Description:FIELD OF INVENTION
[001] The present invention relates to the field of item sorting. Particularly, the present invention relates to an automated multiple item feeding and sorting system and a method of operation thereof, facilitating each automated sorting device to carry multiple items at a time, thereby enabling feeding and sortation of multiple items at a time according to their corresponding destination.

BACKGROUND OF THE INVENTION

[002] In today’s global marketplace, logistics and parcel management plays a pivotal role in facilitating the seamless movement of goods and products from manufacturers to consumers. In the ever-expanding world of logistics and parcel management, the need for efficient, reliable, and high-throughput feeding and sorting systems has become paramount. As the volume of parcels continues to surge, traditional sorting methods struggle to keep pace with the demand, leading to delays, errors, and increased operational costs.

[003] The commercially available robots for sorting items consist of a transportation system that generally carries only one item at a time on a single platform. This platform, loaded with the item to be sorted, is carried to a desired drop location, and the item is then dropped. The bot returns to the feeding track to get the next feed of a single item. However, in this construct, the bots are capable of carrying only one item at any given point in time. Further, in this construct, the number of robots required is higher, leading to a high cost and complexity of the construct. Moreover, the total travel distance of all the bots for a defined number of items is higher as they carry single items.

[004] There are several patent applications that discloses feeding and sorting systems. One such United States Patent Application US20170183158A1 relates to a parcel and article sorting system and method. The cited prior art discloses a system comprising an article supply location; a first and second transport vehicles; and a control system. The article supply location comprises a plurality of articles that needs to be sorted. The first and second transport vehicles comprises of a first position wherein an article is stowed about the vehicle and a second position wherein the article is deposited into a proximal container. The control system receives an order for a plurality of disparate articles, determine one destination container of a plurality of destination containers so as to direct the transport vehicle for depositing a selected article, direct the first transport vehicle for transporting a selected article to the destination container and deposit the article by manipulating first transport vehicle from first position to second position for deposit of the selected article in destination container, direct the second transport vehicle for transporting a disparate article to the destination container and deposit the disparate article by manipulating the second transport vehicle from the first position to the second position for deposit of the disparate article in the destination container; and determine when order has been completed. However, the cited prior art may face challenges in terms of articles it can handle simultaneously, which may lead to bottlenecks during peak periods, slowing down the sorting process and affecting overall efficiency. Further, the intricate design of the system involves multiple transport vehicles and a control system, leading to increased complexity. Moreover, advanced control system and transport vehicles as disclosed in the cited prior art may involve significant upfront costs. Furthermore, coordination of multiple transport vehicles to avoid collisions while navigating platform may be complex and may require precise programming and control.

[005] Another European Patent Application EP1265174A1 discloses an apparatus for sorting a stream of products into a set of destination bins. The system comprises of a transport means for receiving the stream of products, and in response to control signals effectuating downstream movement of individual products and selectively diverting individual products from said transport means into a designated destination bin, and means to identify each individual product and generate identification signals; the means to track the position and movement of individual products within the transport means and generate tracking signals, and a control unit responsive to the identification and the tracking signals, for generating control signals to control operation of said transport means. The said means for tracking comprises an array of photoelectric detectors longitudinally dispersed along the length of said transport means. However, the cited prior art involves a computer-controlled transport path with a tracking system, photoelectric detectors, and diverting gates. Moreover, the apparatus as disclosed in the cited prior art require significance amount of space to accommodate the transport path, roller pairs, and diverting gates. Such arrangement and space occupancy makes such a system complex and may lead to higher initial setup costs and maintenance setup. Further, the reliance on photoelectric detectors and tracking systems make the sorting process sensitive to malfunctions or inaccuracies in these components. Any failures or errors in such tracking and identification systems may lead to mis-sorted products, affecting accuracy and efficiency.

[006] Moreover, none of the above cited prior art involves carrying more than one item in a bot/apparatus at a time and does not provide any provision for feeding and sortation of multiple items at a time based on their corresponding destination.

[007] In order to overcome the challenges associated with the above mentioned prior art, there is a need to develop a cost-effective, efficient, easily operable multiple item feeding and sorting system/system.
OBJECTIVES OF THE INVENTION
[008] The primary objective of the present invention is to provide an automated multiple item feeding and sorting system and a method of operation thereof.

[009] Another objective of the present invention is to provide an automated sorting device carrying multiple items at a time.

[0010] Another objective of the present invention is to enable feeding and sortation of multiple items at a time according to their corresponding destination.

