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 an assembly for detecting items being loaded onto or discharged from the vehicles.

A sorting conveyor has pivotally mounted flaps for sorting articles into sorting outlets as a function of a sorting indication affixed to each of the articles. The conveyor includes a monitoring and control unit designed to cause each flap to pivot between a closed position in which the flap forms a conveyor portion suitable for conveying an article in a certain conveying direction and an open position in which the flap interrupts conveying of an article on the conveyor to deflect it towards an appropriate sorting outlet. The monitoring and control unit is also arranged to retrieve thickness data from a memory giving a certain thickness for the article to be deflected, and to respond by causing the flap to pivot into an open position through a certain opening amplitude determined as a function of the thickness data about the article that is to be deflected.

An automated shuttle sorter is disclosed that includes a carriage that is movable from a load position at which the carriage may be loaded, and at least two destination locations into which any contents of the carriage may be provided from the carriage.

Systems, methods, and apparatuses are disclosed for automated securing and releasing of items on shuttles. In one embodiment, an example item sortation system may include a shuttle having a conveyor, a first gate portion having a second width that is about half a first width of the conveyor, a second gate portion having the second width, an optional third gate portion having the second width, and an optional fourth gate portion having the second width, wherein the third gate portion and the fourth gate portion are disposed at a second side of the conveyor. The first gate portion, the second gate portion, the third gate portion, and the fourth gate portion may be configured to: (i) secure the at least one item on the conveyor during transport, and (ii) guide the at least one item along the conveyor when the item is unloaded.

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.

A method and apparatus are provided for delivering items to a plurality of storage locations is provided. The system includes a plurality of storage locations. The storage locations may be positioned to provide an aisle and a plurality of delivery vehicles may be operable within the aisle to deliver items to the storage locations. The system may include a track that the guides the vehicles to the storage locations. A reorientation assembly may be provided for re-orienting the vehicles relative to the track to reduce misalignment between the vehicles and the track.

A sorting device for sorting articles, comprising a conveyor which is movable in a conveying direction along a conveying path, the conveyor comprising a number of sorting units, each sorting unit comprising a carriage and at least one load-carrying element connected to the carriage for supporting articles, wherein the load-carrying elements are movable with regard to an associated carriage for unloading articles from the load-carrying elements at predetermined unloading positions, at least two of the sorting units being coupled together, a gap being formed between two adjacent load-carrying elements of two sorting units that are coupled together, the gap being covered by an intermediate element adapted to support an article, the sorting device comprising a stationarily arranged removal device for moving a selected article in a transverse direction off the conveyor at a predetermined removal position, wherein the removal device comprises a support element, the support element being movable along a longitudinal direction extending parallel to the conveying path, a first drive means being adapted to move the support element with a speed and in a transversal position corresponding to the selected article, the removal device further comprising a pushing element supported by the support element, a second drive means being adapted to move the pushing element in the transverse direction in order to remove the article from the conveyor.

A tray assembly is provided for use with a carrier in a product sortation system. The tray assembly includes a platform to receive parcels loaded onto the carrier. A pair of movable edge members are disposed at opposite sides of the platform. Each edge member is integrated with a combination including a pair of pivotable support arms and a spring element intermediate of the support arms. Each support arm supports its edge member at one end and is pivotally mounted at another end to a tray framework. The spring element is fixedly mounted at one end to the tray framework and is connected at another end to its edge member in a biasing relationship. In response to an applied load resulting from a parcel bearing down on the edge member, the support arms pivot downward in a manner sufficient to allow the parcel to reach and then rest on the tray platform. At the same time as the support arms pivot, the spring element deflects. After the package is unloaded from the tray platform, the return action of the spring restores the edge members back to their original location, as guided by the support arms.

A material handling system reduces or eliminates human interaction with articles sorted and deposited into an order container to maintain validation and integrity of the order. Validated articles are inducted onto a sortation conveyor that selectively dispenses or deposits each article at a destination into a container. A shuttle vehicle moves along a first side of row of such containers to replace an empty container in place of any container that holds a completed order and moves the latter onto a transport conveyor.

In an exemplary embodiment, an apparatus (10) and associated method for sorting a plurality of items includes a plurality of sort destinations and a plurality of delivery vehicles (200/400) for delivering items to the sort destinations. Each vehicle (400) includes a surface (406) for supporting items to be delivered and an edge-detection assembly (402,404) for detecting an edge of an item when the item is conveyed onto or discharged from the vehicle. The edge-detection assembly (402,404) includes an emitter for emitting a beam of light toward the surface. The emitter (104) is positioned below the surface so that the beam of light is projected transverse the surface. The emitter edge-detection assembly also includes a plurality of detectors for detecting the beam of light, wherein an object on the surface of the vehicle affects the beam of light received by the detectors.