SYSTEMS AND METHODS FOR PROVIDING ORDER FULFILLMENT USING A CONVEYOR TAKEAWAY SYSTEM

Abstract

A storage, retrieval and processing system for processing objects is disclosed that includes a plurality of bins including objects to be distributed by the storage, retrieval and processing system, the plurality of bins being provided on an input conveyance system, a programmable motion device that includes an end effector for grasping and moving any of the objects, a perception system for providing perception data regarding a selected object that is presented to the perception system by the programmable motion device, and a routing conveyance system for receiving the selected object, and for moving the selected object in each of horizontal and vertical directions toward a destination container responsive to the perception data, the destination container being provided among a plurality of destination containers in a row that are provided as a set on a destination conveyance system.

Claims

1.-31. (canceled)

32. An object processing system for processing objects, said object processing system comprising: a plurality of objects that are provided at a processing station; a programmable motion device that includes an end effector for grasping and moving any of the objects, said programmable motion device reaching any of the objects at an input area of the processing station; a plurality of arrays of destination locations, each array of destination locations including horizontally extending destination locations and vertically extending destination locations, the plurality of arrays of destination locations being mutually parallel and spaced apart by a routing conveyance spacing; a first routing conveyor unit that includes a first bidirectional conveyor thereon, the first routing conveyor unit being mounted on a first track system on a first side of the routing conveyance spacing, the first routing conveyor unit being adapted to receive a first object at the processing station and to move the first object into any destination location of the plurality of arrays of destination locations; a second routing conveyor unit that includes a second bidirectional conveyor thereon, the second routing conveyor unit being mounted on a second track system on a second side of the routing conveyance spacing, the second routing conveyor unit being adapted to receive a second object at the processing station and to move the second object into any destination location of the plurality of arrays of destination locations; and a control system for providing that the first routing conveyor unit and the second routing conveyor unit avoid one another.

33. The object processing system of claim 32, wherein the processing station further includes a feed conveyance system with a discharge end at which each of the first and second routing conveyor units receive the first and second objects respectively.

34. The object processing system of claim 33, wherein the object processing system further includes a perception system at the processing station for providing perception data regarding each of the plurality of objects, and wherein first and second objects are routed to the first and second destination locations respectively responsive to the perception data.

35. The object processing system of claim 34, wherein the perception system includes a drop perception unit that is positioned above an input end of the feed conveyor system.

36. The object processing system of claim 32, wherein the plurality of arrays of destination locations each include an associated destination bin.

37. The object processing system of claim 36, wherein the destination bins of the plurality of destination locations are provided in two sets of stacked rows of conveyor systems.

38. The object processing system of claim 37, wherein the conveyor systems each include a source end at which empty destination bins are provided, and a discharge end at which the destination bins are discharged from the system.

39. The object processing system of claim 38, wherein the source end of at least some of the conveyor systems includes a helical conveyor.

40. The object processing system of claim 38, wherein the discharge end of at least some of the conveyor systems includes a helical conveyor.

41. An object processing system for processing objects, said object processing system comprising: a plurality of objects that are provided at a processing station; a perception system for providing perception data regarding a selected object that is presented to the perception system; a plurality of arrays of destination locations, each array of destination locations including horizontally extending destination locations and vertically extending destination locations, the plurality of arrays of destination locations being mutually parallel and spaced apart by a routing conveyance spacing; a first routing conveyor unit that includes a first bidirectional conveyor thereon, the first routing conveyor unit being mounted on a first track system on a first side of the routing conveyance spacing, the first routing conveyor unit being adapted to receive a first object at the processing station and to move the first object into any destination location of the plurality of arrays of destination locations; a second routing conveyor unit that includes a second bidirectional conveyor thereon, the second routing conveyor unit being mounted on a second track system on a second side of the routing conveyance spacing, the second routing conveyor unit being adapted to receive a second object at the processing station and to move the second object into any destination location of the plurality of arrays of destination locations; and a control system for providing that the first routing conveyor unit and the second routing conveyor unit avoid one another.

42. The object processing system of claim 41, wherein the object processing system further includes a programmable motion device that includes an end effector for grasping and moving any of the objects, said programmable motion device reaching any of the objects at an input area of the processing station.

43. The object processing system of claim 41, wherein the processing station further includes a feed conveyance system with a discharge end at which each of the first and second routing conveyor units receive the first and second objects respectively.

44. The object processing system of claim 43, wherein the perception system includes a drop perception unit that is positioned above an input end of the feed conveyor system.

