CA2223789A1

CA2223789A1 - Method and apparatus for reforming grouped items

Info

Publication number: CA2223789A1
Application number: CA002223789A
Authority: CA
Inventors: Herbert L. Markman
Original assignee: Individual
Current assignee: Individual
Priority date: 1995-06-06
Filing date: 1996-06-06
Publication date: 1996-12-12
Also published as: US5794213A; EP0855063A1; AU698721B2; WO1996039672A1; EP0855063A4; AU6159596A; JPH11507259A

Abstract

Articles (24) such as garments to be cleaned are associated in a group (26) (e.g., one customer's order). After processing together with articles (24) from other groups (26), the articles (24) are to be reassembled in their original group units. Coded labels (32) are attached to each of the articles (24) and identify or are cross-referenced to its group (6), e.g., with barcodes (34). If articles (24) with permanent labels (32) are processed, group codes are assigned and stored for such articles (24), indexed to the permanent label information. Other articles (24) are each labelled as to their group (26). The total count or number of articles (24) in each group (26) is recorded, preferably on the article labels (32) but also possibly in a data memory accessible to a data processor (44) coupled to a scanner (70). For manually regrouping the articles (24), a scanner (70) is used and the group (26) identification is determined as articles (24) are encountered. The data processor (44) assigns and indicates visually one of a number of assembly locations (84) to be used temporarily to store the articles (24) for each group (26). As the articles (24) are scanned and manually placed, they are counted. The data processor compares the current count with the total for that group (26), and signals when the group (26) is complete, whereupon the location (84) can assemble another group (26). The device can be coupled to an inventory control system or operated as a stand alone unit, particularly if the number of articles (24) in each group (26) is recorded on the label (32).

Description

METHOD AND APPARATUS FOR REFORMING GROUPED ITEMS
I~ac~,ou.ld of the Invention 1. Field of the In~ iull The invention relates to the h-q-ntiling of articles in groups that are sepa.nt~ d and/or mir~l~d during procecsing with articles of other groups, and which must be re-formed into a group ~.c.e~r~l. The invention is particularly applicable to articles of laundry and dryc1e-q-ni~, or other articles that are ~coci~ed~ for ~ le, as the articles ~le~t for l.r~ce~ by a given .;~ .. After ~luces~ g the articles of a ~ of such groups tOg~ l, the articles for each group (e.g., ~ c~ ) must be sorted from the articles of other groups and ~cs~ ~hled into their original groups for return to the les~ecli~e C.~lu...- r~. In particular the l~ll Col.~-~ ..c an ;~ Pd ~c~;~l;.n~ for mqm1q11y re-follllillg gl~,ulled articles that can operate in a stand alone mode, or in data co~ l;ol- with a c~ t~; Fd ill~ ,.y control system, or so as to collect data that is co~ t d in batch mode to an hl~ t,ly control system.
Accûldiug to the invention arti~les are l~bell~d to idelltiry or permit i-le .1; r.~ ;on of their l~ccliv~ groups by q~lu...~1ed sca~ means. A record is kept of the .. - ..kel of articles in each group, preferably by a code carried on a label ~tta(h~ to each of the articles. Infonn~tion as to the group i~lf ~ll;r~ on and the number of articles in the group enable the sorting ~ccict~nt of the invention to assign a location for assell-bling each group and after sca~.,.il-g the label on each article to i".li. ,a,lt~ to an opel.ltol the particular location (i.e., group) to which that article ~ belûngs. Thus, a lot co.-1~;n;~ a number of con.. n;.~gle~ groups can be quickly sorted back into the original grûups. In addition to sign~11ing an ~ccignlod loc~tion, preferably by a visual signal, the sorting ~csict~nt signals the ope-ator when all the articles of an individual group have been ~ccù~..ltod for and the group is s~lccescfully ~cfollucd, whe~ on the group is removed, freeing that location for use in assembling a next group.