[0011] Another objective of the present invention is to logically define a path for the automated sorting device based on the drop location identified from the items placed on the automated sorting device, ensuring higher number of items sortation per unit distance travelled by the automated sorting device.

[0012] Yet another objective of the present invention is to provide automated logical mechanism of dropping each item into its corresponding destination bag.

[0013] Other objects 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
[0014] The present invention comprises of an automated multiple item feeding and sorting system and a method for operation thereof. The system comprises of a scanner to scan product code of items by an operator; a plurality of automated sorting devices to carry the items along a track and deliver each item in its corresponding destination bag, a central database configured to store pre-determined destination codes characterized according to the delivery address of the items; and scanned information of the item, indicating the destination of each item; a server connected to the central database to retrieve destination related data from the central database for further processing; an electronic unit connecting the server and the motors; an operating device connected to the server to receive data from the server regarding sequence of the items to be places in each tray; and a feeding track to load the items on the automated sorting device by the operator. The automated sorting device comprises of a hollow frame to hold the components of the automated sorting device together in place; a first set of rollers movably installed on lower end of the hollow frame to facilitate the movement of the automated sorting device along the track; at least four trays installed in space within the hollow frame, wherein each tray comprises of one item; a plurality of conveyor belts, wherein each conveyor belt is mounted on each tray to facilitate dropping of the item from each tray; a second set of rollers installed beneath each conveyor belt of each tray to rotate the conveyor belt to unload the items in its corresponding destination bag; and a plurality of motors, wherein each motor is provided between every two rollers of the second set of rollers of each tray to rotate the second set of rollers of a particular tray. The trays are arranged one above other, forming a vertical stacking configuration. Each tray represent one level, forming a multiple levels for feeding and sorting of multiple items. Each automated sorting device is configured to carry and sort multiple items with varying destination at a time. The present invention also provides a method for operating an automated multiple item feeding and sorting system. The present invention ensures that each automated sorting device carries multiple items at a time, thereby enabling feeding and sortation of multiple items at a time according to their corresponding destination.

BRIEF DESCRIPTION OF DRAWINGS
[0015] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:

[0016] Figure 1A and Figure 1B illustrates front view and side view of automated multiple item feeding and sorting system, respectively.

DETAILED DESCRIPTION OF THE INVENTION
[0017] The following description describes various features and functions of the disclosed system with reference to the accompanying figures. In the figures, 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 can be arranged and combined in a wide variety of different configurations, all of which have not been 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 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 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 illustrative 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, steps or components but does not preclude the presence or addition of one or more other features, steps, components or groups thereof.

[0023] Accordingly, the present invention relates to the field of item sorting. Particularly, the present invention relates to an automated multiple item feeding and sorting system and a method of operation thereof, facilitating each automated sorting device(104) to carry multiple items at a time, thereby enabling feeding and sortation of multiple items at a time according to their corresponding destination.

[0024] As shown in Figure 1, the automated multiple item feeding and sorting system (100) comprises of the following components:

[0025] a) Scanner (102)– The system (100) comprises of a scanner (102) to scan product code of items by an operator.

[0026] b) Automated sorting devices (104): The system (100) comprises of a plurality of automated sorting devices (104) to carry the items along a track and deliver each item in its corresponding destination bag. In a preferred embodiment, each automated sorting device (104) is configured to carry and sort multiple items with varying destination at a time. Each automated sorting device (104) used in the present invention comprises of a unique number, differing each automated sorting device (104) from other automated sorting devices (104). The automated sorting device (104) comprises of:

• Hollow frame (106) – The automated sorting device (104) comprises of a hollow frame (106) to hold the components of the automated sorting device (104) together in place. The hollow frame (106) serves as support structure for the components of the automated sorting device (104).

• First set of rollers (108): A first set of roller (108) is movably installed on lower end of the hollow frame (106) to facilitate the movement of the automated sorting device (104) along the track. The first set of rollers (108) may be fixed in the space provided on the track, making the rollers movably mounted on the frame (104). In an exemplary embodiment, the first set of rollers (108) comprises of a pair of rollers.

• Trays (110) – The automated sorting device (104) comprises of at least four trays (110) installed in space within the hollow frame (102) to hold the items to be sorted. The trays (110) are arranged one above other, forming a vertical stacking configuration. Each tray (110) represents one level such that stacking of trays (110) facilitates multi-level sorting of multiple items as well as allows for efficient use of vertical space and.

• Conveyor belts (112): The automated sorting device (104) comprises of a plurality of conveyor belts (112) wherein each conveyor belt (112) is mounted on each tray (110) to facilitate dropping of the item from each tray (110).

