Patent Application
20240417176
The present invention relates to the field of automated order fulfilment systems. In particular, the present invention relates to an improved system and method for the handling, or manipulation of containers in fully or semi-automated storage and retrieval systems.
Various forms of both fully- and semi-automated order processing and fulfilment systems are known. They, and the various components they comprise, may take many forms.
In some forms of goods-to-man picking systems, for example, bins or other storage containers containing inventory and/or other items may be stored within, and retrieved from, a storage and retrieval system, in order to facilitate picking of items from the storage containers at picking stations. Pallet goods and/or other multi-packs of inbound items are separated and placed, individually or in groups corresponding to their stock keeping unit (SKU) into separate storage containers for storage in the storage and retrieval system.
Storage and retrieval systems typically comprise a three-dimensional storage grid framework structure, within which storage containers/bins are stacked on top of each other, are well known. PCT Publication No. WO2015/185628A (Ocado) describes a known storage and fulfilment system in which stacks of bins or containers are arranged within a grid framework structure. The bins or containers are accessed by load handling devices remotely operative on tracks located on the top of the grid framework structure. A system of this type is illustrated schematically in
As shown in
The grid framework structure is made up of a plurality of storage columns or grid columns 15. Each grid in the grid framework structure has at least one grid column for storage of a stack of containers.
The three-dimensional grid framework structure 14 comprises a plurality of upright members or upright columns 16 that support horizontal members 18, 20. A first set of parallel horizontal grid members 18 is arranged perpendicularly to a second set of parallel horizontal grid members 20 to form a grid structure lying in a horizontal plane and supported by the upright members 16. The members 16, 18, 20 are typically manufactured from metal and typically welded or bolted together or a combination of both. The bins 10 are stacked between the members 16, 18, 20 of the grid framework structure 14, so that the grid framework structure 14 guards against horizontal movement of the stacks 12 of bins 10, and guides vertical movement of the bins 10.
The top level of the grid framework structure 14 includes rails 22 arranged in a grid pattern across the top of the stacks 12. Referring additionally to
As an alternative to the grid framework structure 14 supporting the 2D grid directly on a plurality of upright columns 16 as described with reference to
The prefabricated modular panels of the grid framework structure described above comprise upright columns 16. For example, a sub-group of the upright columns can be braced by one or more bracing members to form prefabricated panels or frames. For the purpose of the present invention, the plurality of upright columns 16 can also include the upright columns 16 in the prefabricated panels. The grid framework structure can comprise any appropriate supporting framework structure to support the grid, including upright columns 16 directly supporting the grid, and/or prefabricated panels and/or frames incorporating upright columns 16.
A known load handling device 30 shown in
The load handling device 30 is equipped with a lifting device (lifting mechanism) or crane mechanism to lift a storage container from above. The crane mechanism comprises a winch, a tether or cable 38 wound on a spool or reel (not shown) and a grabber device 39. The lifting device or crane mechanism comprise a set of lifting tethers 38 extending in a vertical direction and connected nearby or at the four corners of a lifting frame 39, otherwise known as a grabber device (one tether near each of the four corners of the grabber device) for releasable connection to a storage container 10. The grabber device 39 is configured to releasably grip the top of a storage container 10 to lift it from a stack of containers in a storage system of the type shown in
The wheels 34, 36 are arranged around the periphery of a cavity or recess, known as a container-receiving recess or container receiving space 40, in the lower part of the load handling device. The recess is sized to accommodate the container 10 when it is lifted by the crane mechanism, as shown in
The container receiving space 40 may comprise a cavity or recess arranged within the vehicle body, e.g. as described in WO 2015/019055 (Ocado Innovation Limited). Alternatively, the vehicle body of the load handling device may comprise a cantilever as taught in WO2019/238702 (Autostore Technology AS) in which case the container receiving space is located below a cantilever of the load handing device. In this case, the grabber device is hoisted by a cantilever such that the grabber device is able to engage and lift a container from a stack into a container receiving space below the cantilever.