CA 02223789 1997-12-0~

2 PCT/U' ,~ 4~37 2. Prior Art In a conventional laundry and drycleaning establishlllellL, a lot system is used to process the articles of a number of cllct~mPrs at the same time. The articles are labelled individually with llulll~red and/or color coded tags that are ~qttqrhPd to articles, for example by a pin or staple, such that the tags are carried through the process. The llwllbe,~ and color codes roll over, that is, the same colors or numbers can r~,apl,ear to tii~tin~lich articles in later groups.
Each dirr~ group has at least one article, and may have any nllmher of articles.Th~ r~fol~, an indefinite number of tags of a particular color and/or number may be needed to identify a particular group (one or more articles of clothing plesenLed by a single c~lstomPr).
T_is complicates the problem of lq-bP-llin~ the articles and also complicates the problem of sorting the groups after ploce~
Article label tags that are numbered and/or colored, etc., can be supplied in rolls or olllclwise in buL~, to be used as needed for groups having dirr.,~ numbers of articles. The articles of each group are labelled with a distinct tag by vir~ue of a nllmhPr and/or color combination. The available number of combinqtic-n~ e~ree(l~ the llwll~el of groups that the OpC~ Ol will process as a lot (i.e., articles from a plurality of groups that will be c~ glP~
during l,locessi..~), so that it will not occur that two groups in the same lot have identical llul~el/color ide~1ir~1iQn~. The lot size is chosen by the o~elalor as some quantity that is collvellient for one reason or another.
Nwll.,lolls variations are possible to define lots or to label grouped articles ~i~tinrtively within each lot. For example, a lot can consist of a given number of articles, or as near to that number as possible without causing groups to be split to place their articles into dirÇe,ellt lots.
A lot can consist of a given number of cllstomPr orders or groups, as opposed to the number of articles. A lot can include all the articles received on a given day or to be retmnPd to cus~c,.-~Fl~ on a given day. In a similar variation lots can include a morning lot and an afternoon lot. Lots can be defined by all the articles from a particular source such as a branch store served by a central facility. In whaLeve- lllal~r the lots are divided, it is n~ces~ to label articles within the lot ~ lively as to their groups, so that groups belonging to different cUstomPrs can be correctly sorted out later.
Many variations are possible for labelling articles ~ Lively as to group. Typically there is an associated group identifr~qtion number, which may appear on the article tag or be ~ cross ,~,rcl~llced to the article tag in a ~1qtqh~q~e (e.g., for "captive" g~ f ~1~ such as uniforms in systems where all possible g~ f..ll!'; are provided with idcllliryillg codes .~ livc to articles that will be cle-qn~d in the future when pr~s~lltcd in dirr~,lcl,l groups). Colors can also di~lhl~;uisll groups, or colors can be used to ~l;.~li.,~.J;~h lots or articles requirin~ special processin~, for example due to fabric type, color sel~ilivily or some other aspect.
As a result, tagging articles and mqnaging groups to which articles belong, present complex problems. For example, with pr~~ tcd article tags it may be n~ce~A. y to provide Scpalalc sets of tags to be used for groups having a particular number of articles and sepaldte sets having difr~ l~,llt colors to distinguish lots or other aspects. The opclator thus may need one hlvcllloly of tags for one-piece "groups," another for two-piece groups, etc., and pcllldps r~J~ A.~I sets in other colors.
To avoid the need for a large i,l~elltoly of tags, articles or groups can be labelled simply with a number or scqnnqhle code, but this makes it .iiffi~ult mqnllqlly to re-sort the articles into groups, and may require an hlvclltol.y control co...~ t~,r that manages which articles belong to which groups. At the completion of proces~;u~ the Opc~ator must find and recombine the articles belonging to each group. This is typically done mqnllqlly, by placing articles together that have the same group number or code on the tag or in a d~qtqhq~e. When the last article of a given lot has been placed with its group colll~al~ions, the mixed-group articles in the lot have l; le~ulllably been sorted s~ccec~fully back into their original groups. This is a labor hllcl~ivc exercise even with the -q~ A~ e of a co..-l--l~er ~atq-h-q-~e, and does not a~ccuu.l1 for occasional Acci~l~ntc such as articles that have been removed during proces~ g or inad~/cllc~llly placed in a dirr~ lot than their comranion~.
cd SCAIII~ g of barcode or the like can be used to assist in mqnaging groups, for e~ullple as disclosed in US Patent Re.33,054 - ~rkmAn From operator input, a data processor records data l. r. l~ ced to a particular customer and preferably records a description of the articles pl~sellled by the customer. At least one barcoded tag is gel~lated for each group, and contains or is rcfclcnced to the desclipti\~e il~lmation on the articles. An OpClàtOl can scan the group tag and compare the descriptions to the articles found when reAcs~mhling groups. This is useful where the articles have collvc..li()nAl numbered/colored tags as above.
However in addition, each article can be provided with a barcoded tag that ir1pntifips the group WO 96/39672 PCT/US~ 7 to which it belongs in a ~l-a~ er similar to the numbered/colored tags ~icr~ls~ed above, enabling the hl~cnloly control system to monitor the articles as well as the groups.
The information entered is used to dctellllh~ the price charged, and by sc~ ;n~ the barcoded tags as articles are lelullled to the cl)stomers ~or otherwise pass a particular step), the data processor can keep and update records such as the physical inventory contents, the dollar value hlvclllol~ of the bushless in progress, the amount of money e,~l,ec~ed to be in the cash drawer, the establi~l,."~nt's rate of throughput and so forth. If a physical contents inventory is taken, by sc~ ,in~ all the group tags and/or all the article tags, the processor can collll,arc the results with stored data and detelllline whc~ller groups or articles are !~ncYl~ecleflly mi~si~, or pelllaps dl tc. ,llin~ that lln-locllm~nted groups or articles are present.
Accoldillg to one embodiment in the l~rkm~n patent, barcode tags are printed for each article together with the group tag, for enabling the individual articles to be monitored (as opposed to lllollil~ling only groups and pe,llaps m~ml~lly CGIlll~ g the articles with their printed or stored descriptions) by sc~-";,-g individual tag barcodes. This is also helpful when allcl~ g to locate extra articles or to identify articles that are mi~ing, particularly if the invclllol~ control COlll~ut,_l stores a descliplion of each r~spc._live article. Space is provided on the co-.-l..llcl gen"nl~d forms for the article tags. The barcoded forms and tags for each group are printed only when the group is accepted into controlled inrellloly. The article tags are perforated and separated from the accompalljil~g form l~reSe~ g the group or batch of articles. However, these forms must be large enough to provide a sufficient number tags for groups of many articles, even though only one may be n~edecl, and for smaller groups many tags go llnllced This ~lcscnls a problem similar to that of colored/numbered tags due to the wide range of possible article counts in each group. The ~cl~lor may need to keep a large variety of distinct tags; or may waste available tags or stationery; or may need to m~int~in and l~fc.~.lce a complex ~t~bace accounting for and cross referencing llulllerous articles, groups, lots and the like. The operator's choice among these ~lt~n~tives affects the relative ease, ~liffirlllty and/or e~tnse with which tagged articles can be re-formed into their original groups later.
The barcode or other data on the tags is s~lbst~nti~lly unique least to the group but also potentially to the individual articles within the group, so that articles can be distinguished from one al~o~er and/or so that desclip~ e data stored relating to the articles can be l~fe.cllced to WO 96/3g672 CO~ the physical articles to the descriptions in memor,v. Another known kind of article lqhe11ing in connection with hlvenlol~ control and reporting is perm~nf nt barcode labelling of articles such as ga....f~ . P~ nP11I labelling of each article (or pell~s classes of articles such as shirts) is helpful if return business is expected from individual CUS~ or in the case of captive gz. .llf~ (e.g., regularly cleqnf d uniforms or the like). A pe ...~nf .It data record is kept for each cnstomfr article to which a p~ fllt label has been attar1lf-d and can be lc;f~nced when an article is received in a group and when all~ tillg to re-form the group.
For these pe....~ ly labelled ~,qrmfntc, an additional article tag is not nfcess~ry, but a large and a~cessihle ~q-tqbqce is required to be set up and mqintqinfd, inrlu-1ing article description and/or cusl~ lation for each article. This is effective but requires subst-q-ntiql memory and data procescin~ as col~ared to a system in which a less complicated labelling system is used.
A p~.",ql,r.,l label is typically heat sealed or sewn into a g,qrmfnt and must be sllffiriently durable to survive many cle-q-ning cycles while the plilllillg on the label r~ ms readable or sc-qnn-q~le. A less l~e~ Illz~rl~t article label can be provided as needed to survive one cle,q-ning, or a limited number of cle~ , while remqining readable or scLq-nnq-hle. Sc-q-nnqhle "one-ride" tags are known and are made and printed using materials having the llf~C~S~Z. y wet sll~ or resistance to solvents to survive and remain readable. For this purpose, various polymer or natural fiber materials can be printed with sc-qnnqble codes iden~iryillg the article or the group to which the article belongs. Such tags have conventionally been printed with group numbers, lot numbers, descriptions of the ~csoci~ted articles and due dates for retrieval by the customer.
An article labelling system for le~csçl~bling groups requires a distinct group or tr~n~action code, which can be sc~nn~hle or cross lef~l~nced to a sc~nn~hle code (e.g., a unique g~ll~nt identifir~tiQn code on a captive g~rm~nt). Thus the articles of a group might be ifi~d NNNN - shirt, white; NNNN - dress, red; NNNN - slacks, green, etc., where "NNNN" ~ sen~ the group. Unless all the articles are captive and uniquely labelled and cross ler~ ced, one or more articles are tagged with the group i~entifirati- n. The tag is typically printed in both barcode and readily-read alph~ ,flic code. Where a proces~ing establi~hm~-~t h~n(lles articles from various sources (e.g., store bldl~ches), it may also assist in re~Sruu~ing the articles to include a name or code identifying the source. When re-assembling PCT~U~ 03S37 groups, the OpClatOl either reads or scans the codes on the articles and places those of the same groups together. When all the articles have been placed with a group, then y~ ull~ably each of the groups has been completely assembled. Where a group or ~l~n~ on tag is available, or where the co~ of the groups are stored in memory, a final step can be to colll~a~ the asselllbled articles of each group with the printed or stored records to verify that each group is co~ lct~ and is neither ...i~si.-g articles nor holding an article belonging to a~ r group. This is a p~inct~king job.
Sorting conveyors are known for di~"ing individual items from a stream of items ~ulo...~lir~lly. For example a trap-door a~lallgellRnt or other diverting m~ch~nicm can be ope~ated au~o,..~lir~lly when the items pass for sepalating the items for one reason or another.
Such a sorting mPrh~ .., can be applied to sorting laundry articles. However, automated sorters are also complex and any savings in human effort may be more than paid by the e~nse of the har.lwale and software involved. Inventory control system with numerous barcode scam~c~r~, cross ler~le-lced data tables for article llunl~ or cl~ctom~rlg~ llum~l~, a~ltom~tPd diverting mPrh~ ...s and the like are possible. However, an inventory control system having very sophictic~t~Pd capabilities also requil~s a good deal of work to enter and m~int~in the data tables and records. What is needed is a system that assists in l~grou~illg articles that is useful over a wide range of situations, from a very sophi~lic~tPd system to a virtually manual one, with III;II;IIRIIII waste of tags or inventory of tags, and Illi~ effort in r~s~çl-.hling groups. The present invention provides this capability in a labelling system preferably for one-use article labels, by encoding the group or batch code and a code r~plcs~ g simply the number of articles in the group. As a result, legl~u~ g of articles can be accomplished simply and quickly, without the need for s~lbst~nti~l data processing, memory and the like.

