DEVICE AND PROCESS FOR AUTOMATED LOADING AND UNLOADING OF PARCELS

Abstract

The invention relates to a device for assembling or disassembling rows of parcels such as boxes and stacking or destacking these rows of parcels into or from a space, such as a container. The device of the invention comprises a transport conveyor to maneuver goods from or to the space, a stacking conveyor (300) positioned adjacent to the transport conveyor to align the parcels in a row or to break up a row of parcels, a pusher system (600) associated with the stacking conveyor (300) to push the row of parcels of the stacking conveyor, a loading arm (200) for sending and/or receiving, for transferring and stacking the row of parcels pushed off the stacking conveyor (300) in the space or pick a row of parcels from the space and transfer this row of parcels to the stacking conveyor (300) .

Claims

1. A device for loading and unloading parcels comprising: a plurality of conveyors, wherein a first conveyor moves parcels between a first conveyor and a second conveyor and vice versa, and the second conveyor moves said parcels onto a third conveyor and vice versa; a pusher system comprising a fixed section and a rotating section with a plurality of suction grippers at one extremity of both sections; a movable arm for supporting a platform holding a plurality of parallel conveyors, pushers and a plurality of grippers; a sensing system; and wherein the second conveyor comprises rollers for rotating the parcels; wherein the third conveyor comprises a mechanism which allows it to expand and retract in size; wherein the pusher system comprises a mechanism which allows it to expand and retract in size; wherein the arm and its elements operate independently of the said plurality of conveyors; and wherein the platform comprises a mechanism which allows it to expand and retract in width.

2. The device of claim 1 wherein said movable arm moves in a plurality of directions including horizontally and vertically and forward and backwards.

3. The device of claim 1 wherein said plurality of pushers and grippers move forward or backward to push or pull a compiled row of parcels onto or from the parallel superimposed conveyors.

4. A process for loading and unloading parcels comprising: a plurality of conveyors, wherein a first conveyor moves parcels between a first conveyor and a second conveyor and vice versa, and the second conveyor moves said parcels onto a third conveyor and vice versa; a pusher system comprising a fixed section and a rotating section with a plurality of suction grippers at one extremity of both sections; a movable arm for supporting a platform holding a plurality of parallel conveyors, pushers and a plurality of grippers; a sensing system; and wherein the second conveyor comprises rollers for rotating the parcels; wherein the third conveyor comprises a mechanism which allows it to expand and retract in size; wherein the pusher system comprises a mechanism which allows it to expand and retract in size; wherein the arm and its elements operate independently of the said plurality of conveyors; and wherein the platform comprises a mechanism which allows it to expand and retract in width.

5. The process according to claim 4, wherein the third conveyor retracts in size to squeeze the parcels together or expands to match the size of the designated area.

6. The process according to claim 4, wherein the pusher system rotates its rotating part to match the width of the third conveyor or the second and third conveyors combined.

7. The process according to claim 4, wherein the suction grippers grab the parcels and move them forward or backward.

8. The process according to claim 4, wherein the movable arm further comprises a plurality of parallel conveyors and a plurality of grippers in between said parallel conveyors, and wherein said grippers push or pull at least one row of parcels along the superimposed conveyors to or from a designated location.

9. The process according to claim 4, wherein the sensing system comprises a plurality of sensors and said sensors determine the final location of the movable arm and parallel conveyors.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 illustrates a side perspective view of the loading / unloading device

[0018] FIG. 2 illustrates a top plan view of the loading / unloading device

[0019] FIG. 3 illustrates a top plan view of the stacking conveyor

[0020] FIG. 4 illustrates a top plan view of the platform

[0021] FIG. 5 illustrates a side perspective view of the platform

[0022] FIGS. 6A to 6E illustrate a top plan view of the row pusher system

DETAILED DESCRIPTION

[0023] This innovation provides in one form a device for loading and/or unloading one or more rows of parcels into and/or from designated areas. What differs this invention from the prior art cited hereinabove is the time and space efficiency resulting from its process as it will be explained.

[0024] Unlike any other cited prior art, the device presented pre-organizes and compiles the parcels for loading. The feature of the 3rd conveyor and the pusher being able to extend their length in order to cover the full width of the designated area is both time and space efficient since it allows the device to load or unload a full row at one time. The time efficiency is emphasized by the split system for (a) preparing row for loading, and (b) stacking row; i.e. next row is being prepared while current row is being stacked. The same is applicable for the unloading cycle where the next row can be removed from stack while previous row is being conveyed to final unloading zone. Finally, time efficiency is clear once more when the unloading cycle is expedited by the use of the 2nd conveyor which angles the unloaded parcels which allows the unloading process to be faster.

[0025] The innovation disclosed herein, in one aspect thereof, is shown in FIGS. 1 and 2, and comprises an autonomous loading / unloading device (1) that comprises a transportable platform (10) that is driven into a storage area, shipping container, trailer, warehouse or distribution center, loads or unloads parcels within the confines of the designated area. The parcels are transported to and from the device on a transport conveyor. Said device comprises:

[0026] Stacking conveyor (300), adjustable in height, as shown in FIG. 3, comprises 3 sections:

[0027] Conveyor (1st conveyor) (301) associated with transport conveyor. This conveyor travels in the same direction as the transport conveyor.