Upon receipt of a customer order, a load handling device operative to move on the tracks is instructed to pick up a storage container containing the item of the order from a stack in the grid framework structure and transport the storage bin to a pick station whereupon the item can be retrieved from the storage bin. Order picking stations can include various forms of systems for receiving storage containers of items retrieved by the storage and retrieval system so as to enable picking of items therefrom, for placement in delivery containers. Such systems typically includes various types and forms of conveyor or trolley based systems, wherein storage containers are loaded on conveyors or picking trolleys for transport to picking areas for automated and/or manual removal of items and placed in delivery containers, which are often of different type(s) than those used to store items, and which are provided by systems or other sources outside the storage system.
Orders assembled for delivery frequently comprise multiple delivery containers. Individual delivery containers, once they have been suitably filled with picked items, are typically set aside in separate order sortation or handling systems until all required delivery containers for an order or a whole delivery vehicle are ready. At that time the multiple containers required to fill the order are assembled and provided to a dispatch facility for loading or delivery.
Empty delivery containers may be returned, following delivery, to the sorting or dispatch area and fed back into the separate order sortation and handling system for re-use. In other embodiments, delivery containers may be in the form of cartons, which are not returned.
While the use of separate order sortation and handling systems can work well for relatively small installations, handling up to, for example, a few thousand bin retrievals per hour, and either relatively few customer orders per hour or relatively few items per customer order, with large systems, involving tens of thousands of bin retrievals per hour or more, and hundreds or thousands of customer orders, each comprising tens of different items, this can become a bigger problem, requiring extensive conveyor systems for transport and sortation of Order Containers.
WO2014/203126 (Ocado Innovation Limited) teaches a system and method for order processing where a delivery container may be placed inside a storage container to form a storage container combination. The upper edges of the delivery containers do not protrude above the upper edges of the storage containers, when placed therein. This allows the storage container combination to be stored within the grid framework structure. One or more delivery containers can be placed inside storage containers at the dispatch facility or between the dispatch facility and the storage and retrieval system. One or more shopping or other bags may be placed within the delivery containers; and the resulting storage container combination can be placed within the grid framework structure until needed at an order picking station. At an order picking station, delivery container(s) within a combination may be stocked with items picked from the same or different storage containers. When all delivery container(s) associated with an order have been appropriately filled, the storage combination is retrieved by the storage and retrieval system, where it is stored until the appropriate time when it is required for fulfilling an order, at which stage the storage combination is transferred to a dispatch facility. At the dispatch facility, the filled delivery containers are removed from its combination(s) and loaded or otherwise processed for delivery. WO2014/203126 (Ocado Innovation Limited) teaches an apparatus to place delivery containers into storage containers with the help of the load handling devices. Here, bagged, delivery containers can arrive by conveyor to a transfer station. Storage containers can be deposited by the load handling devices onto the transfer stations and then moved by conveyor to a merge station conveyor. A transfer mechanism lifts the delivery container and moves it over the merge station conveyor. The merge station conveyor with the empty storage container can then be elevated by a lifting mechanism and the delivery container released from the transfer mechanism. The combined delivery and storage containers can now be transferred from the merge station conveyor onto a conveyor and on to a pick-up station. From the pick-up stations, the combined delivery and storage containers can be retrieved by the load handling devices and taken to an order picking station.
To separate the delivery container from the combined delivery container and storage container, typically a load handling device deposits the combined delivery container and storage container onto a transform platform. The delivery container is then secured by clamps, which can travel vertically on a lift mechanism. Whilst the delivery container is secured by the clamps, the transfer platform drop down and moves sideways carrying the storage container away from the delivery container. The clamps can now move down using a lift mechanism and deposit the delivery container to a transfer location where a conveyor or other mechanisms can transfer the delivery container to another location.
Whilst the art, WO2014/203126 (Ocado Innovation Limited), teaches an apparatus to automatically combine and separate a delivery container and a storage container, the apparatus occupies a significant proportion of the footprint of the storage and retrieval system requiring significant alternations to be made to the grid framework structure to accommodate the apparatus. For example, multiple feed and retrieval stations are required to feed and retrieve the combined delivery container and storage container to and from storage in the grid framework structure. An apparatus for combining and separating a delivery container and a storage container is thus required that occupies less footprint of the storage and retrieval system and is able to be incorporated into the storage and retrieval system with minimum alteration to the grid framework structure.