CA 02223789 1997-12-0~

WO 96139672 PCT/U~i3 5. ~ 7 S~ lla~ of the Invention It is an object of the invention to assist in s ~kst~nti~lly manual assembly of groups of sepa,aled articles, by reading a group id~ntifi~tion code and r~ illg inrol",ation on the number of articles in each of a plurality of groups, then using a pfocessor to select and in~lic~tP
an available location for assembly of the group, and to count the articles placed with each group until the known number is completed for a given group, wll~ u?oll the ope.ator is cign~llPtl that the group is co.,lplete.
It is a"ull,er object to label articles of groups with the ~ .her of articles contained in the group as a means to facilitate assembly, especially when using aulo"lalic scanl.;.-~ to read the group nl-mher and/or the article count.
It is also an object of the invention to assist in l~,gloupillg articles in a way that is at least som~tim.os in data co.~ tion with an illv~ control system and can accol,ll"odate some pen..~-F--Ily labelled articles, but is also useful sl~ ;n~ alone.
It is a further object of the invention to reduce the waste and e~l~nce associated with article tags by con~..l..i.-g only the llulllbel needed for a particular group, and by avoiding any need for a stock of distinct p" paled tags.
It is also an object to automate assembly of groups of articles from co.. -i~ groups of articles in an ;n~ .cl.~iv-e and col~l~ient ll~ ner.
These and other objects and aspects of the invention are provided in for associated articles such as garm~ntC to be c!e~ned, which are accoci~t~d in a group (e.g., one customer's articles), are sepa,ated from other m~mhers of the group and mixed with other articles and groups during procescing, then are ~eglou~ed in their original units. A label gellelator prints labels for at least some of the articles, to identify the associated group. The total number of articles cGlllailled in each group is recorded, preferably on the article labels but also possibly in a data memory . When ,eglvupillg the articles, the group idc~ rlr~ ion of each article is read in turn, preferably by sc~nning a barcoded group code and article count. For the first article of a group, a data processor selects and signals which of a ~u~llber of locations or receptacles will be used to temporarily store the articles for that group. The processor in~ tec that location wllelle~el another article of that group is encountered. The processor also conlpafes the count of açc~lm~ tecl articles of the group with the total number for that group, and signals the opela~or when the group is complete. The device can be coupled to an i~lvellloly control PCT/U~ O!I S37 system moniloring the status or location of the articles, or the device can be operated as a stand alone unit, particularly if the number of articles in each group is recorded on the label.
The invention can be more or less complicated in various embodimPntc, in a ..~
embo~1imP-nt for example, having a label printer operable to produce alph~ ic labels showing the ~ hel of articles in each group on the labels for all the articles in the group, for aC~ ;n~ an opelator in r~5ruuping them later. Such data can be entered by keystrokes when .~.ouping the articles. In a more ~ulolllatic embodiment, the group codes and article count are printed in barcode by the label printer and sç~nnPd by the ope-ator using a hand held scalmer coupled to the processor. In a more automatic embodiment the label printer and l~ )upillg Z~S~ l-ISC ~1.,~ are coupled to an i.-ve--lu-~ control system, and in that case the group identifier code is placed on the labels and the count of articles in the group can be .~r~nced by the group code to an article count stored els~wl.~ in the invelllo-y control system. In systems having uniquely il1.ontifi~d articles (e.g., "captive" p~ ly labelled gallllcll~), the articles can be ~ccign~d a group code when received into controlled inventory and counted together with articles that are labelled with the group code. When legloù~ing, the group code and article count is .ef~.ellced as stored in memory, for ~ccictin~ in sorting the uniquely id.ontified articles together with those labelled by group.