• Second set of rollers (114): A second set of rollers (114) are installed beneath each conveyor belt (112) of each tray (110) to rotate the conveyor belt (112) to unload the items in its corresponding destination bag. In an exemplary embodiment, the second set of rollers (114) comprises of a series of a plurality of rollers. In an exemplary embodiment, closed loop belt is used as conveyor belt (112) in the present invention. The closed loop belt is a continuous belt that forms a loop such that the ends of each belt are connected, creating endless conveyor system, and thereby allowing items to be carried along a continuous path. Each conveyor belt (112) is equipped with a gripper configured to hold and prevent slippage of the item during the movement of the automated sorting device (104) from one location to another. The gripper may securely grasp the items, preventing the items from falling or shifting during the sorting process.

• Motors (116): The automated sorting device (104) comprises of a plurality of motors (116), wherein each motor (116) is provided between every two rollers of the second set of roller (114) of each tray (110), facilitates rotation of the second set of rollers (114) of a particular tray (110).

[0027] (c) Central database (118): The system (100) comprises of a central database (118) that serves as a repository for storing pre-determined destination codes which are characterized according to the destination i.e. delivery address of the items. The destination codes stored in the central database (118) serve as a unique identifier for a particular destination center. The central database (118) also stores the scanned information of the item, indicating the destination of each item.

[0028] (d) Server (120): The system (100) comprises of a server (120) connected to the central database (118). The server (120) retrieves destination related data from the central database (118) for further processing. The server (120) is configured to perform the following functions:

• determining which particular automated sorting device (104) will retrieve the scanned items based on the unique number associated with each automated sorting device (104) and transmit the signal to that automated sorting device (104) is approach the operator and ultimately reach the feeding track (126);
• notifies the operator regarding sequence of placing the item in the tray (110) on operating device (124) wirelessly;
• generates and transmits a signal defining a route for the movement of the automated sorting device (104) based on drop location of the each item, ensuring all the items are dropped in a minimum time and transmits the signal;
• determines drop location of each item i.e. destination bag in which each item is to be dropped; and
• transmits signal to electronic unit (122) for dropping of the item in destination bags

[0029] (e) Electronic unit (122) – The system (100) comprises of an electronic unit (122) connecting the server (120) and the motors (116). The electronic unit (122) is configured to:
• receive signal from the server (120) regarding actuation of the second set of rollers (114) of a particular tray (110) for dropping the item in its corresponding destination bag; and
• transmit signals to the motor (116) via cables integrated inside the hollow frame (106) regarding actuating the rollers of the second set of rollers (114) for dropping the item in a particular destination bag.

[0030] (f) Operating Device (124) – An operating device (124) connected to the server (120) to receive data from the server (120) regarding sequence of the items to be places in each tray (110).

[0031] (g) Feeding track (126) – The system (100) comprises of a feeding track (126) for the operator to load the items on the automated sorting device (104) for further sortation.

[0032] In an exemplary embodiment, number of trays (110) may vary depending on the type of items to be sorted. For instance, if fragile items are to be sorted then the number of tray (110) may not exceed four in number as more number of trays (110) may increase the height resulting from leveling up of the tray (110) and thus dropping of the fragile item into destination bag from such a height may cause damage to the items. On the contrary, if the items to be sorted are not fragile item such as documents, etc., the number of trays (110) may exceed beyond four as dropping of such items from a height may not cause any damage to the items. In a preferred embodiment, at least four trays (110) are installed in the space within the hollow frame (106) one above the other.

[0033] Each destination bag represent a particular distribution center comprising of a single pin code or a plurality of pin codes where the items are destined to be delivered.

[0034] In an alternate embodiment, each tray (110) is equipped with an enclosure to safeguard the item loaded onto each tray (110). The server (120) transmits the signal to the tray (110) to open when the item needs to be dropped in a specific destination bag.