This application claims priority from GB application no. GB2114725.1 filed on 14 Oct. 2021, GB application number GB2118530.1 filed on 20 Dec. 2021, GB application number GB2114723.6 filed on 14 Oct. 2021, and GB application number GB2118537.6 filed on 20 Dec. 2021, there contents being herein incorporated by reference.
The present invention has mitigated the above problem by providing a combination and separation apparatus for combining and separating a delivery container and a storage container, the delivery container being able to be contained within the storage container, the apparatus comprising:
Configuring the storage container station, delivery container station, the merge/separation station such that they are configured to respectively convey a storage container, a delivery container and a combined delivery container and storage container respectively in parallel directions not only reduces the footprint of the apparatus but simplifies the construction of the apparatus. For the purpose of the present invention, the term “convey” or “conveying” covers feeding or receiving in a direction. Preferably, any one of the storage container station, delivery container station, combined station and the merge/separation station comprises a transfer mechanism configured for transferring a respective storage container, delivery container or combined delivery container and storage container between the merge/separation station and their respective storage container station, delivery container station or the combined station. Optionally, the transfer mechanism comprises at least one conveyor unit. For example, the storage container station may comprise a storage container conveyor unit configured for feeding or receiving a storage container in a first direction. Similarly, the delivery container station may comprise a delivery container conveyor unit configured for feeding or receiving a storage container in a second direction and the combined station comprises a combined conveyor unit configured for feeding or receiving a combined delivery container and storage container in a third direction. This could be by the conveyor unit comprising a drive mechanism to drive the movement of the storage container or the delivery container or the combined delivery container and the storage container to and from the merge/separation station and the other stations. Alternatively or in addition to the conveyor unit, the transfer mechanism may be configured to transfer the clamping device between the merge/separation station and the delivery container station. Thus, instead of the delivery conveyor unit being configured for feeding the delivery container to the merge/separation station, the transfer mechanism can be configured to transfer the clamping device between the delivery container station and the merge/separation station. Thus, a delivery container clamped to the clamping device can be transferred between merge/separation station and the delivery container station.
The first, second and third directions are parallel to each other, i.e. the first direction is parallel to the second direction, and the second direction is parallel to the third direction and the first direction is parallel to the third direction. The footprint of the combination and separation apparatus is determined by the movement of the storage containers along the first, second and third directions. Since the first, second and third directions lie in the same axis, the storage containers move along a single axis and therefore the footprint of the combination and separation apparatus may occupy a row of three aligned storage containers. By having the first, second and the third directions being parallel to each other, the apparatus can additionally function either as a combination apparatus, in which case the apparatus is configured for combining a delivery container and a storage container, or a separation apparatus, in which case the apparatus is configured for separating a delivery container and a storage container. In the case where the apparatus functions as a combination apparatus, then the present invention provides a combination apparatus for combining a delivery container and a storage container, the delivery container being able to be contained within the storage container, the apparatus comprising:
In the case where the apparatus functions as a separation apparatus, then the present invention provides a separation apparatus for separating a combined delivery container and a storage container, the delivery container being able to be contained within the storage container, the apparatus comprising:
Optionally, the lifting device is arranged for lifting or lowering a storage container towards or away from the delivery container so as to combine or separate a storage container and a delivery container clamped to the clamping device. In the case where the lifting device is configured for lifting or lowering a storage container towards or away from the delivery container, preferably the transfer mechanism of the merge/separation station comprises a merge/separation conveyor unit and the lifting device is arranged for lifting or lowering the merge/separation conveyor unit to combine the storage container with the delivery container in a raised position of the merge/separation conveyor unit and lower the storage container away from the delivery container to separate the delivery container and the storage container in a lowered position of the merge/separation conveyor unit. Optionally, the delivery container station is directly opposite the combined station such that in the raised or lowered position of the merge/separation conveyor unit, a continuous conveyor system extends from the delivery container conveyor unit to the combination conveyor unit via the merge/separation conveyor unit. Optionally, the delivery container station is directly opposite the combined station such that in the raised or lowered position of the merge/separation conveyor unit, a continuous conveyor system extends from the delivery container station to the combined station via the merge/separation station.
