Patent Application
20240166445
This invention relates to automated devices for storage and retrieval of grocery goods. Especially, the invention relates to an automated modular storage and retrieval device which allows various sizes of storage as well as various speeds of delivery depending on the selection of modules in the device.
An example of an early disclosure of a method of delivering groceries purchased over the internet is provided in EP1614375. The method includes filling up internet orders in a warehouse by filling the ordered groceries in totes, moving the totes on a rack into a truck transporting the groceries closer to destination and smaller vehicles then picking up the totes from the truck to deliver the totes to customer's homes.
US20200361711 filed by the applicant, discloses a solution where preordered groceries are stored in totes in an automated grocery terminal and the grocery totes are picked up and loaded by a loader moving vertically on a horizontally moving mast along a corridor between two shelving units. The terminal has two loading areas allowing one person to operate simultaneously at both of the loading areas to speed the process of loading and unloading. A limitation of this solution, however, is that even if two transactions can be allowed simultaneously due to the two loading areas, the mast and loader can serve only one grocery tote at a time, whereby the flow of crates is limited to the moving speed of the mast and loader. Accordingly, even if the system provides clear benefits, it is still not capable of allowing continuous loading and/or unloading of the totes.
The next level of performance of automated storage and retrieval systems are established by large multilevel storage/retrieval systems, for example such as described in WO2023280688. This type of multilevel systems are generally designed for large warehouses. The items to be stored can be moved by unmanned shuttle vehicles moving along rails in the warehouse, such as described in U.S. Pat. No. 8,790,061.
Thus, the current state of the art is such that there are small parcel terminals with relatively limited storage space suitable to be fitted inside or outside of a retail store (e.g. US20200361711) and on the other hand, there are the large warehouse-scale devices (e.g. WO2023280688).
Accordingly, there is a need for modular storage and retrieval terminals that can be assembled in different sizes and would be versatile in regards with storage space. There is a need for a versatile storage and retrieval terminal system which can be assembled in and dimensioned for an existing space, and which can be easily modified for example when the need of storage capacity is changing over time. Moreover, there is a need of devices and methods for retrieving and storing goods, especially groceries in a manner where a multitude of persons can operate at the device simultaneously and continuously, and where throughput times are optimized and the waiting times are minimized.
Accordingly, this invention addresses the shortcomings of the existing systems by providing a versatile modular device and method for inserting crates and retrieving goods simultaneously, along with a continuous deposit of crates into the storage space.
The modular device can be used in urban areas where space is limited, and retailers need to be closer to their customers. By using a smaller warehouse space and automating the fulfillment process, retailers can reduce their overhead costs while still providing fast and reliable order fulfillment. The modular device disclosed here can be incorporated into existing space or on a separate purpose built structure. The capacity of the modular device is adjustable and depends on number and type of modules in the device. The modules are seamlessly attached to each other, which in this context means that the rails inside the storage modules extend from one storage module to the next horizontally attached storage module, that the lift module connects storage modules attached to each other in vertical direction as well as connects the conveyor modules underneath the storage modules to the storage modules, and further that the conveyor lines extend from one conveyor module to another and that the self-moving independent platforms can move from one conveyor module to another.
To facilitate the movement of crates between different areas of the modular device, a conveyor system is integrated beneath a storage area of the modular device. The conveyor system may be an integrated conveyor or it may comprise multitude of self-moving platforms within one or more conveyor modules and the system provides a highly efficient and streamlined way of moving crates through the modular device with optimized throughput time. This built-in conveyor system is designed to integrate seamlessly with the layout and design of the modular device and further optimizes the use of space by utilizing vertical space by incorporating multi-level shuttle systems into the modular device.
The storage area is formed of multitude of storage modules comprising two shelving rows and being accessibly joined together and the modular device has a multitude of automated shuttles equipped with sensors and software to move crates within the storage area inside the modular device. With a multi-shuttle system, where each shuttle-device is configured to move on rails on a single level in the storage area above the conveyor system, the shelving rows have several levels in each storage module and each level has rails mounted to the shelving rows, thus allowing for quick and efficient movement of crates between storage locations (each level of the shelving rows has multitude of storage locations each suitable for storing one crate). Transfer of the crates from one level to another and/or from a conveyor module to a shuttle-device at a level is arranged by incorporation of multiple lifts into the modular device. The computer controlled lifts can be programmed to move crates between different levels based on the order information and fulfillment requirements. Incorporating multiple lifts into the modular device optimizes throughput times and reduces bottlenecks and delays as crates from one order can be moved to different levels by means of the multiple lifts. A shuttle-device suitable for use in the currently claimed modular device is disclosed in U.S. Ser. No. 18/218,376 by the applicant, and further details and alternative embodiments that are applicable in the currently claimed modular device are disclosed in the U.S. provisional patent application 63/493,151 by the applicant.
