition roller activated to pull the one of a subset of the plurality of destination containers onto the output conveyor as the one of the subset of the plurality of destination containers is ejected by the rotatable arm.
14 . The object processing system according to claim 10 , wherein the subset of the plurality of containers are biased to the end of the buffer conveyor by gravity.
15 . The object processing system according to claim 10 , wherein each of the plurality of containers include a box tray assembly, the box tray assembly comprising a box and a box tray, the box tray including a flat surface upon which the roller engages.
16 . The object processing system according to claim 15 , wherein the box tray includes a recessed area with identifying indicia.
17 . A method of processing objects, the method comprising:
indiscriminately receiving a plurality of objects at an in-feed area;
presenting the plurality of objects to a perception system, the perception system adapted to provide perception data regarding the plurality of objects;
assigning an identification of a bin to one of the plurality of objects using the perception data;
placing the one of the plurality of objects in the bin, the bin on a conveyor in a known order of bins;
ejecting the bin from the conveyor using a displacement mechanism, the displacement mechanism moving on a track adjacent the conveyor; and
adjusting the known order of bins on the conveyor after ejecting the bin.
18 . The method according to claim 17 , wherein the bin is ejected from the conveyor when another of the plurality of objects assigned to the identification of the bin is not expected.
19 . The method according to claim 17 , wherein the bin is ejected from the conveyor when the bin is empty.
20 . The method according to claim 17 , wherein the bin is ejected from the conveyor when the bin is full.