Alternatively or in addition, the lifting device is arranged for lifting or lowering a delivery container towards or away from the storage container so as to combine or separate a storage container and a delivery container clamped to the clamping device. For example, the lifting device can be configured for lowering or raising the clamping device.
In terms of the layout of the different stations of the apparatus, optionally, the combined station is arranged directly above the storage container station. Equally, the combined station is arranged directly below the delivery container station. In order to reduce the footprint of the apparatus in comparison to a prior art apparatus, preferably, the merge/separation station, the storage container station, the delivery container station, and the combined station all lie in the same vertical plane.
To simplify the feeding or receiving of the storage container and/or the delivery container and/or the combined delivery container and the storage container, preferably the merging/separation station is arranged between the storage container feeder station and the delivery container feeding station.
In order for the apparatus to combine or separate a delivery container and a storage container, it is necessary that the apparatus comprises a clamping device to clamp the delivery container whilst it is being combined or separated from a storage container. In addition, to enable the combined delivery container and storage container to be stored in the vertical storage columns bound by the vertical members and to engage with the grabber device of a load handling device, it is necessary that the delivery container does not protrude above the upper edges of the storage container when combined with the storage container. Thus, to allow the combined storage container and the delivery container to be stored in the grid framework structure as well as to enable the delivery container to be clamped whilst being combined with the storage container, at least one side wall of the storage container comprises a cut-out such that when the delivery container is placed or nested inside the storage container, the cut-out extends below the height of the delivery container so exposing at least a portion of the side wall of the delivery container. Typically, at least one side wall of the delivery container comprises a delivery container handle such that the delivery container handle can be engaged to remove or place the delivery container into the storage container. To enable the delivery container handle to be engaged, e.g. by the clamping device, it is necessary that the delivery container is correctly positioned relative to the clamping device.
Optionally, the merging/separation station further comprises an alignment mechanism arranged to position the delivery container relative to the clamping device so as to enable the clamping device to clamp the at least one side wall of the delivery container when combined with the storage container. Optionally, the alignment mechanism comprises at least two inserts or locating pins that are arranged to be inserted in the spacing between the storage container and the delivery container so as position the delivery container relative to the clamping device. Preferably, the lifting device is arranged for lifting the storage containers into engagement with the alignment mechanism. The at least two inserts or locating pins are diagonally opposed and sized such that when inserted in the spacing between the storage container and the delivery container when combined, the delivery container is correctly positioned relative to the clamping device. Preferably, at least a portion of the at least two inserts or locating pins is wedge shaped so as to enable the at least two inserts or locating pins to be inserted in the spacing between the storage container and the delivery container without fouling the edges of either the storage container and/or the delivery container.
To further correctly position the storage container relative to the delivery container when being combined, the merging/separation station further comprises a datum edge and a datum clamp, said datum clamp being arranged for clamping a storage container against the datum edge so as to position the storage container relative to the clamping device, i.e. the alignment mechanism further comprises the datum edge and the datum clamp. The datum edge provides a reference point for the storage container to correctly position the storage container relative to the delivery container above, more specifically, position the open end of the storage container relative to the delivery container. This allows the storage container to encircle the delivery container when the delivery container is nested within the storage container. Such re-positioning prevents any misalignment of the storage container and the delivery container causing both storage container and delivery container to crash into each other when being lifted towards each other. The datum clamp is configured to push the storage container against the datum edge such that an edge of the storage container butts up against the datum edge and thereby, correctly position the storage container relative to the delivery container.