~ Brief Descliy~ion of the Drawin~s There are shown in the drawings certain exemplary embo~1im~-nts of the invention as pl~ velllly yl~ f~ ,d. It should be understood that the invention is not lirnited to the embo~
disclosed as examples, and is capable of variation within the scope of the appended claims. In the ~llawi~s, FIGURE 1 is a partial elevation view functionally illuvllating the app~alus of the invention.
FIGURE 2 is a block sr~Pmqtir diagram coll~,syol~ding to FIGURE 1 and showing co----..i~*1i~-g and re~ mhly of two groups.
FIGURE 3 is an elevation view showing exemplary article label for a group of four ~,~- ---. .~lc.
FIGURE 4 is a block diagram showing a ylcfell~d output ~l~ulgellRnl for operation of intlirators.

wo 96/39672 PcT/u$96/09437 Detailed Description of the Prt;fe.l~d Emb~imçnts Acco-dillg to the invention, an alltom~ted assist~nt 20 as shown generally in FIGURE
1 is provided for aiding an ope~dtor in m~naging articles 24 in groups 26 that become co.. in~,lçd with articles belonging to a plurality of groups and th~,~art~l are re-~c~oci~ted with the articles of their original group. To this end, the number of articles 24 in each of the groups 26 is recorded before the groups are co.. inglçd A label printer 30 produces a label 32 for each article 24, having an i-l~ntifiration code 34 that is unique to its group, at least within the groups to be commin~l~d When the groups 26 are re~cse~--hled after processin~ of the articles 24, for example through clç~ninP process 36, the sorting assistant 20 uses the group identifir~tion codes 34 from labels 32 to dn --.in~ the group 26 to which each article belongs, and assigns and in~lic~t~s a discrete location at which the article is to be placed. Whereas the recorded llu~ of articles is available, ~ict~nt 20 also drl~ s by cuunting articles 24 passing for each group during re~sernbly, when the ~,;,pecli~e groups are complete, sign~lling that a completed group can be removed to free the location for acc~lmlll~tion of another group 26.
The invention is particularly useful for ~ llr~ i to be cleaned or dry cle~n~d. Gallllell~
are plesell~ed by cu~lolllcl~ in groups which each form an order having an indefinite number of articles. The g~ ; of many cu~lolllel~ are processed (e.g., cleaned) together in a lot. The original groups (c ~ctom~r orders) are then l~ sç~.~hled and r._~ullled to the customer. The invention is also applicable to other situations in which articles belonging to dirrelclll groups must be segr~ ed into groups for which they are intPn-1ed The articles are labelled with a sufficiently unique code 34 to dis~ h among thegroups 26 that are processed together. In the embodiment shown in FIGURE 1, at least the number of articles 24 for each group 26 is entered by an operator on an input means such as kcyboal~d 42, coupled to a controller 44 u~el~ g label printer 30. Label printer 30 can g~ -Fl~te a label 32 for all articles 24, which includes identifir~tion code 34 for that group.
For operations capable of proce~ing at least soîne articles that are already uniquely identifi~d, for example with a unique article identifir~tion code lcf~lenced to a particular customer in an inventory control system memory, that article identifir~tion code can be sc~nnPd initially, and a group code ac~i~n~d to the article for this round of proces~ing. Whereas the article is already uniquely identffll~d, it can be processed together with other articles willwul CA 02223789 1997-12-0~