45. The object processing system of claim 41, wherein the plurality of arrays of destination locations each include an associated destination bin.

46. The object processing system of claim 45, wherein the destination bins of the plurality of destination locations are provided in two sets of stacked rows of conveyor systems.

47. The object processing system of claim 46, wherein the conveyor systems each include a source end at which empty destination bins are provided, and a discharge end at which the destination bins are discharged from the system.

48. The object processing system of claim 47, wherein the source end of at least some of the conveyor systems includes a helical conveyor.

49. The object processing system of claim 47, wherein the discharge end of at least some of the conveyor systems includes a helical conveyor.

50. A method of processing objects comprising: providing on a conveyance system a plurality of objects at a processing station; grasping and moving a first object of the plurality of objects to a feed conveyance system of the processing station; providing first perception data regarding the first object of the plurality of objects at the processing station; routing the first object from the processing station in each of first horizontal and vertical directions using a first routing conveyor unit; discharging the first object from the first routing conveyor unit in either of two mutually opposing directions from the first routing conveyor unit to a first selected destination location responsive to the first perception data; grasping and moving a second object of the plurality of objects to the feed conveyance system of the processing station; providing second perception data regarding the second object of the plurality of objects at the processing station; routing the second object from the processing station in each of second horizontal and vertical directions using a second routing conveyor unit such that one of the first and second routing conveyor sections travels above the other of the first and second routing conveyor sections; and discharging the second object from the second routing conveyor unit in either of the two mutually opposing directions from the second routing conveyor unit to a second selected destination location responsive to the second perception data.

51. The method of claim 50, wherein the first and second destination locations are provided in a plurality of arrays of destination locations that are mutually parallel and spaced from one another by a routing conveyor spacing.

52. The method of claim 51, wherein the plurality of arrays of destination locations each include an associated destination bin.

53. The method of claim 52, wherein the destination bins of the plurality of destination locations are provided in two sets of stacked rows of conveyor systems.

54. The method of claim 53, wherein the method further includes loading at least one row of destination bins on a conveyor system.

55. The method of claim 54, wherein the loading at least one row of destination bins incudes using a loading helical conveyor.

56. The method of claim 53, wherein the method further includes discharging at least one row of destination bins on a conveyor system.

57. The method of claim 56, wherein the discharging at least one row of destination bins incudes using a discharge helical conveyor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The following description may be further understood with reference to the accompanying drawings in which:

[0010] FIG. 1 shows an illustrative diagrammatic front isometric view of a storage, retrieval and processing system in accordance with an aspect of the present invention;

[0011] FIG. 2 shows an illustrative diagrammatic enlarged view of an intake portion of the system of FIG. 1;

[0012] FIG. 3 shows an illustrative diagrammatic underside view of the bin perception unit of FIGS. 1 and 2;

[0013] FIG. 4 shows an illustrative diagrammatic view from the bin perception unit of FIG. 3 directed to a bin and its contents;

[0014] FIG. 5 shows an illustrative diagrammatic enlarged view of the object perception unit of the system of FIG. 1;

[0015] FIG. 6 shows an illustrative diagrammatic front elevated view of the object perception unit of FIGS. 1 and 5;

[0016] FIG. 7 shows an illustrative diagrammatic rear elevated view of the object perception unit of FIGS. 1 and 5;

[0017] FIGS. 8A-8D show illustrative diagrammatic views of an object being moved in the object routing conveyance system of FIG. 1;

[0018] FIGS. 9A-9C show illustrative diagrammatic views of movement of object conveyors in the object routing conveyance system of FIG. 1;

[0019] FIGS. 10A-10C show illustrative diagrammatic views of an object being moved to a destination container in the system of FIG. 1;

[0020] FIG. 11 shows an illustrative diagrammatic view of a routing conveyance system in accordance with a further aspect of the present invention that includes mutually orthogonally disposed sets of rollers;

[0021] FIG. 12 shows an illustrative diagrammatic view of the system of FIG. 1 with a row of completed destination containers being removed;

[0022] FIG. 13 shows an illustrative diagrammatic view of the system of FIG. 1 with the row of completed destination containers being further moved along an unloading helical conveyor;

[0023] FIG. 14 shows an illustrative diagrammatic view of the system of FIG. 1 with the row of completed destination containers being provided to an output conveyor;

[0024] FIG. 15 shows an illustrative diagrammatic view of the system of FIG. 1 with a row of empty destination containers being moved toward a loading helical conveyor;

[0025] FIG. 16 shows an illustrative diagrammatic view of the system of FIG. 1 with the empty destination containers being moved upward along the loading helical conveyor;

[0026] FIG. 17 shows an illustrative diagrammatic view of the system of FIG. 1 with the empty destination containers being moved off of the loading helical conveyor onto an empty row;

[0027] FIG. 18 shows an illustrative diagrammatic view of the system of FIG. 1 with the empty destination containers being moved onto the empty row; and

[0028] FIG. 19 shows an illustrative diagrammatic rear isometric view of the system of FIG. 1.

