Patent Application
20070270999
The present invention relates to a system for automatic handling of articles, and more particularly, in one aspect of the invention whereby the handling includes storage and distribution of the articles. Even more specifically, the invention relates to a system for automatically receiving, storing and dispensing containers and/or articles, and in a further embodiment, where at least some of the containers have a plurality of articles positioned therein.
The accompanying drawings, if any, which are incorporated herein and constitute part of this specification, illustrate embodiments and details of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention.
In one aspect of the invention, an enclosed structure or housing includes a loading port for receiving containers to be transported into the housing, storage locations for storing at least some of the containers and/or articles, and a retrieval port for allowing containers and/or articles to be transported from inside the housing to a user of the system who is outside of the housing. A computerized control system is located in or near the housing and can control the apparatuses related to the system.
It is noted that it is not required that the loading port and retrieval port be structures that are separate from the housing, and in some embodiments of the invention, the loading and retrieval ports can utilize the same or different structures as the housing. It is also noted that the loading or retrieval port can be formed using a separate structure which is connected to the housing. The port may include conveyance apparatus which can include conveyor belts, elevator systems, pneumatic tube structures that are connected to or part of the housing. Additionally, in another embodiment, the port can be a secure door through which containers or packages are placed or retrieved manually.
In accordance with the invention, the housing includes apparatus for providing automatic handling of articles to be located therein.
One type of such automatic handling includes a conveyance apparatus for transporting a plurality of containers into the housing via the loading port and a conveyance apparatus for transporting the containers (or articles that were located inside the container), via the retrieval port, to a user of the housing who is located outside of the housing. The conveyance apparatuses noted above can be totally separate from one another, or can comprise a combined or even the same apparatus. It is noted that by the term container, applicant means any type of containing device, such as a box, carton, bag, tube, etc. The containers can have one article or item contained within them and or can have a plurality of items stored within them.
Additionally, the system can have a container identification (ID) system which can determine which container is being presented to the housing and which can then enable the control system to determine whether the container is authorized to be conveyed into the housing or into the storage area within the housing. This determination by the control system can be based on many factors, which may include, whether the control system was anticipating the specific type of container or the specific unique package at that time. Additionally, the determination to allow the container into the housing can be based on whether the control system determines that there is sufficient space in the housing to store the container. The ID system can include a bar code scanner, an RFID device, a camera, an optical sensor, mechanical sensors or other sensors
The housing may also include an apparatus for automatically creating an opening in a portion of a container which may include the removal of a portion of a container, the opening created in the container being of sufficient dimension and location in the container so that articles located in the container may be removed from the container. Alternatively, the container may never be opened by the opening apparatus, and transported to the second storage location in an intact and unopened state.
It is noted that various types of known systems can be used for manipulating the container, and/or the cutting instruments for creating the opening in the container, such as rotating and/or stationary blades, laser beam cutters, etc. Such cutting devices are known in the industry, see for example U.S. Pat. No. 6,863,486.
A conveyance apparatus is used for bringing the container to a storage location in the housing whereby the storage location can include a shelf or rack, and whereby the conveyance apparatus may include a traditional type of conveyor belt or chain driven transport system (powered by a device such as a motor, a hydraulic or pneumatic system, a screw feed, a rack and pinion, or a piston mechanism or some other mechanical device), and may or may not be used in conjunction with further article handling mechanisms, such as a gantry robot, a multi axis articulated arm robot, or some other mechanically based article handling system.
This conveyance to the storage location can be done before or after any opening is made in the container.
In the event the container is to be opened, once the opening in a container is provided, an article retrieving device located in the housing can access the opening for removing the articles from inside the container, thereby enabling the articles to be transported to a second location. Such transportation of the article to the second location can be done by the article retrieving device, or can be done in combination with a further conveyance apparatus.