W O 96/39672 PCTrU~'?~ 7 ~ requiring an additional group identifiPr code label, the required i~ ation being stored in memory and cross ~cf~ ced to the article identifi~qtiQn.
Preferably, the group code includes sc-q-nnq-ble indicia 50 on a label for some or all of the articles in a lot, e.g., interleaved two-of-five barcode, or code-39 barcode or another scqnnqble code. Preferably the ..u...ber 52 of articles 24 in the ..,s~ecLive group 26 is inc~ ed in the scq-nnqhle code 50 for each of the articles 24 in the group. If applied to the labels, the article count enables the sorting ~s~ to operate indep~n~lF ,lly of a complicated inventory control system, as di~-;ucsed below. However the invention is applicable as an extension of an inventory control system, and is also applicable to a system in which the article count and/or group identificq-tion is stored rather than printed on the labels.
The labels 32 are attached and remain attq-r?~-~d to articles 24 through the process 36 of cle-q-nin~ or the like. Each article has either a group label or a unique article ide~llifyillg label cross l~,r~,lelced to its group. Acco-dingly, the labels 32 should be suffl~iently durable to survive at least one pass through the process. Various materials for the label and its pli.lli~, made of polymers, natural fibers, high rag content paper labels or the like can be used. The labels can be ~ttJ~ d to the articles by any conv~ni~--l means such as pins, staples, heat sealing, adhesive b~ ,s or the like.
According to one embo~im~nt, the count or total number 52 of articles in each respective group 26 appeal~ on the sc~nn~ble indicia 50 of each label and thus each article in the group.
,A1L.. ~ ;vely, the total ~-u~bel 52 can be recorded only on at least one of on the labels 32 for the group. As another alternative, in an embodiment where the label p~ illg unit 30, 44 at the input side of the process is in data co"~ ;r.~iQn with the assembly station at the output side of the process, or perhaps where data can be L ~Ç~ ,d on disk or the like, the number of articles in each group can be stored in a data lll~lllol~ to which a data processor 72 on the output side of the process is coupled at least for batch lla-~r~l of article counts for the groups.
As a further ~1L ~"~ive, the total count and group number can be r~fel~.lced to a unique article idel~tifiration code. In any event, the number 52 of articles 24 in each group 26 is acces~ihle at the output side to assist in completing the manual r~,~cse~"bly of the groups.
On the output side of the process, a data input means 70 is coupled to the data processor 44, for c .-l~ g from labels 32 the i~Pl~lirl~ on 34 of the group 26 to which each article belongs. In the embodiment of FIGURE 1, the same data processor 44 is used to produce labels 32 and to m~n~e the output side rea~cernhly. In the block diagram embodiment of FIGURE
2, a se~ala~e controller 44 and data processor 72 are employed. In other l~,S~Je~.l, the same r~re.ellce nurnbers have been used throughout the dldwiugs to identify col.~sponding harlwal~, or functional cle ..f ~
In the ~l~rel~ed embodiment employing optical sc~n~ g, a scal~ 70 is coupled to the data processor 44 or 72 for this purpose. ~ liv~ly (and less cou~. niently), the group i.1f ~.lirfation 34 can be entered using keystrokes on a keyboard (e.g., 42). The recorded total number of articles for each of the groups 26 is in-l~xf d with the group j~ntifit~ation 34 in the data memory 60 of the processor (see FIGURE 2).
Data ~locessol 72 or 44 has at least one output 76 all~ged to operate inr~iratQrs 80 for poil~ out selected ones of a plurality of dis-,lete storage locations 84. The locations 84 can be, for eAuu~)le, provided along a h~ bar 86 subdivided by p&lliliolls 88 and having at least one visual indir~or 92 for each partitioned location 84. ~1L~ ;Ve1Y~ or in ?~dition, ululle~ical readout~ can identify ulunbe~ed locations or cubicles (not shown), and/or an audio signal can be provided to draw the attention of the G~rdtor to the selected location. Preferably, at least one LED in~lir~tor is provided at each position 84 for ~ign~llin~ an instruction to place a next article at the i-.~lical~d position. The il~-1ir.~tol is operable in a distinct mode, or an additional indir~,lol or indirator is provided, for sign~llin~ when the article count is complete.
This can be accomplished, for example with a red LED and a green LED at each position 84, or with some other allallgelllent such as a seven se~ulenl numeric readout showing both the present count and the group total count (e.g., "1 of 3" then "2 of 3" and so forth).
As each article 24 of the commingl~-l set of groups is encountered and its id~ntifir~tion code 34 is entered (preferably sc~nn~d), data processor 60 or 44 searches its memory 60 to d~t~ ...;I~e whether the particular article is the first article ellc-)ullt~l~,d in its group. If the article is a first of its group, data processor 72 selects an unoccupied one of the storage locations 84 and o~e.~tes the associated in~ tor 92. If the article is not the first of its group, the data processor selects the storage location 84 already ~ign~cl to one or more previous members of the group and opelates that intli~ator 92.
As the group id~ntifiration of each article is entered in turn (or looked up for uni~uely coded articles), data processor 72 counts the articles 24 that have been assembled for the ~;,~cli~re group. The count of assembled articles is cc,ul~ d to the recorded total number for CA 02223789 1997-12-0~

W O 96/39672 PCT/U~3CI'~ 7 the group (which could be one or many). When the assembled count is equal to the total number that was entered at the input side, and preferably printed as a sc-qnn-qble code 52 on labels 32, data processor 72 opeldles the intlirqtQr 94 at the location of the co,llpletcd group to signal the operator that the count has reached the total "um~. and the group has been succe~fully assembled.
The completion signal can be any signal that will alert the ope.ator to the particular location 84, in a .~ er that is distinct from the location i~ntifir2tion signal otherwise used to draw the opelatol's attention to the particular location. For example, a single inrlir~q,tor light 92 or 94 at each location 84 can be operable in distinct modes such as steady versus flqchin~, bright versus dim, etc., for location irlpntiflr~qtinn and completion ~ignqllin~, ~e-;lively. Two or more inrlic,qtors 92, 94 can be provided for rli~ ly signqllin~ location and completion. A
location i"~ or can be operated in conju,l~lion with an audio completion alarrn, and so forth.
Moreover, completion signqllin~ can be accomplished in a nlam,~r not limited to a signal occurring at the point of completion. For example, the co",pletion signal can be operated upon pl~en~rnt of the next-to-last article, etc. In that case, instead of placing the last article and then immeAiqtely l~l,ic./ing it together with its completed group, upon sc~ g a last article the O~lalOI can be signq-lled to remove the co,llenl~ and rejoins it with the last sc~ -?d article to complete and remove the group. Similarly, groups collsi~lillg of a single article can be signqllçd as a complete single-article "group" when they are enru~ . ~d, to avoid n~e~ ssly placing and imm~ tely removing that one article.
Preferably, the i~l~ntific,qtion of the group and the total llulllb.,l are recorded at least partly in optically scqnnqble code 50 on the labels attqr~l~d to each of the articles. FIGURE 3 shows a series of exemplary article labels for a group 26 having four articles 24. Thus, the data input device 70 coupled to data processor 60, 44 inrlllcle~ a SCdl)lle,~ for reading the sc~nn~hle code 50. As shown, it is also possible to provide additional hlru,l,lalion on the label, such as an alph~...~...~ .ic version of the group identific~tion 34 and article count 52, for all~lnative keystroke data entry for labels which cannot be succes~fully sc-~nnPd. A desc,i~lion of the article can be included, which is useful if a label should become det~rhPd and needs to be re~tt~rllrd to the appro~lial~ article. Other il~,ll,ation such as a code idellliryii~g the source of the order, e.g., a branch location served by a centralized cle~ning facility, may be useful.
A serial article count may also be included (e.g., "1 of 3," "2 of 3," "3 of 3," etc.).