Having the storage container conveyor station, the delivery container station and the merge/separation station being configured to convey their respective storage container, delivery container and the combined delivery container and storage container in a substantially parallel direction allows the apparatus of the present invention to be used interchangeably as a combination apparatus or a separation apparatus. This reduces the number of different spare parts separately required for the combination apparatus and the separation apparatus since the same parts can be used for both the combination apparatus and the separation apparatus.
Preferably, the present invention provides an order processing system comprising:
Multiple apparatuses of the present invention can be assembled together such that one apparatus can be configured to function as a separation apparatus to separate a combined delivery container and storage container and another apparatus can be configured to function as a combination apparatus to combine a delivery container and a storage container, i.e. the apparatus of the present invention can modularised. A bridge station can be interposed between the first apparatus and the second apparatus such that a storage container separated from the first apparatus can be transferred in a fourth direction to the second apparatus whereupon the second apparatus can be configured to combine the storage container with a fresh delivery container. Optionally, the fourth direction is substantially perpendicular or orthogonal to the first, second and third directions.
The order processing system of the present invention can be integrated into a storage and retrieval system comprising a three dimensional grid framework structure and one or more load handling devices operative on the three dimensional grid framework structure. Preferably, the order processing system further comprises:
Preferably, the at least one delivery port column and/or the at least pick-up port column comprises a vertical chute having an opening in cooperation with a grid cell of the grid structure for delivering or picking-up a combined delivery container and storage container by a load handling device through a grid cell. More specifically, the apparatus further comprises a vertical chute having a first opening in cooperation with a grid cell and a second opening leading to the combined station of the apparatus.
A load handling device operative on the grid structure can be instructed to deliver a combined delivery container and storage container through a vertical chute via its lifting mechanism to the combined station of the apparatus, whereupon the combined station is configured to convey the combined delivery container and storage container to the merge/separation station.
Similarly, a combined delivery container and storage container can be fed from the merge/separation station to a pick-up chute, whereby a load handling device operative on the grid structure can pick-up the combined delivery container and storage container and return it for storage in a grid framework structure. For the purpose of the present invention, the grid members comprises tracks or rails arranged in the grid pattern. The tracks or rails can be integrated into the grid members, e.g. by extrusion, or alternatively, secured to the grid members, e.g. by a snap-on arrangement or use of fasteners.
Alternatively or in addition to a load handling device delivering or picking up a combined delivery container and storage container from a respective vertical chute, the at least one of the delivery port column and/or the at least pick-up port column comprises at least one bin lifting device for lifting or lowering a combined delivery container and storage container at least partially along their respective vertical chute, i.e. along the a least one of the delivery port column and/or the at least pick-up port column. The bin lifting device could be hydraulic driven or belt driven and be integrated into the vertical chute and be arranged to transport a combined delivery container and storage container in a vertical direction at least partially along the vertical chute. For example, the bin lifting device of the vertical chute can work together with the lifting mechanism of the load handling device to transport a combined delivery container and storage container along the vertical chute to and from the apparatus of the present invention.
The present invention further provides a method of operating an order processing system of the present invention, comprising the steps of.
Optionally, the combined delivery container and storage container is transported in a vertical direction down the at least one delivery column and/or up the at least one pick-up column by the lifting device of the load handling device operative on the grid structure. Alternatively or in addition to the combined delivery container and storage container being transported by the lifting device of the load handling, optionally, the combined delivery container and storage container can be transported in a vertical direction down the at least one delivery column and/or up the at least one pick-up column by the bin lifting device.
The ability of nesting the delivery container within the storage container has provided the advantage that the delivery container can be stored in the storage and retrieval system until when required by an order picking station. This greatly improves the sortation of the delivery containers for dispatch at the dispatch facility. To allow the delivery container to be placed inside the storage container to form a storage container combination, the upper edges of the delivery container do not protrude above the upper edges of the storage containers, when placed therein. However, once the delivery container is placed inside the storage container, there needs to be an effective way to remove the delivery container from the storage container. The present invention has mitigated the above problem by providing a combination and separation apparatus for combining and separating a delivery container and a storage container, the delivery container being containable within the storage container, the apparatus comprising:
It is essential that the delivery container is clamped in order for the storage container to be separated from the delivery container. To clamp the delivery container, it is important that the delivery container is correctly positioned relative to the clamping device in order for the clamping device to properly engage with the delivery container. Without correctly positioning the delivery container relative to the clamping device, there is risk that the clamping device may not correctly engage with the delivery container. The provision of the alignment mechanism according to the present invention enables the delivery container to be correctly positioned so as to be positively engaged by the clamping device. Optionally, the alignment mechanism is configured for engaging with at least one side wall of the delivery container.
