Description:FIELD OF INVENTION

[001] The present invention relates to the field of sortation systems that have been used to sort orders in warehouses or distribution centers when there are multiple items. Particularly, the present invention relates to a tilt tray integrated put-to-light (PTL) sortation system and a method thereof.

BACKGROUND OF THE INVENTION

[002] Put-to-Light systems are an effective automated sortation method to break larger quantities of product into individual customer orders, using light devices to direct operators to ‘put’ items. Merchandise that is typically batch picked beforehand is brought to a put station. Operators scan barcodes on individual pieces of merchandise, then lights turn on at any individual customer orders requiring that product. The Put to Light (PTL) systems are widely used for single level sorting of shipments based on the indication of lamp provided on the PTL Module affixed to a Rack with slots.

[003] The PTL Racks in use presently consume a lot of space and support only a single level sorting that limits the number of sorting destinations at sites with space constraint. Further the warehouses or other storage spaces become infrastructures heavy due to requirement of multiple racks for catering to a larger number of destinations. The sites with limited space need sortation systems that are compact and portable, for quick movement of the assets from one facility to another, when the lease period ends.

[004] Various patent literature disclose about PTL racks and their working as such a US patent US10384234B2 discloses a sorting device comprising a support member drivable in a conveying direction for supporting and transporting an article. The sorting device includes a loading station at which at least an article can be loaded to the support member, and an unloading station at which at least an article can be removed from the support member. The unloading station is provided with a plurality of receivers for receiving an article that is removed from the support member. The receivers are arranged transversely with respect to the conveying direction and disposed such that they are below the support member when the support member is at the unloading station. Furthermore, the sorting device comprises a controller for directing an article that is supported and transported by the support member to a selected one of the receivers. However, the said patent literature fails to disclose an integrated rack with the put to light sortation system to provide compact infrastructure. In the said literature a support member comprises a tray which is tiltable about a tilting axis extending transversely with respect to the conveying direction for discharging the article from the tray at the unloading station. Depending on the location of the article on the tray in transverse direction with respect to the conveying direction it falls into one of the receivers. Whereas the present invention provides plurality of tiltable tray stacked onto the rack itself to provide more compact and easy solution to sort the articles which the prior patent literature fails to disclose.

[005] In view of the above problems associated with the state of the art, there is a need to provide compact and portable put to light sortation system, for quick movement.

OBJECTIVES OF THE INVENTION

[006] The primary objective of the present invention is to provide a tilt tray integrated put-to-light (PTL) sortation system and a method thereof.

[007] Another objective of the present invention is to provide a Tilt Tray Sortation mechanism along with Put to Lights system for more productive and compact sortation system.

[008] Yet another objective is to provide two level sorting, where the Primary Sorting is done using the PTL light system, while for the secondary sorting tilt tray is used.

[009] Another objective is to provide a sorting system that enables optimized and high speed sortation of the shipment.

[0010] Yet another objective of the present invention is to provide compact infrastructure.

[0011] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

SUMMARY OF THE INVENTION

[0012] The present invention relates to a tilt tray integrated put-to-light (PTL) sortation system and a method thereof. The PTL system is integrated with a tilt tray sorting mechanism in the present invention and is used for 2 level sorting that is both Primary and Secondary sorting, where a single PTL Module can cater to 4 destinations. The system includes a cloud server configured to manage the light-directed shipment sortation process. The dedicated shipment after the operator scans the barcode label on the item with the scanning means is received on the PTL rack mounted on a MS base frame. Further, a tilt tray configured to tilt and drop the shipment into plurality of bin that store or collect the shipments or packages. The said system provides compact and portable put to light sortation system, for quick movement of the shipment.

BRIEF DESCRIPTION OF DRAWINGS

[0013] A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when taken in conjunction with the detailed description thereof and in which:

[0014] Figure 1 illustrates the systematic view of tilt tray integrated put-to-light (PTL) sortation system of the present invention; and

[0015] Figure 2 illustrates the isometric view of the tilt tray.

[0016] Reference numerals of the components is discussed herein:
S.No. Components Reference Numerals
1. tilt tray integrated put-to-light (PTL) sortation system 100
2. Scanning means 101
3. Cloud Server 102
4. PTL racks 103
5. MS Base Frame 104
6. Side Wall 105
7. PTL Modules 106
8. Sliding Plate 107
9. Exterior Cover
108
10. Tilt Tray 109
11. Sorting Bins 110
12. Electrical Actuators or Pneumatic Cylinders 111
13. Shaft 112
14. Frame 113
15. Square Plate 114
16. ball and socket joint 115

DETAILED DESCRIPTION OF THE INVENTION

[0017] The following description describes various features and functions of the disclosed system and method with reference to the accompanying figure. In the figure, similar symbols identify similar components, unless context dictates otherwise. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system and method can be arranged and combined in a wide variety of different configurations, all of which are contemplated herein.

[0018] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0019] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0020] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.

[0021] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise

[0022] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. The equations used in the specification are only for computation purpose.