W 0 96~9672 PCTrUS9'1/0,'~7 The invention is operable with or wi~ ul a larger i"~ o,~ control system. If the total article count 52 is encoded on at least one article label 32 in each group 26, and the group i~Pntifir~tion codes 34 are unique within the c~)llllllil-~lPd groups being processed as a lot, it is not n~cessA, ~ to provide data co,,,,,~ AIiQns b~lweell the input and output sides of the process in order to employ the sorting ~c~i~tAnt of the invention. In the event that the total article count 52 is not provided on all the labels 32, the count can be collll..~ rale~ to the data processor 72 when one label co..lAining the count is sc~nn~d, and colly~ of the current count to the total can commenre at that point. Preferably, however, the total count 52 is inrlude-l on each label 32, or in a system linked to an hl~llto,y control system the total count is always available as in~PY~ to the group or article ide~lirirAlion code.
The te~ ,ol~ ~ storage locations 84 have spaces for the articles of a plurality of groups, preferably slJffici~nt to place all or a substantial pl-pollion of the groups 26 of a lot into an ~csign~l location before the space is exhA~lct*~. In a pler~ d embo~lim~nt~ capability is provided to count and signal for 64 coll~;ullelllly processed groups 26 for the example of a laundry and drycleAnin~ establi~hmrnt and two ~;clin--lly colored visual in~ic~tQrs 92, 94 are provided for each location. DirÇ~l~nl operations may have varying physical arrangements for nc~ Atin~ articles when l~glcu~illg them, and accordillgly the signAlling arrAn~en ~nt is preferably mo~ r, as shown in FIGURES 1 and 4.
r~ocessol 72 can co"""ise a simple ~,og,~ll"able controller, microcolll~ul. r, personal con,~ul~r or motherboard, for example having an RS-232 serial port for b~wise si~nAlling to control up to 64 dual light modules 102 col-nPc~ed to an intrrf-ee box 110 in a daisy chain all~ r'll using s~ld~d eight wire telephone cables and jacks. The processor 72 signals via the serial port to the interface box 110, for example at a switch-sel~ctAble baud rate and/or protocol. Each byte of data can contain a numeric address idenliryillg a single module, one or both of whose in~ir~tors are to be a.;liv~l~d to identify an available space for a group or tO
identify a completed group. Interface box 110 functions as a serial to parallel coll~ l as shown in FIGURE 4, and can also function as a multiplexer by sucressively addressing modules 102. Of course, parallel ~ignAlling arrangements, serial shift register arrangements and the like could also be used to control the visual in~irators.
In a pl~;Çell~d embodiment with 64 modules, each contAinin~ a green LED for location i~iP,I~ i r,r~ ion and a red LED for completion signAlling~ the output of interface box 110 contains CA 02223789 1997-12-0~

WO 96/39672 PCT/US9 ~ 7 six bits for addressing a particular one of sixty-four modules 102 (i.e., location 84) and two bits for on/off signq-lling of the red and green LEDs, lc~eclively. When a module 102 is addressed, gating in the module applies the signal then present on the red and green ~ignqllin~
bits to switch the LEDs on or off. For single module signqllin~, the interface box can hold the address and signal lines in the required states, or in a multiplexed al~ ...Pnt, the modllles can include latches coupled to the LEDs for retqining the state of intlir~q,tiQn from the last time they were addressed, enabling more than one module's intlic,q-tors to remain on at the same time (e.g., the completion in~ q,tors). Upon power up, all the ml~lllPs 102 are reset.
The location in-lirqtQrs 92 are selected and activated upon sc~....i..g the first article 24 from a group and when additional articles for that group are encou,l~crcd. The location in-lic~q~tQrs 92 can be activated and remain aclivalcd until a next article 24 is scq-nnPd (it being a~llmP~l that because a new article has been scqnnP~l the previous article has been placed where in-lic~ l, and the count is incçe~ t~d). .Alt~ livcly~ a pu~ hu~ol- (not shown) can be provided on the il~ir~lor modules 102 for ~ignqlling back to processor 72 that the article 24 has been placed. As anc,~ alle~ ive, the operator can be required to scan a barcode 114 on the location 84 to confirm plq~ en~Pnt of the article at that location. Similarly, the completion alarm or i,~lir~tQr 94 can remain activated until a next article 24 is scqnnPd or can be opcl~lcd m~ ..ily or provided with a resettable latch means or the like.
In a plcfell~ d embodiment, a distinct signal is provided when a location is first qc~ignPd to a group. For example, both LEDs 92, 94 can be activated when a location 84 is q~si~n and no article 24 has been placed there as yet, or ptlhaps the location intlicqtor can be blinked.
This helps in the initial placement of articles into slots by di~lin~,uishing the particular article as the start of a new group. The oper~tor otherwise looks for both an activated location in-liC~tQr 92 and a previously placed g~llllent 24. The completion in~1ic~tor 94 is preferably aclivated until the opcl~tor scans the bar code 114 idellliryillg the location 84 or module 102 as a signal that the group has been removed and the location is again available to begin tion of a new group.
Provision can be made for moving a partial or complete group 26 from one location 84 to anolllel. For example, certain articles may have been removed from the balance of the lot for special processing steps, such that the associated group cannot be completed until the removed article is returned. When allelll~ting to ~glOu~ the articles in that case, one or more CA 02223789 1997-12-0~