Preferably, at least one sidewall of the storage container comprises at least one cut-out so as to expose the at least one sidewall of the delivery container through the at least one cut-out. This is to allow the clamping device to engage with the at least one side wall of the delivery container through the cut-out in the storage container.
In one exemplary embodiment of the present invention, the alignment mechanism comprises a centring device comprising one or more guides configured for engaging with the exterior surface of the delivery container such that the one or more guides centres the delivery container relative to the storage container when the delivery container is nested within the storage container. Optionally, the one or more guides is mounted to a frame such that the one or more guides is arranged to centre the delivery container relative to the frame when the one or more guides engages with the exterior surface of the delivery container.
Optionally, the one or more guides comprises a plurality of locating pins configured for engaging with the exterior surface of the delivery container. The plurality of locating pins can be configured to engage with opposing sidewalls of the delivery container. Optionally, the plurality of locating pins are diagonally opposed so as to engage with the corners of the delivery container. The spacing between the locating pins are such so as to engage with the exterior surface of the delivery container. Any slight misalignment of the delivery container to prevent the clamping device engaging with the delivery container, engagement with the plurality of locating pins repositions the delivery container so that it is in the correct position relative to the clamping device. To enable the plurality of locating pins to engage with the exterior surface of the delivery container, at least a portion of each of the plurality of locating pins is wedge shaped. The inclined surface of the wedge shaped locating pins interact with the exterior surface of the delivery container so as to guide the delivery container into the correct position relative to the storage container when combined together, i.e. nested. Preferably, the lifting device is configured for lifting the delivery container into engagement with the alignment mechanism.
Optionally, the clamping device, the lifting device and the alignment mechanism defines a merge/separation station; and wherein the apparatus further comprises a combined station configured for conveying a combined delivery container and storage container into the merge station.
The clamping device, the lifting device and the alignment mechanism can form part of an apparatus where the clamping device, the lifting device and the alignment mechanism defines a merge/separation station and the apparatus further comprises a combined station configured for conveying a combined delivery container and storage container into the merge station. To combine a delivery container and storage container in the merge/separation station, preferably the apparatus further comprises:
Preferably, the apparatus further comprises a transfer mechanism configured for transferring the clamping device between the merge/separation station and the delivery container station. This allows the clamping device to pick up a delivery container from the delivery container station and transfer it to the merge/separation station where it is subsequently combined with a storage container. Equally, the clamping device can transfer a delivery container separated in the merge/separation station to the delivery container station.
Preferably, the clamping device comprises a pair of clamps configured for engaging with at least one side wall of a delivery container. Alternatively, the clamping device comprises a pair of arms moveable to clamp at least one side wall of the delivery container. To allow the pair of clamps to engage with the at least one side wall of a delivery container, preferably at least one of the pair of clamps comprises at least one engagement pin configured for being received into an opening in a delivery container. The alignment mechanism of the present invention ensures that the at least one engagement pin of the at least one clamp is correctly received in an opening in a delivery container.
To further ensure alignment of the delivery container with respect to the storage container, preferably, the alignment mechanism further comprises a datum edge and a datum clamp, said datum clamp being arranged for clamping a storage container against the datum edge so as to position the storage container relative to clamping device.