[0035] In an embodiment, as the operator scans the product code items using the scanner (102), the scanned information is transmitted to the central database (118) comprising of pre-determined destination codes. The server (120) fetch the destination related information from the central database (118) and further determines which automated sorting device (104) will retrieve the scanned items based on the unique number associated with each automated sorting device (104). The server (120) then transmits the signal to the automated sorting device (104) to reach feeding track (126). The operator loads each scanned item on its corresponding conveyor belt (112) mounted on each tray (110) of the automated sorting device (104) based on the basis of signal received from the server (120) in an operating device (124) of the operator. The items are loaded in a manner such that each tray (110) comprises of one item, thereby enabling the automated sorting device (104) to carry multiple items at a time for sortation. Once the trays (110) are filled with the items, the server (120) generates and transmits a signal to the automated sorting device (104) defining an optimized route to be followed depending drop location of each item. The automated sorting device (104) moves according to the defined path on the track with the help of the first set of rollers (108) movably fitted in the space provided on the track. Further, the electronic unit (122) on receiving the signal from the server (120) regarding actuation of the second set of rollers (114) of a particular tray (110), transmit the signal to motors (116) positioned in between the every two rollers of each tray (110), which in turn actuates the rollers of the second set of rollers (114) of a particular tray (110). The second set of rollers (114) rotate the conveyor belt (112) to unload the item in its corresponding destination bag. The automated sorting device (104) then moves to the next location and drops the item in its corresponding destination bag and continues the process for all the items followed by returning to the feeding track (126) upon completely uploading all the items. Thus, the automated sorting device (104) is capable of sorting multiple items at a time. Once all the items are unloaded in their corresponding destination bags, the destination bags are transported for further sorting. The same process is repeated for another lined up automated sorting device (104) as the first automated device is out for unloading the items in their corresponding destination bags.

[0036] In an exemplary embodiment, the operating device (124) may be selected from a group consisting of, such as, but not limited to, mobile device, laptop, computer, etc.

[0037] In an alternate embodiment, each level of the automated sorting device (104) comprises of a proximity sensor to map the scanned product code of each item to the item placed on a particular tray (110) in any order.

[0038] In an embodiment, the present invention provides a method for automated multiple item feeding and sorting. The method comprises of the following step:
(a) scanning of an item by an operator using a scanner (102);
(b) transmitting of scanned information to a central database (118) comprising of pre-determined destination codes characterized as destination i.e. address of the items;
(c) fetching destination related information from the central database (118) by a server (120);
(d) determining an automated sorting device (104) that is required to retrieve scanned items based on unique number associated with each automated sorting device (104) by the server (120);
(e) transmitting signal to the automated sorting device (104) by the server (120) to reach feeding track (126);
(f) loading each scanned item on its corresponding conveyor belt (112) mounted on each tray (110) of the automated sorting device (104) on the basis of signal received from the server (120) in an operating device (124) of the operator;
(g) generating and transmitting a signal to the automated sorting device (104) defining an optimized route to be followed depending drop location of each item;
(h) moving of the automated sorting device (104) on the defined path on a track with the help of first set of rollers (108) fitted in the space provided on the track;
(i) transmitting signal from the server (120) to an electronic unit (122) regarding actuation of a second set of rollers (114) of a particular tray (110);
(j) transmitted signal to motors (116) positioned in between the every two rollers of each tray (110);
(k) actuating the rollers of the second set of rollers (114) of a particular tray (110);
(l) rotating of the second set of rollers (114) so as to rotate conveyor belt (112) to unload the item in its corresponding destination bag;
(m) moving of the automated sorting device (104) to the next location and dropping the item in its corresponding destination bag followed by continuing the process for all the items and returning to the feeding track (126) upon completely uploading all the items;
(n) transporting of the destination bags for further sorting; and
(o) repeating the process for another lined up automated sorting device (104) as the first automated device is out for unloading the items in their corresponding destination bags.
[0039] In a preferred embodiment, the scanned items are loaded in a manner such that each tray (110) comprises of one item each, thereby enabling the automated sorting device (104) to carry multiple items at a time for sortation.

[0040] The present invention exhibits a plurality of advantages:

a) The present invention ensures a fast, continuous, smooth process for multi-level feeding and sorting of multiple items destined to delivered to a different location at a time.
b) The present inventions ensures reduced number of automatic sorting device and the distance travelled in complete functioning sorting system, thus helps improve management of the traffic on the track, as well as the complexity and cost due to reduction in number of automatic sorting device.
c) The method of the present invention ensures better utilization of the routes taken by the automated sorting device.
d) The stacked configuration of the trays maximizes the use of vertical space, allowing the system to handle more items within a limited footprint.
e) The conveyor belt with grip arrangement enables a continuous feeding and sorting process. The conveyor belt allow items to be carried along a continuous path, thereby reducing the need for manual intervention. The use of conveyor belt with grip arrangement can efficiently enhance automation capabilities as items can be transported and sorted without the need for extensive manual intervention.
[0041] 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. An automated multiple item feeding and sorting system, comprising:
• a scanner (102) to scan product code of items by an operator;
• a plurality of automated sorting devices (104) to carry the items along a track and deliver each item in its corresponding destination bag, comprising:
o a hollow frame (106) to hold the components of the automated sorting device (104) together in place;
o a first set of rollers (108) movably installed on lower end of the hollow frame (106) to facilitate the movement of the automated sorting device (104) along the track;
o at least four trays (110) installed in space within the hollow frame (106), wherein each tray (110) comprises of one item;
o a plurality of conveyor belts(112), wherein each conveyor belt is mounted on each tray (110) to facilitate dropping of the item from each tray (110);
o a second set of rollers (114) installed beneath each conveyor belt (108) of each tray (110) to rotate the conveyor belt to unload the items in its corresponding destination bag; and
o a plurality of motors (116), wherein each motor (116) is provided between every two rollers of the second set of rollers (114) of each tray (110) to rotate the second set of rollers (114) of a particular tray (110);
• a central database (118) configured to store:
o pre-determined destination codes characterized according to the delivery address of the items; and
o scanned information of the item, indicating the destination of each item;
• a server (120) connected to the central database (118) to retrieve destination related data from the central database (118) for further processing;
• an electronic unit (122) connecting the server (120) and the motors (116);
• an operating device (124) connected to the server (120) to receive data from the server (120) regarding sequence of the items to be places in each tray (110); and
• a feeding track (126) to load the items on the automated sorting device (104) by the operator;
characterized in that,
(I) the trays (110) are arranged one above other, forming a vertical stacking configuration;
(II) each tray (110) represent one level, forming a multiple levels for feeding and sorting of multiple items; and
(II) each automated sorting device (104) is configured to carry and sort multiple items with varying destination at a time.

2. The system as claimed in claim 1, wherein each automated sorting device (104) comprises of a unique number, differing the automated sorting devices (104) from other automated sorting devices (104).
3. The system as claimed in claim 1, wherein the first set of rollers (108) comprises of a pair of rollers.
4. The system as claimed in claim 1, wherein the second set of rollers (114) comprises of a series of a plurality of rollers.
5. The system as claimed in claim 1, wherein the conveyor belt is a closed loop belt.

6. The system as claimed in claim 1, wherein each conveyor belt is equipped with a gripper configured to hold and prevent slippage of the item during the movement of the automated sorting device (104) from one location to another.
7. The system as claimed in claim 1, wherein the destination codes stored in the central database (118) serve as a unique identifier for a particular destination center.
8. The system as claimed in claim 1, wherein each destination bag represent a particular distribution center comprising of a single pin code or a plurality of pin codes where the items are destined to be delivered.

9. The system as claimed in claim 1, wherein the trays (110) may vary in number depending on the type of items to be sorted.

10. The system as claimed in claim 1, wherein each tray (110) is equipped with an enclosure to safeguard the item loaded onto each tray (110).

11. The system as claimed in claim 1, wherein each level of the automated sorting device (104) comprises of a proximity sensor to map the scanned product code of each item to the item placed on a particular tray (110) in any order

12. A method for operating an automated multiple item feeding and sorting system as claimed in claim 1, comprising steps of:
(a) scanning of an item by an operator using a scanner (102);
(b) transmitting of scanned information to a central database (118) comprising of pre-determined destination codes characterized as destination i.e. address of the items;
(c) fetching destination related information from the central database (118) by a server (120);
(d) determining an automated sorting device (104) that is required to retrieve scanned items based on unique number associated with each automated sorting device (104) by the server (120);

(e) transmitting signal to the automated sorting device (104) by the server (120) to reach feeding track (126);
(f) loading each scanned item on its corresponding conveyor belt mounted on each tray (110) of the automated sorting device (104) on the basis of signal received from the server (120) in an operating device (124) of the operator;
(g) generating and transmitting a signal to the automated sorting device (104) defining an optimized route to be followed depending drop location of each item;
(h) moving of the automated sorting device (104) on the defined path on a track with the help of first set of rollers (108) fitted in the space provided on the track;
(i) transmitting signal from the server (120) to an electronic unit (122) regarding actuation of a second set of rollers (114) of a particular tray (110);
(j) transmitted signal to motors (116) positioned in between the every two rollers of each tray (110);
(k) actuating the rollers of the second set of rollers (114) of a particular tray (110);
(l) rotating of the second set of rollers (114) so as to rotate conveyor belt to unload the item in its corresponding destination bag;
(m) moving of the automated sorting device (104) to the next location and dropping the item in its corresponding destination bag followed by continuing the process for all the items and returning to the feeding track (126) upon completely uploading all the items;
(n) transporting of the destination bags for further sorting; and
(o) repeating the process for another lined up automated sorting device (104) as the first automated device is out for unloading the items in their corresponding destination bags.