WO 96/39672 PCT/U~3.s~S 137 groups remain incomplete when the last article found in a lot has been placed. Such incomplete groups can be a~ign~d to special locations 84 (e.g., the most pclil,~.al ones) and carried rolwald from lot to lot until the mi~ing article(s) catch up to complete the group.
Sign~lling from the interface box 110 to the modules 102 can be unidirectional for simple control of the LEDs 92, 94, or bidirectional for si~n~llin~ back to processol 72. A return signal to the processor can be used to ;~ e that the interface box 110 is present (i.e., powered and plugged in), or when an article has been placed in a particular location, when a group has been removed, etc. The inlelrdce box also can be a~ ged to signal if a flall~ing error occurs at the RS-232 port. In that event the state of the in~lir~tor lights is not changed and the device waits for a valid data co~ A rla--~ing error might occur, for example, if the wrong baud rate is set such that a stop bit is not ~etect~d where çxrected, and in the embodiment shown could oth~ vise cause e.-o-leous operation of the i~--lic~o,~.
On the input side of the process, the label plin~ g arrangement can be more or less complex. Label printer 30 need only generate labels 32 under Opclator control in the number needed for the articl~s 24 and co..l;~;..i.-g the group i~Pntifir~tion 34 and preferably article count 52. The article count can be entered by the opelator via a ktyl,oal.l 42 as shown, or can be d~l~....i..fd by an ~ o...~lrd cuu--ling device such as an optoeiecl-onic light source/receiver al.ange,..ent (not shown) having a path broken by articles tossed through the beam, with the ope.ator sign~lling the end of a group via a switch. The controller 44 for the printer can accept input from the o~.ator (such as article description, source, etc., as above) or can simply cycle through group ..u--.be.~ in some order wl~c.~ the same group idp~ rlr~lion does not often ~OC~Ul.
Controller 44 and printer 30 can be of any type capable of follllillg the required ch~a~ on a durable ticket stock, and need not be coupled to the output side of the process.
An exemplary printed ticket is shown in FIGURE 3. Preferably, the characters include sc~nn~hle indicia 50. An appr~.iale controller is the Co~ ul~ise model TT5B, which can control the printer to provide tickets with or without barcode as well as accept SC~ input and provide control signals to the visual indicators. As ~ c~ ed above, the invention can also be illcol~o.àl~d into a more capable full blown inventory control CO~ ul~r system.
An appr~plial~ printer is the Epson TM-300B dot matrix printer, including a cutter (not shown) for det~rhing the individual tickets 32 from a continuous roll of stock. Various other CA 02223789 1997-12-OF.
types of plhltel~ are also possible. In addition to article labels 32, the printer can be all~lgcd to produce a sul~ laly ticket (not shown) for the customer's order or other group, for example including infollnation such as a customer name or i~enti~lr~tion, a list of the article descriptions, a due date, associated charges and the like, some or all of which can also be printed on the tickets for the articles as shown in FIGURE 3.
The invention provides an aulolllated method to assist in manual h~ntllin~ of articles 24 of various types, that are associated with one another in groups 26. The method can be more or less ~tom~ted by haldwa~ and/or software to accomplish certain steps, the rem~in~1P.r of the steps being accomplished with some human h~lelv~ ion. In a simple configuration, the method inrl~lde~ recording a total number of articles 24 in each group 26, from data entry or other counting means. Each of the articles is l~bellrrl with a code 34 idellLiryillg the group to which the article belongs, or if articles are included with p... ~ n~ labels they can be cross ref,~ ced to their group. For assembling the articles into their groups, reliance is placed on the group code 34, preferably on the labels on the articles, and on the count 52 of the articles.
An available klll~Olclly storage location 84 is chosen from a plurality of storage locations when enc~ulll~,lillg a first article 24 in each group 26. This article and subsequent articles are placed in their lei")c~live storage locations 84 for the groups while coll;ull~ ly counlillg assembled articles for each group as each article for that group is sc~ rd and placed, using the group identiffc~tion code to trigger counting. By c~lyillg this count using aulonlated means and cGllli~ring the count for each group to the total number, it is possible not only to guide the user to the correct pl~cPm~nt of every article 24, but also to i~-dir~te when the count reaches the total number 52 for each respective group, thereby m~n~ing the assembly process in a convenient and ine~l~sive lllal~l~r.
Accorlillg to the foregoing embo~lim~nt~, the input (label generation) and output (assembly) sides of the arrangement need not be in data cu~..... ..ir~tion unless nrcec~ly to co... ,-ir~r the article count for each group to the processor 72 h~ndling the assembly side, effectively requiring (as in FIGURE 2) one processor or controller at the input for control of printer 30, and another at tne output for control of the indic~tors 92, 94. It will be ~reciat~d that label gelle~alion and inrlic~tor control can be functions of a single processor 44 as in FIGURE 1. Moreover, the foregoing printer and inr.ic~tors can be coupled to an inventory control and lepollillg system such as that disclosed in US Patent Re.33,054 - M~r'cm~n, the disclosure of which is hereby incorporated, with the functions according to the invention accon-plished using the processor therein. According to one embodiment in the patent, individual articles within a process are monitored in an effort to identify extra and micsing articles, and a lul~ lg hlvellloly of articles and the ~csoci~ted charges are kept or are obtainable by sc~nning codes associated with the articles or with groups of articles having descriptions of their articles recorded. The present invention can be merged into such a system, for example, by using the completion of a re~ccPmhled group to trigger appi~lial~ changes in the hl~
records. In addition, the article counting, label gel ~IOlion and serial port cign~lling functions needed according to the invention are available or readily provided as fealules of the hl~ellloly control system.
The sc~nn~l le label embod ;~ c have been rliccllcsed with respect to optically sc~nn~hle barcode. Other optically sc~nn~hle indicia can be used as well, as can electrically enroded sc~nn~hle indicia such as RF or ~-~ag-.rlir~lly encoded tags. ~ rn~tively, a less so~,hi~l;r~t~d encoding is possible, such as coding shown alph~ rically and entered by k~y~lrl l-rs.
The invention having been disclosed in coll~le~;lion with the fo~going variations and examples, additional variations will now be ~ l1 to persons skilled in the art. The invention is not i"t~ d to be limited to the variations ~pecirlcally mentioned, and accG-~ingly lcç~,~el~ce should be made to the appended claims rather than the folc;goill~ ~li~.JssiQn of ple~ d examples, to assess the scope of the invention in which exclusive rights are cl~im~d

Claims

I claim:

1. A system for assisting in manually regrouping associated articles from a plurality of groups of articles, comprising:
a label generator operable to print labels for the articles, the labels including an identification of the group;
means for recording a total number of articles contained in the group, the total number being recorded at least one of on said labels and in a data memory;
data input means coupled to a data processor, for entering from the labels the identification of the group, wherein the recorded total number of articles for each of the groups is accessible to the data processor, and wherein the data processor is operable for each article to count the articles assembled for a respective group and to compare a count of the assembled articles to the total number for the group, a first indicator coupled to the data processor for at least one of visually and audibly signalling a user when the count reaches the total number.

2. The system for assisting in regrouping associated articles of claim 1, wherein the identification of the group and the total number are recorded at least partly in optically scannable code on the labels attached to each of the articles, and wherein the data input means coupled to the data processor comprises a scanner for reading the scannable code.

3. The system for assisting in regrouping associated articles of claim 1, wherein the total number is recorded on at least one of the labels associated with the group, and wherein the total number is entered into the data processor from said at least one of the labels.

