US-12617615-B2 - Pallet sorting system and method of use

US12617615B2US 12617615 B2US12617615 B2US 12617615B2US-12617615-B2

Abstract

A method for conveying a pallet through a pallet sorting system that includes receiving a pallet at a first position. A first set of pallet data is sensed from first sensors, where the first set of pallet data is non-image data. A second set of pallet data is sensed by image sensors. A logic module receives the first set of pallet data and the second set of pallet data. A subset of pallet data is selectively communicated to a machine learning module, which determines a third set of pallet data. A conveyance path is determined based at least on the third set of pallet data.

Inventors

BRADLEY D. RIETEMA
Brian Haas
KRIS A. CHAYER
MICHAEL R. HOLMES
ADAM LEE WINNER

Assignees

Kamps Pallets Inc.

Dates

Publication Date: 20260505
Application Date: 20250715

Claims (19)

1 . A method for conveying a pallet through a pallet sorting system, the method comprising: receiving a pallet at a first position of a feeder, a loading assembly, or a conveyor system; at least partially locating the pallet within a tunnel scanner assembly having first sensors, a mirror, and image sensors; sensing from the first sensors a first set of pallet data, wherein the first set of pallet data is non-image data, and wherein at least one first sensor of the first sensors senses data by: emitting an electromagnetic signal that is reflected by a mirror to the pallet, wherein the pallet reflects at least a portion of the emitted electromagnetic signal; and detecting the at least a portion of the emitted electromagnetic signal reflected off the pallet via the mirror; sensing, by the image sensors, a second set of pallet data, wherein at least one image sensor of the image sensors detects light reflected from the pallet via a mirror; receiving, at a logic module the first set of pallet data and the second set of pallet data; selectively communicating a subset of pallet data from the logic module to a machine learning module, the subset of pallet data comprising: the first set of pallet data or a subset of the first set of pallet data; and the second set of pallet data or a subset of the second set of pallet data; determining a third set of pallet data at the machine learning module based on the subset of pallet data; communicating the third set of pallet data from the machine learning module to the logic module; determining, at the logic module, a conveyance path based at least on the third set of pallet data; communicating the conveyance path from the logic module to a controller module; and transporting the pallet along the conveyance path to a second position via the conveyor system in communication with the controller module, wherein the transporting the pallet along the conveyance path includes conveying the pallet to a repair station and conveying the pallet to the tunnel scanner assembly or another tunnel scanner assembly after the conveying the pallet to the repair station.
2 . The method of claim 1 , wherein the pallet is a first pallet and the method further comprises, receiving a second pallet at the first position after the communicating the conveyance path of the first pallet is complete.
3 . The method of claim 1 , wherein the transporting the pallet along the conveyance path further comprises reducing pallet speed with a friction brake assembly.
4 . The method of claim 3 , wherein the reducing the pallet speed with the friction brake assembly includes adjusting doors, adjusting a paddle, or a combination thereof.
5 . The method of claim 1 , wherein the transporting the pallet along the conveyance path to the second position is complete in less than 4.5 seconds.
6 . The method of claim 1 , wherein the first set of pallet data, the second set of pallet data, the third set of pallet data, or any combination thereof is used to determine a maintenance list provided to the repair station or a screen.
7 . The method of claim 1 , wherein the transporting the pallet along the conveyance path includes, after the tunnel scanner assembly, conveying the pallet to one of a receiving portion, a side conveyor, the loading assembly, or a refuse area based on post repair data obtained by the tunnel scanner assembly.
8 . The method of claim 1 , wherein the first set of pallet data includes at least one of a length or a width of the pallet and wherein the at least one of the length or the width of the pallet is indicative of pallet origin.
9 . The method of claim 1 , wherein the first set of pallet data includes a two-dimensional or three-dimensional topography of the pallet.
10 . The method of claim 1 , further comprising activating a clearing device at a predetermined frequency or upon determination that the mirror is unclean.
11 . A method for conveying a pallet through a pallet sorting system, the method comprising: receiving a pallet at a first position of a feeder, a loading assembly, or a conveyor system; at least partially locating the pallet within a tunnel scanner assembly having first sensors, a mirror, and image sensors; sensing from the first sensors a first set of pallet data, wherein the first set of pallet data is non-image data, and wherein at least one first sensor of the first sensors senses data by: emitting an electromagnetic signal that is reflected by a mirror to the pallet, wherein the pallet reflects at least a portion of the emitted electromagnetic signal; and detecting the at least a portion of the emitted electromagnetic signal reflected off the pallet via the mirror; sensing, by the image sensors, a second set of pallet data, wherein at least one image sensor of the image sensors detects light reflected from the pallet via a mirror; receiving, at a logic module the first set of pallet data and the second set of pallet data; selectively communicating a subset of pallet data from the logic module to a machine learning module, the subset of pallet data comprising: the first set of pallet data or a subset of the first set of pallet data; and the second set of pallet data or a subset of the second set of pallet data; determining a third set of pallet data at the machine learning module based on the subset of pallet data; communicating the third set of pallet data from the machine learning module to the logic module; determining, at the logic module, a conveyance path based at least on the third set of pallet data; communicating the conveyance path from the logic module to a controller module; transporting the pallet along the conveyance path to a second position via the conveyor system in communication with the controller module; and activating a clearing device at a predetermined frequency or upon determination that the mirror is unclean.
12 . The method of claim 11 , wherein the transporting the pallet along the conveyance path includes conveying the pallet to a repair station.
13 . The method of claim 12 , wherein the transporting the pallet along the conveyance path includes conveying the pallet to the tunnel scanner assembly or another tunnel scanner assembly after the conveying the pallet to the repair station.
14 . The method of claim 11 , wherein the activating the clearing device includes fluidly coupling, via at least one valve, a compressed air source and a knife blower.
15 . A pallet sorting system comprising: a conveyance system comprising: a receiving portion and a delivery portion, wherein the delivery portion couples to a loading assembly to provide at least one pallet from a feeder to the loading assembly and wherein the loading assembly couples to an overhead conveyor system having a push rail and a friction brake; a tunnel scanner assembly located between the receiving portion and the delivery portion, wherein the tunnel scanner assembly includes: a camera configured to obtain image data; a sensor configured to obtain non-image data; and a mirror, wherein light detected by the camera is received from the mirror, and wherein the mirror reflects an electromagnetic signal provided by the sensor; and a control system operably coupled to the conveyance system and the tunnel scanner assembly, the control system configured to receive the image data from the camera and the non-image data from the sensor, determine from the image data and the non-image data information related to a pallet located at least partially within the tunnel scanner assembly, provide a conveyance path for the pallet based on the information related to the pallet, and activate the conveyance system to transport the pallet along the conveyance path.
16 . The pallet sorting system of claim 15 , wherein the conveyance system further comprises a first belt and a second belt located at least partially within the tunnel scanner assembly and wherein at least a portion of the mirror is located at least one of between the first belt and the second belt or spatially below the first belt and the second belt.
17 . The pallet sorting system of claim 15 , wherein a cycle time to move the pallet from a first position to a second position is less than 4.5 seconds.
18 . The pallet sorting system of claim 17 , wherein the cycle time is 3 to 4 seconds.
19 . The pallet sorting system of claim 15 , further comprising a clearing device.