In one embodiment the removal of an article from a container can be accomplished using a gripper. The gripper can include a vacuum based suction cup or mechanical claw type gripper or other material handling mechanism, all of which are commonly know in the art. In order to facilitate the proper retrieval of items from the container, a robotic device utilizing optical, vision, vacuum or other sensors can be used.
It is noted that in a preferred embodiment, a disposal apparatus is provided for securing to the material, if any, which may have been removed from the container to form the opening, so as to transport any such material to a disposal or recycling area. Such securing apparatus can include a mechanical or suction-type gripper, a robotic arm, or some other material handling device. A portion of the apparatus that removes a portion of the container and creates or forms the opening, can also form part of the apparatus used to remove and dispose of that material removed to form the opening.
It is also noted that the housing could have multiple storage locations therein so as to accommodate a plurality of containers of similar or different shape and/or size. Each container may have similar or different items or articles inside them. A container could have only one item contained inside, while another container could have a plurality of items or articles contained inside.
It is noted that the article retrieving device which removed the article from the container, could be all or part of the conveyance apparatus that puts the article in the second storage location. Alternatively, e the article can be moved with a separate conveying apparatus to the second location.
In accordance with one aspect of the invention, the second location can be or have co-located therewith, a further container, such as a non-returnable bag or box, that is delivered to an end user. Such further container is hereinafter called a delivery container. In one embodiment, the delivery container can move with the article retrieving device so as to be positioned to directly receive one or a plurality of articles from the article retrieving device, which articles were removed from one or a plurality of containers. Once the article is in the delivery container, the system can dispense that container with one or a plurality of items requested by the user, to be conveyed out of the retrieval port of the housing and to the end user (or a package delivery service). Alternatively, the delivery container can be held for an indeterminate period of time in order to receive additional items and/or to be held for a few hours, days, or more for later pick-up by an end user (or a package delivery service). Thus, the delivery container receives the items requested by the end user. In the event that the items requested are unopened containers, then it is possible that no delivery container would be used.
The delivery container may be of the type which is preformed before being located in the housing, or it may be of the type which is formed within the housing, such forming can be accomplished using any one of known carton or bag forming devices, and the carton or bag can be formed so as to have handles to assist the user or a delivery service for the transportation and/or movement of the container to the end user.
In another embodiment, there is no delivery container, and the stored articles are delivered directly and individually to the user waiting at the retrieval port, via the conveyance apparatus without the use of a bag or carton.
In a preferred embodiment, the system can seal the delivery container, using for example an adhesive tape. Additionally, automatic means can be provided so as to print or otherwise affix to the container addressee, user or shipping information so that the delivery container is ready to be received by a package delivery service for delivery to the end user.
It is noted that the housing can have various sections, each section having a different environmental condition, such as a different temperature or humidity, such conditions being attained by the use of air-conditioning or other refrigeration system located in, on, or near the housing, thereby enabling at least a portion of the inside of the housing to kept air conditioned, refrigerated, frozen, heated and or ambient.
In accordance with a further aspect of a preferred embodiment of the invention, a payment mechanism and or order entry interface is associated or otherwise included with the automated storage and distribution system. For example, when the system and structure comprises a retail store for the storage and sale of goods, there are several ways a user of the store can order items and or access the payment system, such as by:
Additionally, a variety of end user payment systems may be used in conjunction with the storage and distribution system for enabling the end user to pay for the articles delivered to him. The end user payment can be made by cash, debit, credit or other electronic method, and can be made at the site of the storage system or can be processed via a remote link which can include via the internet or cell phone.
The automated storage and distribution system can also be accessed using a security code or other method which can include a magnetic card, a biometric device, a PIN number code or other similar system. This will enable a delivery service to deliver or remove articles or packages from the enclosure in a secure manner.
The system can be used as a sales system thereby distributing goods in exchange for payment, or alternatively, it can be used as a secure distribution system which prevents access of stored items from being retrieved unless a person has authorization to do so, such as a delivery service which is retrieving a parcel from the enclosure for further transportation.