4. The system for assisting in regrouping associated articles of claim 1, further comprising a temporary storage apparatus having space for the articles of a plurality of groups, and a second indicator coupled to the data processor, the processor being operable to at least one of visually and audibly signal via the second indicator an available space for a group upon scanning a first article from the group, and to signal via the first indicator when the count for each respective group reaches the corresponding total number for said group.

5. The system for assisting in regrouping associated articles of claim 4, wherein the processor is operable to signal via at least one of the first and second indicator upon scanning of each article, the space for the group to which the article belongs.

6. The system for assisting in regrouping associated articles of claim 5, wherein the first and second indicator comprise means for operating a single indicating device in distinct modes, the indicating device having a group indicating state for indicating a location for a scanned article, and a finished indicating state activated when the count equals the total number.

7. The system for assisting in regrouping associated articles of claim 5, wherein the articles are garments.

8. A method for computer assisted manual handling of articles associated with one another in groups, comprising the steps of:

labelling each of the articles with a code identifying the group to which the article belongs;
counting and recording on at least one of an article label and a data memory, a total number of articles in each group;
entering for each article the code identifying the group;
processing the articles and then regrouping the articles according to the code on the articles, by automatically providing at least one of a visual and audible indication of an available temporary storage location from a plurality of storage locations when encountering a first article in each group, manually placing subsequent articles in respective storage locations for their respective groups, concurrently counting assembled articles for each group when each article for that group is placed; and, comparing the count for each group to the total number and providing at least one of a visual and audible indication when the count has reached the total number foreach respective group.

9. The method of claim 8, comprising labelling the articles with the total number.

10. The method of claim 9, wherein the group identification and the total number are attached to each article via a scannable code label.

11. The method of claim 8, comprising recording the total number in a data memory and referencing the total number for said comparing step.

12. The method of claim 8, further comprising reporting the group identification to an inventory control system after the count equals the total number.

13. A method for computer assisted manual handling of garments to be processed in groups, comprising:
assigning a substantially unique group code to garments in each of the groups;
counting and recording the total number of garments in each of the groups;
labelling each of the garments with a scannable indicia representing the unique group code to distinguish its group from other groups;
processing the garments including commingling the groups;
scanning the indicia of individual garments for each garment in turn to determine its respective group;
automatically assigning and at least one of visually and audibly indicating one of a plurality of garment assembly locations upon encountering a first garment belonging to a respective group, and placing said garment at said assembly location;
proceeding to scan, indicate and manually place the garments while concurrently counting the garments assembled for each group at the respective locations, and comparing a count of the garments to the recorded total number of garments for each group; and, automatically providing at least one of a visual and audible indication when the assembled garments for each group are equal to the total number of garments for that group.

14. A system for assisting in regrouping associated articles from a plurality of groups of articles, comprising:
labels for each of the articles, the labels including indicia representing at least one of an identification of the group and an identification of an associated article;

means for recording a total number of articles contained in each of the groups, the total number being recorded at least one of on said labels and in a data memory;
data input means coupled to a data processor, for entering the indicia from the labels identifying the group, wherein the recorded total number of articles for each of the groups is accessible to the data processor, and wherein the data processor is operable for each article to count the articles assembled for a respective group and to compare a count of the assembled articles to the total number for the group, a first indicator coupled to the data processor for at least one of visually and audibly signalling when the count reaches the total number.

15. The system for assisting in regrouping associated articles of claim 14, wherein the identification of the group and the total number are recorded at least partly in optically scannable code on at least one of the labels attached to the articles, and wherein the data input means coupled to the data processor comprises a scanner for reading the scannable code.

16. The system for assisting in regrouping associated articles of claim 14, wherein the identification of the group is recorded on all the labels attached to the articles, and is entered into the data processor via the data input means.

17. The system for assisting in regrouping associated articles of claim 14, wherein at least one of the articles is permanently labelled with an article identification code comprising said indicia and the data processor is operable store the group identification and the total number for the group as cross referenced to the indicia.

18. The system for assisting in regrouping associated articles of claim 14, further comprising a temporary storage apparatus having space for the articles of a plurality of groups, and second indicator coupled to the data processor, the processor being operable to at least one of visually and audibly signal via the second indicator an available space for a group upon scanning a first article from the group, and to signal via the first indicator when the count for each respective group reaches the corresponding total number for said group.

19. The system for assisting in regrouping associated articles of claim 18, wherein the processor is operable to signal via at least one of the first and second indicator upon scanning of each article, the space for the group to which the article belongs.

20. The system for assisting in regrouping associated articles of claim 19, wherein the first and second indicator comprise means for operating a single indicating device in distinct modes, the indicating device having a group indicating state for indicating a location for a scanned article, and a finished indicating state activated when the count equals the total number.

21. A system for assisting in regrouping associated articles from a plurality of groups of articles, comprising:
a label generator operable to print labels for the articles, the labels including an identification of the group;
means for recording a total number of articles contained in the group, the total number being recorded in a data memory;
data input means coupled to a data processor, for entering from the labels the identification of the group, wherein the recorded total number of articles for each of the groups is accessible to the data processor, and wherein the data processor is operable for each article to count the articles assembled for a respective group and to compare a count of the assembled articles to the total number for the group, the data processor having an output for visually or audibly signalling a user when the count reaches the total number.

22. A method for computer assisted manual handling of garments to be processed in groups, comprising:
assigning a substantially unique group code to garments in each of the groups;
labelling each of the garments with a scannable indicia representing the unique group code to distinguish its group from other groups;
labelling each of the garments with a scannable indicia representing the number of articles in the group;
processing the garments including commingling the groups;

scanning the indicia of individual garments for each garment in turn to determine its respective group;
scanning the indicia of the number of individual garments in the group;
automatically assigning and at least one of visually and audibly indicting one of a plurality of garment assembly locations upon encountering a first garment belonging to a respective group, and placing said garment at said assembly location;
proceeding to scan, indicate and manually place the garments while concurrently counting the garments assembled for each group at the respective locations, and comparing a count of the garments to the scanned total number of garments for each group; and, automatically providing at least one of a visual and audible indication when theassembled garments for each group are equal to the total number of garments for that group.