The modular device and method according to this invention allows continuous insertion of crates onto the conveyor system in a designated area. The conveyor system has means to automatically scan the inserted crate and to move the scanned crate through the modular device, eliminating a need to wait for the modular device to process the inserted crate before inserting next crate. The conveyor system acts as a buffer for crates before they are transferred to the storage area as well as a buffer before crates are presented at customer console.
One or more designated consoles for the customers (persons who retrieves the goods loaded in the crates) and one or more designated consoles for the associates (persons who loads the crates with ordered goods) allows both loading and retrieving crates at the same time. This helps to ensure that both the customers and the associates have sufficient space and time to perform their respective tasks without getting in each other's way.
It is an object of this invention to provide a modular device for storing, and managing grocery orders loaded in crates having an adjustable capacity, the capacity of the device being determined by a number and type of modules in the device, wherein the device comprises:
and at least one controller configured to control the at least one lift, the at least one conveyor line or the self-moving independent moving platforms, and the at least one shuttle device.
According to an aspect of the invention the adjustable capacity of the modular device is determined by a storage capacity and capacity to move the crates in the modular device, wherein the storage capacity depends on the number of storage modules and number of shelves in the shelving rows of the storage modules, and the capacity to move the crates in the device depends on the number of conveyor lines or independent moving platforms in the conveyor modules and the number of lifts in the lift modules.
It is an object of this invention to provide device as described above and comprising a multitude of storage modules, one or more conveyor modules, one or more lift modules, and one or more loading platforms, wherein a flow of loaded crates from the one or more loading platforms through the at least one conveyor module to the at least one lift module, and further to one of the multitude of storage modules is optimized by one or more computers, such that loading of the crates can be a continuous process, wherein the optimization comprises adjusting a number of actively used storage modules attached to each other horizontally and/or vertically, adjusting the number of actively used conveyor lines or self-moving independent platforms in the conveyor modules, and adjusting the number of actively used lift modules and the number of actively used lifts in the lift modules.
This invention is aimed to provide a computerized method to operate an automated modular device comprising a multitude of storage modules, a multitude of lift modules, a multitude of conveyor modules, a multitude of shuttle-devices, at least one loading platform to load crates with orders into the device, and at least one customer console to retrieve orders; wherein
According to certain aspects of the invention is provided a method to move storage crates from a conveyor module to a storage location in a storage module of the automated storage device as described above, wherein the method comprises moving the crates by one or more lifts located in one or more lift modules, wherein each lift has means to hold one crate, and
According to certain aspect of the method, the means to hold one crate comprises a pair of carrying arms connected to a vertically moving carriage, wherein the carrying arms are capable of moving horizontally in relation to each other, and
According to certain other aspects of the method, the means to hold one crate is a lift conveyor section, wherein upon positioning a crate on a conveyor cell or on a self-moving independent platform underneath the lift, the controller causes the conveyor cell, which forms a moving conveyor section, to move upward and the lift to move downward such that the lift conveyor section is at same level with the moving conveyor section and the moving conveyor section is caused to move the crate horizontally to the lift conveyor section, and upon a sensor recognizing the crate on the lift conveyor section the controller causes the lift to move upward to the predetermined level.
a-c is another view illustrating the operation of the automated modular device. This figure shows the alternative embodiment of the modular device (depicted in
This disclosure provides a highly efficient and versatile modular device, which is constructed of one or more storage modules 200/250, conveyor modules 300, lift modules 400, and console modules 500. Depending on the location of the modular device, it may be equipped with an outer shell to provide additional protection and insulation.
Each storage module 200/250 comprises two opposing shelving rows 205 having a multitude of levels and an aisle in between the rows. Each level in the storage module comprises a platform 203 where crates can be stored, and horizontal rails 204 on which a shuttle-device 350 can move. The shuttle-device is a platform moving on drivewheels 352 along the rails and being capable of carrying one crate 100 at a time and load/unload the crate onto/from the platform 203. Multiple storage modules can be joined together on vertical or horizontal directions. When the storage modules are joined vertically one on top of another, the modular device will have more levels; when the storage modules are joined horizontally such that the aisles of each module match with each other, the modular device will have longer aisles and more storage spaces in each level. One or more storage modules can be designated as a different temperature zone, such as a freezer section. This different temperature section formed by one or more storage modules is insulated from the rest of the storage modules. Moreover, movable doors 221 are configured to close off the aisle 202 to further isolate the different temperature zone from abutting storage modules.