[0029] The drawings are shown for illustrative purposes only.

DETAILED DESCRIPTION

[0030] In accordance with an aspect, the invention provides an ASRS system 10 in which objects are provided in a plurality of bins 12 at an input area 14 of an input conveyance system 16. Objects are processed at a processing station 18, then routed via a routing conveyance system 20 to any of a plurality of destination containers at a destination area 22. The processing station 18 may include a programmable motion device 24, a bin perception unit 50 and an object perception unit 26.

[0031] Generally, objects are provided to the input area 14 in bins 12, are moved by a programmable motion device 24 to an object scanner 26, fall to an object conveyance system 48, and are routed to any of a plurality of destination containers in one or the other of a plurality vertically-coupled stacked rows of containers 44A, 44B. Empty containers are provided to each vertically-coupled stacked rows 44A, 44B, and completed containers are removed from each vertically-coupled stacked rows, by a container movement system adjacent either of output conveyors 34, 36. Each set of stacked rows may be vertically-coupled by an unloading helical conveyor 52, 56, as well as a loading helical conveyor 54, 58. With reference to FIG. 2, the input conveyor 16 may include a plurality of detectors 15 that monitor movement of the conveyors, and may confirm the identity and position of a conveyor at the input area 14 for processing at the processing station 18.

[0032] The operations of the system are coordinated with a central control system 100 as shown in FIG. 1 that communicates wirelessly with each of the conveyors and conveyor sensors, the programmable motion device 24, the perception units 50, 26, as well as all elements of the routing conveyance system, container arrays, container movement systems, and output conveyance systems (all components and systems). The perception unit 50 aids in grasping objects from the bins 12 with an end effector of the programmable motion device. Once grasped by the programmable motion device, the object is dropped into the drop perception unit 26, and the system thereby determines from symbol strings the UPC associated with the object, as well as the outbound destination for each object. The central control system 100 is comprised of one or more workstations or central processing units (CPUs). For example, the correspondence between UPCs or mailing labels, and outbound destinations is maintained by a central control system in a database called a manifest. The central control system maintains the manifest by communicating with a warehouse management system (WMS). The manifest provides the outbound destination for each in-bound object.

[0033] In particular, the system of an aspect includes a perception system 50 that is mounted above a bin of objects to be processed next to the articulated arm 24, looking down into a bin 12. The system 50, for example and as shown in FIG. 3, may be attached via a mount 41 to a perception unit stand 40, and may include (on the underside thereof), a camera 72, a depth sensor 74 and lights 76. A combination of 2D and 3D (depth) data is acquired. The depth sensor 74 may provide depth information that may be used together with the camera image data to determine depth information regarding the various objects in view. The lights 76 may be used to remove shadows and to facilitate the identification of edges of objects, and may be all on during use, or may be illuminated in accordance with a desired sequence to assist in object identification. The system uses this imagery and a variety of algorithms to generate a set of candidate grasp locations for the objects in the bin as discussed in more detail below.

[0034] FIG. 4 shows an image view from the perception unit 50. The image view shows a bin 12 in the input area 14 (a conveyor), and the bin 12 contains objects 78, 80, 82, 84 and 86. In the present embodiment, the objects are homogenous, and are intended for distribution to different break-pack packages. Superimposed on the objects 78, 80, 82, 84, 86 (for illustrative purposes) are anticipated grasp locations 79, 81, 83 and 85 of the objects. Note that while candidate grasp locations 79, 83 and 85 appear to be good grasp locations, grasp locations 79, 85 do not because each associated object is at least partially underneath another object. The system may also not even try to yet identify a grasp location for the object 84 because the object 84 is too obscured by other objects. Candidate grasp locations may be indicated using a 3D model of the robot end effector placed in the location where the actual end effector would go to use as a grasp location. Grasp locations may be considered good, for example, if they are close to the center of mass of the object to provide greater stability during grasp and transport, and/or if they avoid places on an object such as caps, seams, etc. where a good vacuum seal might not be available.