[0028] Conveyor (2nd conveyor) (302) with or without rollers with adjustable angles which is the corner conveyor between the 1st conveyor and the 3rd conveyor (see next) which allows for the uninterrupted movement of the parcels between the 1st conveyor and the 3rd conveyor. Also may be used to rotate or re-position direction of parcels passing through.

[0029] Compiling conveyor (3rd conveyor) (303) which is perpendicular in space to the 1st conveyor and has the ability to compress and extend in size so as to compile the parcels and push them against each other prior to loading or to match the width of the designated area. This feature is novel regarding the prior art and makes the device space efficient.

[0030] The stacking conveyor (300) is configured to form and/or break up at least one row of parcels.

[0031] During the loading cycle, the cords of the 2nd conveyor (302) are at a 90° angle so the parcels will have a 90° transfer which will be time efficient for the row assembly. During the unloading cycle, the cords are at a 45° so the parcels will have a curved trajectory allowing the unloading process to be faster.

[0032] A pusher system (600), shown in FIGS. 6A to 6E, sits on top of the 3rd conveyor and comprises two attached segments as follows:

[0033] One section (601) sits right on top of the 3rd conveyor and like the 3rd conveyor, can extend and compress in length to adjust its size to the 3rd conveyor as it extends and compresses in size due to a folding mechanism along its length.

[0034] A second smaller section (602) which is the length of the 2nd conveyor and will assume one of two main positions:

[0035] At the beginning of the loading, the smaller section (602) is in the closed position at an angle of 90 degrees to the first longer section (601). In this position, parcels can travel between the 3 different conveyors unobstructed.

[0036] Once the number of parcels to fill a row is reached, the smaller section (602) rotates horizontally to the open position to reach a 180 degree or flat position with the longer section.

[0037] Together, both sections then move forward to push the compiled row of parcels onto the loading arm.

[0038] In this way, the row to be loaded can be the width of the 2nd and 3rd conveyors (302 and 303) which may be adjusted to meet the width of the loading container or designated space.

[0039] Both sections, the first longer section (601) and the second smaller section (602), have at their ends suction grippers (603) with an extended part to allow the grabbing of the parcels during the cycle.

[0040] A support column holds the stacking conveyor (300) and the pusher system (600) at an adjustably fixed height.

[0041] In one embodiment, the support column is mounted on a transportable platform (100) giving the device the ability to be moved left or right and forward or backward.

[0042] A loading arm (200) moveable in a plurality of directions, at least one being horizontal and the second being vertical. It may be a robotic arm or a mechanical arm but at least an automated moving arm. Said arm is mounted on a movement system to traverse the length of the transportable platform.

[0043] The arm (200) comprises a plurality of elements which form a sort of platform onto which the pusher will push the row of parcels. These elements may vary in length but be no less than the largest parcel to in the row to be stacked when loading or unloading.

[0044] The arm (200) moves horizontally so as to position the said elements which form a sort of platform to the level and position of the 3rd conveyor, and can extend to as far as the back of the container being loaded or unloaded so as to stack a row of parcels in the requisite position.

[0045] The arm (200) moves vertically so as to load or unload a row of parcels starting from the bottom of the container or cargo space all the way to the highest row for stacking the parcels in a most efficient and optimal manner.

[0046] The elements which form a sort of platform (400), as shown in FIG. 4, comprise a plurality of parallel conveyors, pushers (502) and grippers (501) between them to further push the compiled row to its predefined row and column in the stacking as shown in FIG. 5. The parallel conveyors move the row of parcels horizontally to position the row of parcels in front of the grippers which resume the pushing of the row to its intended final position.

[0047] The platform (400) can extend and compress in width to adjust its size so it extends and compresses in size due to a folding mechanism along its length.

[0048] The platform (400) can be tilted at the level of its connection with the arm (200) to match the tilting of the designated area.

[0049] The grippers (501) comprise suction elements at the end which allows them to securely grab the row of parcels, and push them evenly. The suction elements also assist in the unloading, whereby a row of parcels is grabbed and held onto under the suction effect of the suction elements and pulled backwards towards the parallel conveyors which then move the row of parcels onto the 3rd conveyor to be unloaded.

[0050] During loading, each gripper (501) independently extends to align the backs of the parcels. During unloading, each gripper (501) independently extends to grab and pull all the parcels in a row simultaneously.

[0051] The grippers (501) and suctions may incline or rotate in a vertical arc as needed to provide for a better grip and positioning of the grip with respect to each row, since not all rows will have homogenous sized parcels.

[0052] A plurality of sensors allowing the following readings:

[0053] The width of the designated area so the 3rd conveyor extends so its length matches the width of the designated area.

