Flats sequencing system and method of use

Abstract

A system and method sequencing objects in trays by assigning a direction to tray locations, where each of the tray locations provides space for trays. The objects are placed into the trays corresponding to assigned directions of the objects. A determination is made as to whether there are additional objects that correspond to the direction and, if so, the direction is assigned to unassigned tray locations based on pre-defined rules. Once all of the objects are in the trays, the trays are moved to the feeder system in a sequential order based on the directions. In a second pass, the directions are reassigned to the tray locations based on a number of trays required to hold the objects. The objects are placed into the trays corresponding to the directions of the objects. The trays are then transported to an unloading stage in a sequential order corresponding to the reassigned directions.

1 - 43 . (canceled)  
   
   
       44 . A method of sequencing objects in trays located at tray locations of bin sections, comprising: 
 moving filled trays with objects through a feeder system in sequential order based on a direction;    reassigning the direction to tray locations based on a number of trays required to hold the objects in the reassigned direction; and    placing the objects into the trays at the tray locations associated with the reassigned directions.    
   
   
       45 . The method of  claim 44 , further comprising: 
 pre-assigning the direction to the tray locations;    providing an unassigned designation to at least one tray location of the tray locations, the tray locations providing space for the trays;    placing the objects into the trays of the tray locations with the direction corresponding to assigned directions of the objects; and    determining whether there are additional objects requiring placement which correspond to the direction and, if so, assigning the direction to an unassigned tray location based on pre-defined rules and placing the objects in the trays of the subsequently assigned tray locations.    
   
   
       46 . The method of  claim 44 , further comprising transporting the trays with the objects to a loading area in a sequential order corresponding to the reassigned direction.  
   
   
       47 . The method of  claim 44 , wherein: 
 the reassigned direction is a set of sequenced delivery or storage points; and    the tray locations include at least one front tray location and at least one back tray location;    the tray locations are positioned in one or more partitions; and    at least one front tray location of each partition includes an unassigned designation.    
   
   
       48 . The method of  claim 47 , wherein the moving step comprises: 
 (i) determining whether a front tray in the front tray location is filled with objects for a pre-assigned direction;    (ii) determining whether a transporting system is empty in front of the front tray;    (iii) determining whether a lower direction assigned tray will be blocked by moving the front tray onto the transporting system; and    (iv) moving the front tray onto the transporting system when steps (i) and (ii) are positive and step (iii) is negative.    
   
   
       49 . The method of  claim 47 , further comprising waiting until the first pass is complete when at least one of the step (ii) is negative and step (iii) is positive.  
   
   
       50 . The method of  claim 47 , further comprising moving a back tray to the front tray location and, if required, placing an empty tray at the back tray location.  
   
   
       51 . The method of  claim 44 , wherein the reassigning step includes assigning pre-assigned directions to the tray locations based on: 
 (i) recorded data used in a first pass;    (ii) scanning away from a sweep order; and    (iii) assigning a direction to a first available tray location in a direction away from the sweep order starting with a lowest direction.    
   
   
       52 . The method of  claim 51 , wherein the reassigning step further comprises: 
 determining whether there are more than two trays in a same direction; and    assigning the same direction to a next available tray location, always filling a front tray location first, when there are not more than two trays in the same direction.    
   
   
       53 . A system for sequencing objects in trays located at tray locations of bin sections, comprising: 
 means for moving trays with objects through a transporting system in sequential order based on predefined rules;    means for reassigning a direction to tray locations based on a number of trays required to hold the objects in the reassigned direction; and    means for transporting the trays, once objects are placed in the trays having a corresponding direction, to an unloading area based on a sequential order of the reassigned directions.    
   
   
       54 . A system for sequencing objects in trays located at tray locations of bin sections, comprising: 
 means for moving filled trays with objects in sequential order based on a direction;    means for reassigning the direction to tray locations based on a number of trays required to hold the objects in the reassigned direction; and    means for placing the objects into the trays at the tray locations associated with the reassigned directions.    
   
   
       55 . The system of  claim 54 , wherein the moving means is a continuous looped carousal system.  
   
   
       56 . The system of  claim 54 , further including a control system for controlling the system of  claim 54.