[0035] With reference to FIG. 5, the programmable motion device 24 includes an end effector 28 that is coupled via a hose mount 30 to a vacuum hose attached to a vacuum source. With further reference to FIGS. 6 and 7, the perception unit 26 includes a structure 170 having a top opening 172 and a bottom opening 174, and the walls may be covered by an enclosing material 176 (e.g., a colored covering such as orange plastic, to protect humans from potentially dangerously bright lights within the perception unit 36) as shown in FIGS. 5 and 6. The structure 170 includes a plurality of rows of sources (e.g., illumination sources such as LEDs) 178 as well as a plurality of image perception units (e.g., cameras) 180. The sources 178 are provided in rows, and each is directed toward the center of the opening. The perception units 180 are also generally directed toward the opening, although some cameras are directed horizontally, while others are directed upward, and some are directed downward. The system also includes an entry source (e.g., infrared source) 182 as well as an entry detector (e.g., infrared detector) 184 for detecting when an object has entered the perception unit 36. The LEDs and cameras therefore encircle the inside of the structure 170, and the cameras are positioned to view the interior via windows that may include a glass or plastic covering (e.g., 186).

[0036] An important aspect of systems of certain embodiments of the present invention, is the ability to identify via barcode or other visual markings of objects, unique indicia associated with the object by employing a perception system into which objects may be dropped. Automated scanning systems would be unable to see barcodes on objects that are presented in a way that their barcodes are not exposed or visible. The perception system may be used in certain embodiments, with a robotic system that may include a robotic arm equipped with sensors and computing, that when combined is assumed herein to exhibit the following capabilities: (a) it is able to pick objects up from a specified class of objects, and separate them from a stream of heterogeneous objects, whether they are jumbled in a bin, or are singulated on a motorized or gravity conveyor system; (b) it is able to move the object to arbitrary places within its workspace; (c) it is able to place objects in an outgoing bin or shelf location in its workspace; and, (d) it is able to generate a map of objects that it is able to pick, represented as a candidate set of grasp points in the workcell, and as a list of polytopes enclosing the object in space.

[0037] The allowable objects are determined by the capabilities of the robotic system. Their size, weight and geometry are assumed to be such that the robotic system is able to pick, move and place them. These may be any kind of ordered goods, packages, parcels, or other articles that benefit from automated sorting. Each object is associated with unique indicia such as a unique code (e.g., barcode) or a unique destination (e.g., address) of the object.

[0038] The manner in which inbound objects arrive may be for example, in one of two configurations: (a) inbound objects arrive piled in bins of heterogeneous objects; or (b) inbound articles arrive by a moving conveyor. The collection of objects includes some that have exposed bar codes and other objects that do not have exposed bar codes. The robotic system is assumed to be able to pick items from the bin or conveyor. The stream of inbound objects is the sequence of objects as they are unloaded either from the bin or the conveyor. With reference to FIG. 7, after an object has been dropped through the perception unit 26, it is guided by a guide chute 32 onto the routing conveyance system 20.

[0039] The manner in which outbound objects are organized is such that objects are placed in a bin, shelf location or container, into which all objects corresponding to a given order are consolidated. These outbound destinations may be arranged in vertical arrays, horizontal arrays, grids, or some other regular or irregular manner, but which arrangement is known to the system. The robotic pick and place system is assumed to be able to place objects into all of the outbound destinations, and the correct outbound destination is determined from unique identifying indicia (identify or destination, such as a bar code or a unique address), which identifies the object or its destination.

[0040] It is assumed that the objects are marked in one or more places on their exterior with a visually distinctive mark such as a barcode or radio-frequency identification (RFID) tag so that they may be identified with a scanner. The type of marking depends on the type of scanning system used, but may include 1D or 2D barcode symbologies. Multiple symbologies or labeling approaches may be employed. The types of scanners employed are assumed to be compatible with the marking approach. The marking, either by barcode, RFID tag, or other means, encodes a symbol string, which is typically a string of letters and numbers. The symbol string uniquely associates the object with unique identifying indicia (identity or destination).