The conveyor modules 300 are located underneath the storage modules to make the most efficient use of the available space. According to certain aspects of the invention, each conveyor module comprises two parallel conveyor lines 301, arranged in such a way that when two conveyor modules are joined together, two parallel continuous conveyor lines are formed. These conveyor lines are used to transport crates around the modular device. The conveyor lines are divided into cells by sensors 303. Each cell can hold one crate 100 at a time and move the crate independently. According to another aspect of the invention, the conveyor module may not have conveyor lines but instead a multitude of self-moving independent platforms 560 each configured to carry one crate.
The modular device can be assembled such that there are different conveyor modules for different applications. A typical conveyor module only comprises one or preferably two parallel conveyor lines. Another type of conveyor module is a diverter or console conveyor module which is capable of moving crates also between two parallel conveyor lines in one conveyor module or capable of moving crates out to a loading platform or of the modular device. The conveyor module directly underneath the lift module 320 can also transfer the crate from conveyor line to the lift and vice versa as is shown in
The lift module 400 comprises at least one lift. It is to be understood that the number of lifts per a module can vary:
Console modules of this modular device are designated areas for the customer or associate to interact with the modular device. An associate, also known as operator, can insert crates into the modular device at one console, and a customer can receive their goods from another console simultaneously. Consoles may be located at the ends of the modular device and/or on the sides. Additionally, consoles may have dedicated users, such as associates or customers only, as they may have constructional differences associated with them.
The modular device and its various functions are controlled by a control system having one or more controllers, such as computing devices capable of storing data and refreshing the stored data. The control system determines and coordinates movements of the shuttle-devices, the conveyor lines, the self-moving independent platforms and well as the lifts. The control system may for example include one or more computer systems, data storage devices, wired and/or wireless networks, software (e.g., programs, modules, drivers, etc.), user interfaces, scanners, and communication modules.
The present invention thus provides a highly efficient and versatile modular device, which can accommodate a wide range of storage requirements. The integration of the storage modules, conveyor modules, lift modules, and console modules provides a comprehensive solution, which maximizes storage capacity and enhances customer experience.
The storage module 200/250 comprises two shelving rows 205 with an aisle 202 in between, designed to optimize the storage and accessibility of crates. The shelving rows have multiple storage levels 201, each configured to store crates and each made of a low-friction material to allow easy sliding of the crates.
The distance between two storage levels 201 in a shelving row is determined by the height of the crates, resulting in more levels in the shelving row for lower crate heights. However, the levels 201 on opposite sides of aisle are on same height. To ensure flexibility, the storage modules 200/250 are constructed using optimized components that allow for the easy assembly of different crate heights. These modules can be connected in horizontal or in vertical manner to create different shelving structures, with walkways 206 in the aisles to provide convenient access for service or maintenance.
Each storage level 201 is equipped with horizontal rails 204 on both sides of the aisle, together forming a shuttle rail to support shuttle-devices 350 moving along the aisle 202. The horizontal rails 204 are designed to accommodate drivewheels 352 on top and stabilizer wheels 353 on the side, with one rail in each pair featuring encoder holes to help the shuttle position itself accurately. This configuration ensures efficient and smooth movement of crates within the storage modules.
The storage modules are configured to form various temperature zones, wherein an entire storage module or several abutting storage modules can have a uniform temperature or one or more storage modules may have multiple temperature zones. To provide separation between the temperature zones, sandwich panels 220 are integrated in between the storage modules of different temperatures, which allows for efficient insulation of each zone.
The aisle between the shelves creates an opening in the sandwich panel, which is covered by movable doors 221 to enable the shuttle-device 350 to enter and exit through the movable door to different temperature zone. The movable doors are designed to cover at least the height between two levels, ensuring a consistent temperature within each zone. The movable doors have rollers at their bottom and the rollers are supported by the same horizontal rails 204 that the shuttle-devices 350 ride on. Similarly to the shuttles, the door drivewheels are accommodated on top and stabilizer wheels on the side of the rail. The shuttle-devices 350 can move the doors by carefully pushing the movable doors 221 from their closed position. Upon returning, the shuttle-device will pull the door back to the closed position with the help of magnets. This door design eliminates any need for motorized doors between the different temperature zones. The panels and doors are constructed using materials that provide high-quality insulation and protect against temperature fluctuations.
