Automated System for Emptying and Sorting Items from Shipping Containers

This patent describes an automated system for quickly emptying items from shipping containers, like totes, by inverting them onto a conveyor belt for scanning and sorting into customer orders.

What it covers

This patent outlines a system and method for efficiently processing items from containers in a warehouse. It involves an incoming conveyor that brings a container, like a tote, to a container handling system. This system then uses a pusher mechanism to slide the container to an inversion mechanism, which grasps and flips the container to dump its contents onto an item conveyor system. As the items travel on this conveyor, a barcode scanner identifies them. Finally, an automated item sorter separates these items into groups based on specific customer orders, while the now-empty container is moved away on an outgoing conveyor. For example, a tote filled with various products for different online orders would be automatically emptied, scanned, and its contents sorted for packing.

What it doesn't cover

• —Does not cover manual unloading of containers by human workers.
• —Does not cover systems that pick individual items from a container without inverting the entire container.
• —Does not cover sorting systems that do not include a barcode scanner to identify items.
• —Does not cover systems where the empty container is not automatically transported away on an outgoing conveyor.
• —Does not cover systems that use methods other than inversion to transfer items from a container to a conveyor, such as scooping or vacuuming.
• —Does not cover sorting items without an 'automated item sorter' as specified in the claims.

The clever bit

The clever bit is the integrated automation of container handling, specifically the precise inversion of a container to transfer its contents directly onto an item conveyor for immediate scanning and sorting, streamlining a traditionally manual or semi-manual process.

Why it matters

This patent addresses the critical need for speed and efficiency in modern order fulfillment, especially with the growth of e-commerce. By automating the process of emptying containers and feeding items into a sorting system, it helps companies like Target reduce labor costs and process orders faster. This efficiency can lead to quicker delivery times for customers and more cost-effective operations for retailers.

Real-world examples

• 1.Target fulfillment centers
• 2.Amazon warehouses
• 3.Walmart distribution centers
• 4.Large e-commerce logistics operations
• 5.Automated parcel sorting hubs