[0041] The operations of the systems described herein are coordinated by the central control system 100 as shown in FIG. 1. This system determines from symbol strings the unique indicia associated with an object, as well as the outbound destination for the object. The central control system is comprised of one or more workstations or central processing units (CPUs). The correspondence between unique identifying indicia and outbound destinations is maintained by the central control system in a database called a manifest. The central control system maintains the manifest by communicating with a warehouse management system (WMS).

[0042] With reference to FIGS. 8A-8D, the routing conveyance system receives objects (e.g., a singulated stream of objects) from the object feed conveyor 48. The routing conveyance system includes one or more routing conveyor units 38A, 38B, each of which includes an object conveyor 37 mounted on a frame 39. Each frame 39 is movably coupled to a vertical rail system 43, the upper and lower ends of each of which are movably coupled to a horizontal rail system 45 (also shown in FIG. 1). In accordance with various aspects, the rail systems may be reversed, providing horizontal rail systems mounted to vertical rail systems.

[0043] Each routing conveyor unit 38A, 38B is adapted to receive a selected object on its object conveyor 37, which is mounted on the frame 39 that travels along the track system 43, 45 in both vertical and horizontal directions between the at least two vertically-coupled stacked rows 44A, 44B of destination containers 46 (e.g., bins, totes, boxes, etc.). The selected object (e.g., 41) is received by the object conveyor 37 from the object feed conveyor 48 of the conveyance system, and brings the object toward a selected destination container among the vertically-coupled stacked rows 44A, 44B. After routing the selected object to the selected destination location, the routing conveyor is returned to the object feed conveyor 48 to receive a new object. Routing conveyor units 38A, 38B are programmed to avoid each other, for example, by generally moving at different elevations when passing one another.

[0044] In particular, with reference to FIG. 8A, while routing conveyor unit 38B approaches the object feed conveyor 48 from an elevation below the object feed conveyor 48, routing conveyor unit 38B may be destined for or located at a container at relatively high elevation. Once the routing conveyor unit 38B receives the object 41 (as shown in FIG. 8B), the system will begin to move the object toward its destination container (e.g., as assigned by a WMS system). If the destination container is located at a higher elevation, the routing conveyor unit 38B will begin to rise and move away from the object feed conveyor 48, while also moving the routing conveyor unit 38A downward and toward the object feed conveyor 48 (as shown in FIG. 8C). When the routing conveyor unit 38B reaches the selected destination container, the routing conveyor unit 38A approaches the object feed conveyor from below (as shown in FIG. 8D). If the assigned destination container is relatively low in one or the other of the vertically-coupled stacked rows 44A, 44B, the returning routing conveyor unit will travel a relatively high path back to the object feed conveyor. Each routing conveyor unit 38A, 38B is coupled via vertical and horizontal rails to one of the two vertically stacked arrays of rows, but they avoid colliding by having the returning unit follow a vertically opposite path than a path to be taken by the other routing conveyor unit in bringing a new object to a selected destination bin. Each routing conveyor unit 38A, 38B may move an object into a destination bin located in either vertically-coupled stacked rows 44A, 44B (to either side of the routing conveyor unit 38A, 38B).

[0045] With reference to FIG. 9A, when a newly loaded routing conveyor unit (e.g., 38B) carrying an object 41 is assigned a selected destination container, the system determines whether the selected destination container is located at an upper elevation or a lower elevation (all locations are assigned to be one or the other). If the destination location is located at an upper elevation, the returning routing conveyor unit 38A moves at a lower elevation back to the object feed conveyor 48 (as shown in FIG. 9B). If, on the other hand, the destination location is located at a lower elevation, the returning routing conveyor unit 38A moves at an upper elevation back to the object feed conveyor 48 (as shown in FIG. 9C).

[0046] The system therefore provides objects to either of two adjacent vertically stacked rows of destination containers, wherein at least two routing conveyor units are used to move objects from a loading location (at conveyor 48) to any destination container in either of the vertically coupled stacked rows 44. The routing conveyor units are moved such that one returns to the loading location while the other is delivering an object, and the returning unit moves vertically opposite the delivering unit. For example, if the delivering unit is moving to a location in the upper half of either of the vertically coupled stacked rows 44, then the returning unit is moved in the lower half of the area between the vertically coupled stacked rows. Conversely if the delivering unit is moving to a location in the lower half of either of the vertically coupled stacked rows 44, then the returning unit is moved in the upper half of the area between the vertically coupled stacked rows. In this way, the routing conveyor units 38A, 38B avoid colliding. Each of the objects is therefore moved vertically and horizontally by a routing conveyor unit, and then moved in a third direction by the container conveyor wherein the third direction is generally orthogonal to the first and second directions. The container may later be removed from the open storage location also along the third direction when completed as discussed in more detail below.