Description

CROSS REFERENCE TO RELATED APPLICATION(S) This application is a continuation-in-part of patent application Ser. No. 18/934,570, filed Nov. 1, 2024, now U.S. Pat. No. 12,530,658, issued Jan. 20, 2026, which is a continuation-in-part of U.S. patent application Ser. No. 18/774,372, filed Jul. 16, 2024, all of which are incorporated herein by reference in their entirety. TECHNICAL FIELD The present subject matter relates generally to a method for conveying a pallet through a pallet sorting system that includes at least a conveyor system. BACKGROUND Pallets are used to move and ship materials or products. The wooden pallet is the most commonly used shipping pallet and can be made from a variety of woods, including oak or pine. Pallets can also be made of, for example, plastic, metal, paper, recycled materials, or combination thereof. Pallets provide an inexpensive and relatively durable platform to transport materials or products. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1 is a schematic view of a pallet sorting system in accordance with various aspects described herein. FIG. 2 is a perspective view of a feeder for use in the pallet sorting system of FIG. 1 in accordance with various aspects described herein. FIG. 3 is a schematic cross section view of a portion of the feeder, further illustrating a tunnel scanner assembly of FIG. 2 in accordance with various aspects described herein. FIG. 4 is a perspective view of a portion of the tunnel scanner assembly of FIG. 3 in accordance with various aspects described herein. FIG. 5 is a perspective view of a loading assembly for use in the pallet sorting system of FIG. 1 in accordance with various aspects described herein. FIG. 6 is a perspective view of a portion of the loading assembly of FIG. 5 and a portion of an overhead conveyor system for use in the pallet sorting system of FIG. 1 in accordance with various aspects described herein. FIG. 7 is a perspective view of a portion of the overhead conveyor system and a portion of the release assembly for use in the pallet sorting system of FIG. 1 in accordance with various aspects described herein. FIG. 8 is a perspective view of a portion of the overhead conveyor system of FIG. 7 further illustrating a friction brake assembly in accordance with various aspects described herein. FIG. 9 is a perspective view of a stacking assembly for use in the pallet sorting system of FIG. 1 in accordance with various aspects described herein. FIG. 10 is a schematic view of a control system for use in the pallet sorting system of FIG. 1 in accordance with various aspects described herein. FIG. 11 is a flow chart diagram illustrating a method for conveying a pallet through the pallet sorting system of FIG. 1 in accordance with various aspects described herein. FIG. 12 is a flow chart diagram illustrating a method for conveying a pallet through the pallet sorting system of FIG. 1 in accordance with various aspects described herein. FIG. 13 is a flow chart diagram illustrating a method for conveying a pallet through the pallet sorting system of FIG. 1 in accordance with various aspects described herein. DETAILED DESCRIPTION Pallets are often reusable and can be repairable. Prior to initial use, before repair, before reuse or any combination thereof, pallets can be graded or sorted. A pallet can be graded or sorted based on one or more physical properties of the pallet such as by way of non-limiting example, cleanliness, integrity of the boards, position of the nails relative to the surface of the boards of the pallet, finishing applied, or any combination thereof. The pallet grade or sorting assignment can be one or more of a letter, a number, or a symbol indicating a classification that is met. The classifications are split up using predetermined physical property thresholds. Pallets can be further sorted based on pallet condition. Optionally, pallet condition can be specific to the type or origin of a pallet or pallet materials. For example, the condition of a plastic pallet can include a surface area analysis looking for one or more holes and comparing the dimensions of the one or more holes to a series of predetermined thresholds. Plastic pallets often include holes on the loading surface, so the origin or type of pallet can determine what series of predetermined thresholds should be applied. Alternatively, wooden pallet condition can be based on board color (e.g., color data), condition, location, or fastener presence or location (e.g., nails or clasps located in appropriate location). Aspects of the disclosure as described herein are directed to a system and method of sorting pallets. The pallet sorting system includes at least a conveyance system and a loading assembly. Such a conveyance system can include a conveyor system but can include any other suitable system for moving pallets. A pallet can be received at a first position of the conveyance system or the loading assembly. At the first position or prior to the f