[0023] It is to be understood that the terms merchandise/ stock/ goods/ product/ item/ shipment are used interchangeably throughout the specification to define the shipments transported in the warehouse.

[0024] The present invention relates to a tilt tray integrated put-to-light (PTL) sortation system and a method thereof. The present invention provides a PTL system that is integrated with a tilt tray sorting mechanism and used for a 2 level sorting that is both Primary and Secondary sorting, where a single PTL Module can cater to 4 destinations.

[0025] A tilt tray integrated put-to-light (PTL) sortation system comprises a scanning means configured to scan the barcode affixed on shipment; a cloud server configured to manage the light-directed shipment sortation process; a PTL rack configured to receive the dedicated shipment after the operator scans the barcode label on the item with the scanning means; a MS base frame configured to mount the PTL Rack; a plurality of bin configured to store or collect the shipments or packages; and a tilt tray configured to tilt and drop the shipment. Further, the tilt tray comprises a square plate mounted on a frame linked via shaft to Electrical Actuators or Pneumatic Cylinders on all the sides where the square plate are connected at one end of the shaft with a mounting frame attached to the Electrical Actuators or Pneumatic Cylinders connected at the middle of the shaft. Furthermore, a plurality of sorting bins or postal bags fastened to the MS frame via a bag holder configured to collect the shipment.
[0026] The components of tilt tray integrated put-to-light (PTL) sortation system (100) are described herein detail:
[0027] (a) Scanning means (101): It is configured to scan the barcode affixed on merchandise/stock/goods/product/item/shipment by an operator and sends the barcode data of the scanned shipment to a server. The scanner may read various barcodes or other identifiers and transmit the information to the server. In an exemplary embodiment the scanning means may be a hand held barcode scanner or a wrist-worn scanner.
[0028] (b) Cloud Server (102): The cloud server utilizes software module to configure and manage the light-directed shipment or package sortation, i.e., to analyze the scanned barcode data to identify the location of the scanned shipment and indicate the destination slot via actuation of a lamp on PTL module. The cloud server stores the data related to the shipment available in the warehouse/any shipment management facility. The data that flows back and forth between server and the operator allows the software on the server to instruct the operator on which products to be put in which slot of the PTL Rack by means of the indication Lamp on the module.
[0029] (c) PTL racks (103): There are a plurality of PTL modules affixed on a rack in the PTL sortation system. The plurality of PTL racks are storage compartments receiving the dedicated shipment after the operator simply grabs an item and scans the label with any barcode scanning device. The PTL rack may be a rectangular shaped mild steel (MS) frame. The PTL rack includes a MS base frame and two side walls having PTL modules sandwiched at the top and middle position. In an exemplary embodiment, the rectangular frame may be implemented as an arrangement having dimensions 600mm width, 2000mm height and 300mm depth, resting on a 100mm high MS base frame. The components of the PTL racks are described here in detail:
[0030] (1) MS Base Frame (104): The base frame is the pedestal on which the said PTL Rack rests, this MS frame contains holes that are to be used for grouting the complete PTL Rack on the ground or Mezzanine floor by means of anchor bolts and fasteners.
[0031] (2) Side Wall (105): The PTL racks includes atleast two side walls facing each other. The side walls of the PTL racks are made of steel wire mesh to provide visibility on any shipment being trapped in the slots.
[0032] (3) PTL Modules (106): The PTL modules are sandwiched in between the top and middle position of the side walls having at least one sliding plate and at least one exterior cover. Each of the PTL rack comprises at least two PTL modules. The PTL module includes an light emitting diode (LED) sensor which glows and confirms the placement of the scanned shipment via the scanning means into the module.
[0033] (4) Sliding Plate (107): The sliding plates are made up of Fibre Reinforced Polymer (FRP) and facilitate the movement of shipment onto the Tilt Tray, when kept by the operator in the PTL rack slot.
[0034] (5) Exterior Cover (108): A Mild Steel (MS) hooded cover is connected on the exterior side of the PTL rack slot covering the tilt tray on three sides for preventing shipments from falling off the tilt tray.
[0035] (d) Tilt Tray (109): Figure 2 illustrates a Tilt Tray Mechanism comprising a square plate (114) mounted on a mild steel frame (113). The said mild steel tilt tray frame (113) provides support to the square plate (114) and also facilitates its tilting movement. The said mild steel frame has but not limited to four arms. The center of the plate (114) is attached to a shaft (112) via ball and socket joint (115) providing the flexibility for tilting, while the tilt tray frame is connected to Electrical Actuators or Pneumatic Cylinders on all four sides (via arms) through ball and socket joints (115), enabling the tray to tilt on the desired side. The Electrical Actuators or Pneumatic Cylinders (111) are connected to the tilt tray frame on one end and to the middle of the shaft (112) on the other end. Further, the shaft (112) is connected with the lower MS Frame (113) provided for sorting bins or bag holders. The tilting mechanism for the tray is achieved pneumatically by using compressed air and a pneumatic cylinder with the piston providing linear movement to extend and retract the arm connected to the tray frame (113). Similarly the electrical actuator (111) also facilitates linear movement of the arm through an electro-mechanical arrangement. Accordingly the tray frame (113) is connected with the Electrical Actuators or Pneumatic Cylinders (111) on all the sides, therefore whenever a Pneumatic Cylinder or Linear Electric Actuator Arm retracts the tray is tilted towards that side. The confirmation of tilting is received via Reed Switches on the Pneumatic Cylinder, while in case of Electrical Actuators the inbuilt limit switches are used. In an exemplary embodiment the square tray may be of dimension 600 × 600 mm.
[0036] (e) Sorting Bins (110): The plurality of sorting bins are meant to store or collect the shipments or packages dropped by the tilt tray, these can be fixed bins or postal bags fastened to the MS frame via a bag holder. Once these bins are full the shipments or packages collected have to be emptied out in another portable storage, while in case of postal bags the filled bag is replaced by an empty bag to resume the sorting process.
[0037] In an embodiment of the present invention the scanning means, cloud server, put to light system integrated with tilt rack, sorting bins and other equipment are connected with a central control unit. The central control unit may be a computer/ processor or any other smart system meant for controlling the actions of the components connected to it via wired or wireless connection. The central control unit controls the action of all the components based on the step by step requirement or working in the warehouse. For the sake of brevity connection of central control unit with the said components is not discussed in detail.