In an alternative use, the system can be used as both an automated warehouse for controlling the access of the goods inside for security purposes, and additionally can also allow items to be sold from the system as the need may arise.
Therefore, it is possible that the very same system can function at any given time as either a secure distribution warehouse and or a retail or wholesale outlet. So for example, a parcel delivery company can use the system as a distribution depot for the transfer of goods from one distribution site to another one or to a final customer where, payments are not necessary for accessing the goods or containers inside. In another scenario, the very same system can be selling items from the housing to other persons who are interested in purchasing goods from the system.
Additionally, the system can be utilized as a public warehousing or distribution system enabling people to have items stored in the housing and whereby they can retrieve the items or packages at a time of their own choosing.
The above noted devices can be accessed by the user from their car, by walking up to the housing or by sitting in an adjacent or attached structure or room which is attached to or in proximity to the housing.
For enhanced services from the store, a user can access a remote site via a remote video and/or audio link to a live person, if the end user at the store needed assistance.
In accordance with a further aspect of a further preferred embodiment of the invention, the automated storage and distribution system includes a container sensing system. The sensing system can be used to identify the orientation of the containers in the housing using sensing mechanisms, such as mechanical sensors, a vision or image or other optical device, as well as a bar code device or radio frequency ID tag device (RFID).
Such a sensing system may cooperate with the robotic or conveyor apparatus, in order to assist with re-orientation of the container in a manner so as to prepare it for storage, or for assisting with the forenoted manipulation so as to ensure the container is properly placed before forming the opening therein.
The forenoted article retrieval device can use an imaging system, and or additional sensors such as suction sensors, pressure sensors or proximity sensors to identify where and how to grab or otherwise secure to the articles to be removed from the container. It is also noted that the article retrieval device may, if desired, grab more than one articles when removing them from the container.
Information relating to metrics of the container dimensions, container contents, opening orientation and instruction set, internal layout of articles within the container or carton, color or shape of the articles or packages inside the container or carton, whether the items contained inside are of a delicate or rugged nature, can all be accessed by the system from a database which can be stored at the site of the housing or can be remotely updated to the system via a remote link, including using the internet, a wireless system or a wired communication connection. These metrics can be used by the control system to assist in the handling and or the manipulation of containers and the articles retrieved from them.
It is noted that in accordance with a further aspect of a preferred embodiment of the invention, a shipping container such as a cardboard box which is stored in the housing, once opened, may be used as a storage container for the articles, that is, the shipping container is moved to a storage location with all the articles still positioned inside the container, and then the article retrieval device selectively removes articles from one or more of the stored containers, in order to fill a request for articles from an end user (i.e., customer). In this way, there is no need to have a person manually load the items discretely into a storage area within the housing, since the container in which the items were transported to the distribution system housing, also acts as the storage device from which the individual items may be automatically retrieved by the retrieval device.
A particular advantage of the present arrangement is that it provides an automatic, i.e., non-human contact, process which allows an end user to obtain individual ones of articles that are shipped in bulk in a sealed container from a manufacturer. That is, the shipping containers received into the housing could have been “sealed” at the factory or warehouse of the manufacturer of the articles, and an end user can obtain one or more of the articles from inside one or more of the various containers stored inside the housing, in a manner that does not involve human contact with the articles.
As noted above, in another embodiment, the system can distribute and or convey unopened containers as well as items from opened containers to the retrieval port. This may be desirable since some containers may only have one item inside, or a given user may wish to retrieve or purchase a full carton of a specific item.
In an even further aspect of a preferred embodiment of the invention, once all the articles have been removed from a shipping container, the disposal apparatus attends to disposal of the container. In one embodiment, the apparatus may convey the empty container to a disposal location with one or more compacting devices that may be located in or attached to the housing.