[0047] FIG. 10A shows the routing conveyor unit 38B at a destination position with a selected object 41 on its object conveyor 37. If the selected destination container is within the vertically-coupled stacked row 44B, the conveyor 37 moves to urge the object into the destination container therein (as shown in FIG. 10B), and if the selected destination container is within the vertically-coupled stacked rows 44A, the conveyor 37 moves to urge the object into the destination container therein (as shown in FIG. 10C). Each routing conveyor unit 38A, 38B may thereby provide an object thereon to any destination container within either vertically-coupled stacked rows 44A, 44B. Destination containers 46 in the vertically-coupled stacked rows 44A, 44B of destination containers are thereby populated with objects from the input bins 12 via the processing station 18 and the routing conveyance system at a destination area 22.

[0048] In accordance with a further aspect of the invention, the routing conveyance system includes one or more routing conveyor unit(s) 51 including mutually orthogonally disposed sets of rollers that engage a grid track system 53, permitting the routing conveyor unit(s) 51 to access destination containers 59 as shown in FIG. 11. Additionally, the unit(s) 51 may further include an additional set of mutually orthogonally disposed sets of rollers 57 for engaging a grid track system on the opposing side, such that each unit 51 may be supported by inside walls of both sets of vertically-coupled stacked rows 44A, 44B of destination containers. Each of the horizontal rollers may be engaged separately from and alternate to the vertical rollers to permit the unit 51 to move about the routing conveyance system 20. Again, where more than one unit 51 is employed, the system may similarly provide avoidance routines to prevent the units from colliding. The movement of objects into destination containers at a first side of the destination containers, and having the completed destination containers removed as completed rows from an opposite second side, permits the object conveyance system to continue to operate while destination containers are being replenished. Further, the system may dynamically assign destination containers in a row such that each destination container in a row may have a similar expected frequency of container completeness factor or receive objects having a similar frequency of object arrival factor. For example, destination containers that are expected to be completed relatively quickly (those with a high expected frequency of container completeness factor or are assigned to receive objects having a high frequency of object arrival factor) may be assigned to spots on a common row, while those with a low expected frequency of container completeness factor or are assigned receive objects having a low frequency of object arrival factor, may be assigned spots on a different row. In this way, the efficiencies of removing one row of completed destination containers at a time may be well utilized. In accordance with further aspects, each row may include destination containers having other aspects in common, such as having all destination containers of a row be assigned to a common shipping destination.

[0049] When each destination container in a row of destination containers is full or otherwise finished being processed, the system may discharge the row as follows. With reference to FIG. 12, the system opens end gates 90 on the selected row, and aligns (opens half-way) end gates 92 in the rows below the selected row. The aligned gates 92 are designed to facilitate the destination containers moving down the un-load helical conveyor 52. FIG. 13 shows a back view of the gates 90, 92, and shows the completed containers from the row being moved downward along the helical conveyor 52. With further reference to FIG. 14, when the completed containers are all provided to the output conveyor 120, 122 (as determined, for example, by sensors 124), the gates 90 are closed to as to prepare the empty row to receive a new set of destination containers.

[0050] With reference to FIG. 15, a new set of empty destination containers is provided by first opening gates 110, and monitoring (e.g., by sensors 112) movement of empty containers along a container in-feed conveyor 34, 36 (e.g., 34 as shown) toward a load helical conveyor (e.g., 54 as shown). In-feed gate 130 is opened on the row to be loaded with the empty containers, and the remaining in-feed gates 132 remain closed as shown in FIG. 16. The empty containers are loaded onto the row (as shown in FIGS. 17 and 18), and registered as being complete with information from the sensors 140 as the containers come to rest against the closed end-stop gates 90. The rollers on the conveyor sections 34, 54 may be actively powered and coated with a friction providing surface such as urethane, polyurethane, vinyl, rubber, etc., and each conveyor 34, 54 may include a plurality of sensors for monitoring the location of each container on the conveyors 34, 54. Once loaded, the in-feed gate 130 associated with the row is closed. FIG. 19 shows a rear view of the system of FIG. 1 showing the un-load helical conveyor 56 and the load helical conveyor 58.

[0051] Those skilled in the art will appreciate that numerous variations and modifications may be made to the above disclosed embodiments without departing from the spirit and scope of the present invention.