The modular device may be constructed to have multiple storeys of storage modules. The uppermost storage modules 250 may be equipped with integrated climate control modules 251 that circulate climate controlled air within the modular device. In one embodiment of the invention, the modular device is located within a climate controlled environment, which eliminates the need for insulation panels on the outside of the modular device. In this configuration, the temperature within the modular device is controlled by the location climate control. Further, the storage modules can be insulated selectively to create one or more different temperature zones, as required. The invention thus provides a highly versatile storage solution, capable of accommodating a wide range of temperature control requirements. The integration of the climate control units and the selective insulation of the storage modules enable precise and efficient temperature control, which is particularly advantageous for storing perishable goods.
The modular device features an associate console 501 located at one end of the modular device, which is intended for use by trained personnel to load or unload crates to and from the modular device. At the walls of the modular device in the associate console there are multitude of openings. In case the modular device is covered with panels there are insulated outer doors 502 which cover the inner loading platforms 503. The inner loading platforms are folded up when the associate is not using the modular device. Loading platforms and outer doors are locked in a closed position with electronic locks.
The associate console is equipped with a touchscreen 504 that allows associates to access the functions of the modular device and identify themselves. On that touchscreen 504 the associate can open the insulated outer doors 502 covering inner loading platforms 503 and fold them down.
The inner loading platforms 503 are extensions of the conveyor lines 301 in the conveyor module or they have connection to the self-moving independent platforms 560 in the conveyor module. The associate can load the crate onto the loading platform and push the crate into the modular device. The modular device may have a multitude of loading platforms and one can be used to simultaneously receive empty crates from the modular device while another one is used to load full crates into the modular device. Once a crate is placed on the inner loading platform 503 and pushed towards the modular device, a sensor is activated, and the conveyor line or a self-moving independent platform is automatically engaged to pull the crate into the modular device for scanning. If the scanning fails, the crate is pushed back out, and an associate is notified through the touchscreen 504 and the associate will be able to scan the crate using a handheld scanner 505 located near the touchscreen.
Additionally, the associate console comprises a maintenance door 506 which can be used to gain access to the inside of the modular device. The maintenance door is electronically locked and can be unlocked on the touchscreen 504. Only trained personnel can have access to enter the modular device. There is a small ladder 507 that can be taken from the modular device and placed in front of the maintenance door 506 to gain easy access into the modular device. Inside the associate console the technician can have access to the electrical cabinet 508 and compressed air system 509. The modular device does not require to be taken offline during this operation due to the rest of the modular device being isolated from the console area. There is a see through inner safety door 510 in the associate console which is electronically locked isolating the console area and rest of the modular device. The door rides on a rail system 511 and can be pushed aside to gain access to the modular device, also on the same rail rides a ladder 512 which can be pulled and placed in the center of the modular device to provide access to the top modules of the modular device.
The modular device may feature a customer console 525 at one end of the modular device. The customer console is designed to be used by customers who come to receive their orders. The console comprises outer doors 526 and a frame 527 around the doors. The frame houses safety light curtains on the sides and provides a wear-resistant surface 528 for handling goods at the bottom. At the top of the frame, a light 529 is provided to ensure proper illumination during operation.
A touchscreen 530 is mounted on the side of the customer console frame to allow customers to access the modular device's functions, such as receiving their goods and identifying themselves. A scanner 531 is mounted under the touchscreen and can be used by the customer to identify themselves by scanning their barcode/QR code or other type of identification code received with the order.
Once the customer has identified themselves, a crate containing the ordered goods is brought to the customer console and secured in place. The outer doors 526 of the console are then opened, and the customer can remove their goods from the crate. However, the crate is fixed in place during this procedure and cannot be removed by the customer. After confirming on the touchscreen that they have taken their goods, the outer doors close, and the next crate with the customer's goods is brought to the console, while the empty crate is unlocked from the console and moved away. This procedure repeats until the customer has no more crates left containing their order.
In the case of a multi-storey modular device, an upper storage module 250 may extend directly on top of the customer and/or associate console at the ends of the modular device, creating an awning that protects the user from the elements during interaction with the modular device (as shown in
In certain embodiments, a specialized console may be positioned at the side of the modular device to cater specifically to the courier, customer, or other parties. The console may even be intended for use with autonomous vehicles. Alternatively, multiple user groups may utilize a common console.