In an even further aspect of a preferred embodiment of the invention, metrics regarding the container are, in advance, and either remotely or directly, input to a computer controller of the automatic storage and distribution system, which metrics provide information to the vision and/or opening devices. Once the container and its contents have been identified, specific to attributes of various ones of the containers and the articles positioned therein can be used to determine and or control further handling and transportation of the container and its contents into and around the inside of the system.
Additional feature of a preferred embodiment can include remote video monitoring of the system which can monitor any part of the process inside or outside the housing so that if there is, for example, a malfunction or a personal security issue, a computer or a person at a remote location can assess the situation and can even remotely take control of the system in order to rectify a given problem.
Additionally, a person loading containers to the port or the housing can be required to input an authorization code through one of various electronic means, including a magnetic card, a PIN number, a fingerprint reader or other method which would enable that person to activate a secure loading port thereby enabling him to load a container into the housing. Both the loading port and the retrieval port can be designed to be secure, thereby not allowing any person access into the housing area or the storage area. So, while a person may be authorized to deliver packages or cartons to the housing, that same delivery person has no access to the inside of the housing and he cannot access any containers or packages which are located inside the housing. In this way, the person delivering the containers does not have to be a person who the owner of the distribution system has had any prior dealings with and there is no need to have any relationship of trust or otherwise in order for the delivery person to facilitate the loading of containers or packages into the housing of the distribution system.
A particular advantage of the above system and its various embodiments, as compared with prior art storage and distribution systems, or retail stores, is that a significant cost of such prior art systems is due to the labor involved in moving cartons (with or without further articles positioned therein) from the manufacturer to an intermediate storage/distribution facility and then to the location where the user will pick-up the articles (i.e., such as onto the shelf of the retail store). Such shipping, storage and handling costs experienced by the article manufacturer and the store owner/operator are ultimately passed on to the end customer, as reflected in a higher final sale price of the article. On the other hand, the system of the invention allows the storage and distribution system (i.e., a retail store or a warehouse distribution system built according to the present invention) to leverage existing article transportation infrastructure and services, such as the United Parcel Service (UPS) and Federal Express (Fex Ex) or other general trucking and transportation companies, to deliver the containers to the housing of the inventive system. These existing transportation service companys typically provide for package and container transportation to any place on the globe at a highly efficient and competitive price. Thus, by using such service company's for container transportation and loading of a structure in accordance with the present invention, this feature results in a significant savings over an article manufacturer having to distribute his products on his own, thereby requiring a fleet of trucks, drivers and a plurality of centrally located distribution centers as well as all of the trustworthy personnel required to stock the shelves and or pick the products.
The system of the invention also includes automated systems inside the housing which attend to the initial sorting, final storing and then ultimate distribution of the articles to the end user, all without additional costs for employee labor or providing the physical and financial infrastructures needed for employees. Thus, many of the financial overhead and real-estate costs involved in the operation of a retail store or a distribution warehouse are avoided.
A further advantage relating to the fact that the above handling of the cartons and articles inside the housing is accomplished in a mechanized and automated way, without human intervention, is that:
While the present invention has been disclosed with reference to certain embodiments, numerous modifications, alterations and changes to the described embodiments are possible without departing from the sphere and scope of the present invention, as defined above. Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it has the full scope defined by the above language, as well as equivalents thereof.
In accordance with the above description, the present invention includes, among other features:
In accordance with further aspects of the invention:
Furthermore:
In accordance with another embodiment, the present invention includes:
In another embodiment, the invention comprises:
Business methods in accordance with the invention include using the above-noted enclosure and apparatus to make an automated package/article storage and retrieval system which can use the shipping facilities of “common carriers” to “load” the enclosure with the packages and articles to dispensed to the end users.
This method allows multiple manufactures, each making a different article, to ship their items in bulk to a given distribution storage facility which can then “load itself” without human intervention, thereby resulting in significant cost savings in shipping, as well as reduced personnel costs at the enclosure.
