Article sorting system

Abstract

The present invention relates to a system for organizing the assembly of a retailer's order. The system of the invention includes a system computer, conveyor assemblies and multiple sections. Each section includes an assembly section computer which controls multiple picking machines, a section conveyor, printers, and bundlers. Multiple bins are filled with articles, such as magazines, by the picking machines; the section conveyor then transports each bin to their next respective picking machine to be filled with that title location's magazine. Once a bin has been serviced by each picking machine of each title location, the contents of the bin are ejected and bundled by a bundler. Then, all bundles of a retailer's order are assembled at a palletizing area awaiting to be loaded into the delivery truck. The system of the invention coordinates the retailer's order in sequence with the orders of other retailers so that the orders are organized within the routeman's truck so that each order is dropped off in sequence along the route. Each retailers' order is output out of the system such that the delivery truck is loaded so that the first delivery to a retailer is the first order to be taken off the delivery truck, and at the second stop of the delivery truck the second retailer's order is the next order of bundles to be taken off the delivery truck.

What is claimed as new and is desired to be secured by Letter Patent of the United States is:  
     
         1 . A system for organizing a plurality of articles, comprising: 
 a system computer;    a plurality of section computers each connected to said system computer;    a plurality of section conveyor assemblies, one of said plurality of section conveyor assemblies operably connected to one of said plurality of section computers, respectively; and    a plurality of picking machines operably connected with each of said plurality of section computers and said respective section conveyor assembly.    
     
     
         2 . A system for organizing a plurality of articles according to    claim 1   , further comprising a plurality of section output sensors and scanners connected to said system computer, one of said plurality of section output sensors and scanners located at an output of said plurality of section conveyor assemblies, respectively.  
     
     
         3 . A system for organizing a plurality of articles according to    claim 2   , further comprising a plurality of system conveyor assemblies, one of said plurality of system conveyor assemblies being operably connected to one of said plurality of section conveyor assemblies, respectively, and connected to said system computer.  
     
     
         4 . A system for organizing a plurality of articles according to    claim 3   , further comprising a final conveyor assembly operably connected to an output end of said plurality of system conveyor assemblies and connected to said system computer.  
     
     
         5 . A system for organizing a plurality of articles according to    claim 4   , further comprising an accumulation area having accumulation conveyor assemblies associated with each of said system conveyor assemblies, respectfully, each of said accumulation conveyor assemblies having an input end located adjacent to the output end of said system conveyor assembly, and each of said accumulation conveyor assemblies having an output end adjacent to the input end of said final conveyor assembly.  
     
     
         6 . A system for organizing a plurality of articles according to    claim 5   , further comprising gates, one of said gates connected to said output end of each of said accumulation conveyor assemblies, respectfully, and connected to said system computer, and each gate having a gate sensor and a gate scanner mounted adjacent to said gate, each of said gate sensors and gate scanners connected to said system computer.  
     
     
         7 . A system for organizing a plurality of articles according to    claim 6   , further comprising a palletizing area located adjacent to an output of said final conveyor.  
     
     
         8 . A system for organizing a plurality of articles according to    claim 1   , wherein each of said plurality of picking machines includes: 
 a picking machine frame;    a picking machine computer mounted on said picking machine frame and connected to said section computer;    a suction mechanism movably mounted on said picking machine frame and connected to said picking machine computer;    stack conveying means on said picking machine frame for delivering a stack of articles to a first position; and    means for moving said suction mechanism to pick up an uppermost article from said stack of articles at said first position and moving said uppermost article to a bin, wherein said bin rests atop said respective section conveyor assembly.    
     
     
         9 . A system for organizing a plurality of articles according to    claim 8   , wherein said stack conveying means comprises a plurality of a vertically moving shelves which each carry a stack of articles.  
     
     
         10 . A system for organizing a plurality of articles according to    claim 9   , wherein each of said shelves is pivotable at said first position from a horizontal position to a vertical position when depleted of stacked articles.  
     
     
         11 . A system for organizing a plurality of articles according to    claim 8   , wherein said suction mechanism is slidably mounted on rods, said moving means sliding said suction mechanism between said first and second positions along said rods.  
     
     
         12 . A system for organizing a plurality of articles according to    claim 8   , wherein said bin rests on said section conveyor assembly.  
     
     
         13 . A system for organizing a plurality of articles according to    claim 8   , wherein said moving means for moving said suction mechanism comprises first means for moving said suction mechanism in a downward direction toward the uppermost article and in an upward direction to lift up the uppermost article.  
     
     
         14 . A system for organizing a plurality of articles according to    claim 8   , further comprising detecting means connected to said picking machine computer for detecting the articles on said shelves at said first position.  
     
     
         15 . A system for organizing a plurality of articles according to    claim 5   , wherein said accumulation area has a length of thirty feet.  
     
     
         16 . A system for organizing a plurality of articles according to    claim 8   , further comprising an article sensor mounted on said picking machine frame and connected to said picking machine computer for detecting delivery of said article to said bin by said suction mechanism.  
     
     
         17 . A system for organizing a plurality of articles according to    claim 8   , further comprising a bin sensor mounted on said picking machine frame and connected to said picking machine computer for detecting a location of said bin.  
     
     
         18 . A system for organizing a plurality of articles according to    claim 8   , further comprising a pneumatic cylinder mounted on said picking machine frame and connected to said picking machine computer for engaging said bin.  
     
     
         19 . A system for organizing a plurality of articles according to    claim 8   , wherein said suction mechanism includes a cylinder device for actuating said suction mechanism in a vertical direction.  
     
     
         20 . A system for organizing a plurality of articles according to    claim 19   , wherein said suction mechanism includes a guide bar mechanism for actuating said suction mechanism in a horizontal direction.