[0054] The dimensions and tilting of the designated area before the device is placed. Same sensing system will determine the arm movement to avoid collision with the designated area’s boundaries.

[0055] During the unloading cycle, the position of the parcels in the designated area so the device would be centered.

[0056] In one embodiment, the device according to the invention may comprise functions as a loading device, transferring parcels from outside the designated area, aligning them in rows and stacking these rows inside the designated area. In another embodiment, the device according to the invention may comprise function an unloading machine, de-staking rows of parcels from inside the designated area, breaking up rows of parcels and transferring them outside the designated area. The device can operate selectively in both modes.

[0057] In both modes, loading and unloading, two cycles can be performed simultaneously. In one embodiment, during a loading cycle, while the cargo is being stacked in the designated area, another set of parcels is being transported on the conveyors in order to be stacked after.

[0058] In a preferred embodiment of the invention, a sorting system sorts the parcels before going through the transport conveyor to create a loading pattern with the designated area’s highest fill-rate. Preferably, the transport conveyor contains an orientation device to orient the parcels before going through the stacking conveyor.

[0059] In an embodiment, we consider a loading cycle. The parcels arrive on the 1st conveyor (301), perform a 90° transfer on the 2nd conveyor (302) and are stacked on the 3rd conveyor (303).

[0060] The pusher system (600) narrows down its width by shortening the 3rd conveyor (303) as explained in FIGS. 6 and herein above. This width narrowing will eliminate any space between the parcels making this invention a space efficient one.

[0061] The pusher system (600), using the first longer section (601) and the second smaller section (602), pushes the row of parcels transferring them to the delivery system.

[0062] While the arm (200) that is holding the delivery system transports the platform of parallel conveyors (400) to the predefined loading location, a new row of parcels is being transported on the transport conveyor towards the stacking conveyor (300) making the device and the process time efficient since two cycles are performed simultaneously.

[0063] Once on the platform of parallel conveyors (400), the row of parcels is conveyed towards the end of the platform (400) through the series of superimposed parallel conveyors. Between each two parallel conveyors of one level, there is a pusher (502) and a gripper (501) mounted on another level of parallel conveyors.

[0064] The pushers (502) and grippers (501), located adjacent to the first set of parallel conveyors, will meet the parcel at the end of the first set of parallel conveyors, and push them out of the platform (400) towards their final position.

[0065] The parcels having different dimensions and width, the grippers extend to push the parcels so that the back sides of all parcels are aligned.

[0066] In another embodiment, we consider the device performing an unloading cycle, the arm (200) will transport the stacking conveyor (300) to a predefined location where a row of parcels is ready to be unloaded. The platform is then placed adjacently to the row of parcels.

[0067] The pushers (502) advance to the tip of the platform (400) to grab the parcels via the grippers (501) located at their end.

[0068] The pushers (502) and grippers (501) advance then towards the parcels. Since the parcels may have different dimensions and may be put in multiple orientations inside a row, the row of parcels may not be aligned, so the extended part of the grippers (501) compensates for that without damaging the parcels.

[0069] All the grippers (501) retreat their extended parts so all the front sides of the parcels realigned.

[0070] The grippers (501) lift the parcels form one side due to the swinging attachment so the transfer to the delivery system is smooth and no damage is done to the parcels.

[0071] The pushers (502) and grippers (501) transfer the row of parcels to the series of parallel conveyors on the platform (400) and release the parcels. The pushers (502) and grippers (501) then retrieve to their location parallel to the set of parallel conveyors. The platform retracts its width in order to squeeze the parcels together. The parcels then travel the length of the platform (400). The arm (200) transfers the platform (400) adjacently to the 2nd and 3rd conveyor (302 and 303).

[0072] The suction grippers (603) hold the parcels. The pusher system (600) then retracts transferring the parcels into the 3rd conveyor (303). The 3rd conveyor (303) narrows its width eliminating the spaces between the parcels.

[0073] The second smaller section (602) of the pusher system (600) returns to the closed position at an angle of 90 degrees to the first longer section (601) so the parcels can leave towards the transport conveyor. The adjustable angles in the 2nd conveyor (302) are at a 45° angle so the parcels will leave the following a curve which allows a faster disassembly of the row of parcels. The parcels on the stacking conveyor exit directly.

[0074] Meanwhile the arm (200) transports the platform (400) to pick the next row of parcels.

[0075] In an embodiment, the device according to the invention may perform the loading or unloading of a total row of parcels by dividing it into a plurality of smaller segments and performing the cycles accordingly.

[0076] In a further embodiment, the platform (400) might be able to carry a plurality of rows of parcels in order to load or unload them adjacently.

[0077] The foregoing description of an embodiment has been presented for purposes of illustration and description. It is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. The disclose embodiments serve merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Although only a limited number of embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its scope to the details of construction and arrangement of components set forth in the preceding description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the embodiment, specific terminology was used for the sake of clarity. It is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. Accordingly, it will be understood that the appended claims are intended to cover all such modifications and embodiments, which come within the spirit and scope of the present invention.