Some embodiments as shown in
Yet another embodiment
The modular device features one or more lift modules each comprising one or more lifts 401. The lifts are used to transport crates between a conveyor modules 300 and storage modules 200/250. In one embodiment, the modular device includes at least one lift for each conveyor line, with each lift having crate carrying arms 402 mounted to a carriage 403 that can carry a crate 100. The modular device is designed such that when a crate 100 correctly positioned on the conveyor line 301 or on a self-moving independent platform is positioned directly underneath the lift, the crate carrying arms 402 can grab the crate. A conveyor module located beneath the lift centers the crate to its correct position and raises it off the conveyor line so that the lift arms can be lowered around the crate without touching it. The lift arms can then move past the crate and move toward each other to decrease the distance between them, thereby positioning them under the crate. The lift arms can then move up towards the storage module and raise the crate with the arms. Once the lift has reached the desired level of the storage module, it stops, and a shuttle-device 350 can pull the crate off the lift arms. The lift may then go to another storage level to receive a new crate from another shuttle-device or go back down to take another crate from the conveyor module.
In another embodiment
The conveyor system is located below the storage modules. The conveyor system is composed of one or more conveyor modules 300 attachable to each other and being configured to be conveniently assembled at the installation site. Each conveyor module has at least one and preferably two parallel conveyor lines 301, which are divided into numerous conveyor cells with sensors. These cells can operate independently of one another, providing a highly adaptable and responsive crate transportation system. Each cell is configured to accommodate a single crate at a time, further increasing the flexibility of the system. The conveyor modules can be placed side by side to form an extended, continuous conveyor line.
The conveyor system may comprise different types of conveyor modules. A typical conveyor module only contains two conveyor lines, whereas a diverter or console conveyor module can move crates between conveyor lines on a single module or off a module to a side console 540, crate processing device, or another conveyor line outside the modular device. Furthermore, the conveyor module located beneath a lift module 320 can transfer crates between conveyor lines and also transport the crates to the lift.
In some embodiments, the conveyor system may include conveyor lines outside or near the modular device for transporting empty crates to an empty crate stacking contraption to prevent empty crates from returning to the modular device. Additionally, an external conveyor may be employed to transport crates to side consoles adjacent to the modular device.
An alternative conveyor system
A shuttle-device 350 is a moving platform that transports crates 100 in the storage modules 200/250 and/or the lift modules. The shuttle-device comprises a platform that has preferably four drivewheels 352. The platform is designed to move along an aisle 202 between shelving rows 205. The shelving rows have horizontal rails 204 parallel to the aisle on each horizontal level 201 and the rails support the drivewheels 352 of the shuttle-device. The shuttle-device further comprises at least two stabilizer wheels 353 on both sides of the platform to maintain a constant distance from the rails.
The shuttle-device is configured to retrieve and deposit crates from and to the lift module and the storage module, respectively. The platform of the shuttle-device is equipped with two telescopic arms 360 that are positioned in the middle of the platform and extend perpendicularly to the platform's direction of movement. These arms are capable of extending in both directions and can extend beyond the width of the platform.
To retrieve a crate from a storage module or a lift module, the extending arms of the shuttle-device move in synchrony past the sides of the crate, and the distance between the arms decreases. This motion causes the rotating levers 361 at the distal ends of the arms to rotate behind the crate, after which the arms can contract back to the platform, pulling the crate along. Conversely, to deposit a crate onto a storage module or to a lift, the shuttle extends its arms pushing the crate with levers and increasing the distance between the arms, when the crate has reached its position the levers are rotated back into the upright position which allows the arms to be retracted without the crate.
In an alternative embodiment the shuttle arms have no rotating levers at the end of the extending arms but fixed edges that can pull the crate. These fixed edges move with the arms. When the arms move closer to each other to grab the crate the fixed edges move behind the crate.
One shuttle-device is configured to move along the rails in one level of the shelving row and to move from a storage module to another at the same level. Furthermore, one shuttle-device may enter multiple lift modules and serve multiple lifts at one level; i.e. the shuttle-device are not configured to move from one level to another.
According to one embodiment multiple modular devices are positioned side by side and a rail system is constructed between the modular devices. Such rail system would require the shuttle-devices to have another set of wheels that would allow them to move perpendicularly to the initial rail system in order to move between the multiple modular devices.
Description of Steps to Load and Unload Crates to and from the Automated Modular Storage Device
Description of method to load crates into the automated modular storage device is illustrated in details in
This application claims priority of U.S. provisional application No. 63/507,317 filed on Jun. 9, 2023 and U.S. provisional application No. 63/382,613 filed on Nov. 7, 2022.
| Number | Date | Country | |
|---|---|---|---|
| 63382613 | Nov 2022 | US | |
| 63507317 | Jun 2023 | US |