[0038] The method of working of the tilt tray integrated put-to-light (PTL) sortation system includes the following steps:
• scanning the received shipment via scanning device (101);
• sending barcode details to the cloud server (102) for sorting shipment;
• glowing of PTL Module lamp based on the input received from the cloud server 102);
• placing the shipment in the PTL module (106) based on the glow indication by the operator;
• confirming the placement of the shipment in the PTL module (106) via light curtain sensor;
• sliding of the shipment via sliding plate onto the tilt tray (109);
• tilting the tray (109) in the required bin via Pneumatic cylinders or electric actuators wherein pneumatically through compressed air and a pneumatic cylinder with the piston providing linear movement to extend and retract the arm connected to the tray frame (113);
• monitoring the tilting of the tray (109) via Reed Switches in case of Pneumatic Cylinders, while using electrical actuators inbuilt limit switches; and
• dropping the shipment into the sorting bin (110) via tilt tray (109) based on the data provided by the server (102) for scanned barcode.

[0039] The advantages of the present invention are discussed herein:
● providing optimized and high speed sortation system;
● improves order accuracy and efficiency; and
● providing compact infrastructure.

[0040] While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
, Claims:WE CLAIM:
1. A tilt tray integrated put-to-light (PTL) sortation system (100), comprising:
i. a scanning means (101) configured to scan the barcode affixed on shipment;
ii. a cloud server (102) configured to manage the light-directed shipment sortation process;
iii. a PTL rack (103) configured to receive the dedicated shipment after the operator scans the barcode label on the item with the scanning means;
iv. a MS base frame (104) configured to mount the PTL Rack;
v. a plurality of bin (110) configured to store or collect the shipments or packages; and
vi. a tilt tray (109) configured to tilt and drop the shipment;
Wherein
● the tilt tray (109) comprises a square plate (114) mounted on a frame (113) linked via shaft to Electrical Actuators or Pneumatic Cylinders on all the sides;
● the square plate connected at one end of the shaft (112) with a mounting frame (113) attached to the Electrical Actuators or Pneumatic Cylinders (111) connected at the middle of the shaft; and
● a plurality of sorting bins (110) or postal bags fastened to the MS frame via a bag holder configured to collect the shipment.

2. The system as claimed in claim 1, wherein the electrical actuators or pneumatic cylinders and the square plate are fixed via ball and socket joint to the shaft.

3. The system as claimed in claim 1, wherein the base frame encases holes for grouting the complete PTL Rack on the ground.

4. The system as claimed in claim 1, wherein the tilt tray frame is connected to Electrical Actuators or Pneumatic Cylinders (111) via ball and socket joints (115).

5. The system as claimed in claim 1, wherein the tilting mechanism of the tray is provided pneumatically through compressed air and a pneumatic cylinder with the piston providing linear movement to extend and retract the arm connected to the tray frame (113).

6. A method for working of the tilt tray integrated put-to-light (PTL) sortation system (100) as claimed in claim 1 comprising the following steps:
● scanning the received shipment via scanning device (101);
● sending barcode details to the cloud server (102) for sorting shipment;
● glowing of PTL Module lamp based on the input received from the cloud server 102);
● placing the shipment in the PTL module (106) based on the glow indication by the operator;
● confirming the placement of the shipment in the PTL module (106) via light curtain sensor;
● sliding of the shipment via sliding plate onto the tilt tray (109);
● tilting the tray (109) in the required bin via Pneumatic cylinders or electric actuators wherein pneumatically through compressed air and a pneumatic cylinder with the piston providing linear movement to extend and retract the arm connected to the tray frame (113);
● monitoring the tilting of the tray (109) via Reed Switches in case of Pneumatic Cylinders, while using electrical actuators inbuilt limit switches; and
● dropping the shipment into the sorting bin (110) via tilt tray (109) based on the data provided by the server (102) for scanned barcode.