	US 11,814,249 B2
	Conveyor and logic systems to return, balance, and buffer processed or empty totes
Nicholas O. Thomas, Centerton, AR (US); Jason Scott Coyle, Rogers, AR (US); Jessica L. Solana, Bentonville, AR (US); and Mustafa A. Harcar, Centerton, AR (US)
Assigned to Walmart Apollo, LLC, Bentonville, AR (US)
Filed by Walmart Apollo, LLC, Bentonville, AR (US)
Filed on Jan. 13, 2022, as Appl. No. 17/575,475.
Application 17/575,475 is a continuation of application No. 16/716,208, filed on Dec. 16, 2019, granted, now 11,254,513.
Application 16/716,208 is a continuation of application No. 15/883,248, filed on Jan. 30, 2018, granted, now 10,507,975, issued on Dec. 17, 2019.
Claims priority of provisional application 62/453,750, filed on Feb. 2, 2017.
Prior Publication US 2022/0135339 A1, May 5, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B65G 43/08 (2006.01); B65G 1/137 (2006.01); G06Q 10/08 (2023.01)

CPC B65G 43/08 (2013.01) [B65G 1/1378 (2013.01); G06Q 10/08 (2013.01); B65G 2203/0266 (2013.01); B65G 2203/042 (2013.01)]

18 Claims

1. A system for distributing empty totes from consolidation areas to picking areas, the system comprising:

a first conveyor line for conveying the empty totes, the first conveyor lines connecting a first consolidation area to a first picking area;

a first sensor configured to detect partial and full empty tote capacity near the first picking area;

a first buffer component coupled to the first conveyor line for conveying the empty totes from the first conveyor line; and

a control circuit in communication with the first sensor and the first buffer component, the control circuit configured to:

output signaling to direct the empty totes from the first consolidation area to the first picking area via the first conveyor line when the first plurality of sensors detects an absence of totes in at least one location proximate the first picking area; and

output signaling to direct at least one empty tote to the first buffer component when the first plurality of sensors does not detect the absence of totes in the at least one location proximate the first picking area.

10. A system for distributing empty totes from a plurality of emptying areas, the system comprising:

first and second conveyor lines, the first conveyor line connecting a first emptying area to a first filling area and the second conveyor line connecting a second emptying area to a second filling area, the first and second conveyor lines connected by a buffer line;

a first sensor configured to detect a need for empty totes at the first filling area, and a second sensor configured to detect a need for empty totes at the second filling area;

a control circuit in communication with the first and second sensors, the control circuit configured to signal at least one transfer device to move empty totes from one of the first and second conveyor lines in response to signals from the first and second; and

at least a first overflow sensor configured to signal the control circuit when the first or second conveyor line reach a specified capacity of empty totes.

14. A method for distributing empty totes from a first area, the method comprising:

moving empty totes along a first conveyor line coupled to a first buffer component, the first conveyor line connecting a first consolidation area to a first picking area, the first conveyor line comprising a first sensor configured to detect partial and full empty tote capacity near the first picking area, the first sensor including at least a first overflow sensor;

signaling a control circuit via the first overflow sensor when the first conveyor line reaches a specified capacity of the empty totes;

moving the empty totes along a second conveyor line coupled to a second buffer component, the second conveyor line connecting a second consolidation area to a second picking area, the second conveyor line coupled to a second sensor configured to detect partial and full empty tote capacity near the second picking area, the second sensor including at least a second overflow sensor;

signaling the control circuit via the first overflow sensor when the first conveyor line reaches the specified capacity of the empty totes;

receiving signals from the first sensor and the second sensor at the control circuit; and

generating by the control circuit a control signal to direct the totes from at least one of the first conveyor line and the second conveyor line to a respective at least one of the first and second buffer components based on signals received from at least one of the first and second sensors.