Other means to combine and separate the delivery container and the storage container besides conveying the delivery container and the storage container into a merge/separation station is applicable in the present invention. In another exemplary embodiment of the present invention, the lifting device comprises a robot having a robot base, and a robot arm coupled to the robot base, wherein an end effector is coupled to the robot arm for controlling the movement of the end effector to combine and separate a delivery container and a storage container, said end effector comprising the clamping device and the alignment mechanism. Combining and separating the delivery container and the storage container can be carried out by a robot having a robot arm that is coupled to an end effector such that the robot arm can control the movement of the end effector, i.e. lift. Having the end effector to comprise the clamping device and the alignment mechanism of the present invention permits the robot to combine and separate a delivery container and a storage container. This has the advantage that the robot base can be mounted to a grid cell and thus, the separation and combination of the delivery container and the storage container can be carried out on the grid structure. Not only does this help with the sortation of the delivery container in storage in the grid framework structure but removes or reduces the need to feed the combined delivery container and storage container down a delivery port column in the grid structure to a combination and separation apparatus external of the grid framework structure.
The present invention further provides an order processing system comprising;
Optionally, the at least one delivery port column and/or the at least pick-up port column comprises a vertical chute having an opening in cooperation with a grid cell of the grid structure for delivering or picking-up a combined delivery container and storage container by a load handling device through the grid cell.
Optionally, the at least one delivery port column and/or the at least pick-up port column comprises a bin lifting device for lifting or lowering a combined delivery container and storage container at least partially along their respective vertical chute.
In another aspect of the present invention, an order processing system for combining and separating a delivery container and a storage container stored in a three dimensional grid framework structure is provided, the system comprising:
Further features and aspects of the present invention will be apparent from the following detailed description of an illustrative embodiment made with reference to the drawings, in which:
It is against the known features of the storage and retrieval system such as the grid framework structure and the load handling device described above with reference to
To fulfil a customer order, it is often necessary to retrieve items from multiple storage containers. The order processing or fulfilling system 40 additionally comprises one or more order picking stations 46. Storage containers can be retrieved from the storage and retrieval system 44 and brought to a desired order picking station 46. Specific containers required for fulfilment of orders are accessed by a load handling device operative on the grid framework structure. The load handling device preferably comprises a control unit which receives control signals from a radio communications unit of a control system or a central control system concerning information on where to pick up and deliver a storage bin or container in the grid framework structure. The control system controls the operation of one or more load handling devices operative on the grid framework structure and comprises one or more processors, a memory (e.g. read only memory and random access memory) and a communication bus. The memory can be any storage device commonly known in the art and include but are not limited to a RAM, computer readable medium, magnetic storage medium, optical storage medium or other electronic storage medium which can be used to store data and accessed by the one or more processors. Items picked to a customer order from the retrieved storage containers are placed in delivery containers. To assist with the dispatch of the picked items to a customer order, one or more carrier bags are placed inside the delivery containers such that items picked from one or more storage containers are placed inside the one or more carrier bags. When a delivery container is appropriately filled with ordered items, it can be returned from the picking station to the storage and retrieval system until ready or otherwise required for delivery to a dispatch facility 48.
To return the filled delivery container to the storage and retrieval system 44, typically, the delivery container is placed inside or nested within a storage container to form a delivery container and storage container combination. This allows the storage containers containing the delivery containers to be manipulated by a load handling device operative on the grid structure and be stacked on top of other storage containers in one or more vertical storage columns. Suitable configuration of delivery containers for such purposes, by, for example, ensuring that upper edges of the delivery containers do not protrude above the upper edges of the storage containers, when placed therein, can allow the combined delivery container and storage containers to be stored within the grid framework structure.
Returning to the flowchart shown in
Combining the delivery containers with the storage containers by nesting the delivery container within the storage container provides the advantage that the delivery containers can be manipulated by a load handling device operative on the grid structure and thus, stored in the grid framework structure until when required for picking or dispatch at the dispatch facility. In the process of both stocking the delivery containers and transferring the delivery containers for dispatch, it is necessary that the delivery container is both combined with a storage container as well as being separated from a storage container for dispatch. The combination and separation of the delivery container and storage container can be performed by separate apparatuses, e.g. a combination apparatus for combining the delivery container and the storage container and a separation apparatus for separating the delivery container and the storage container.
For example, the storage container station 58 comprises a storage container conveyor unit 66 for a transporting a storage container in a first direction. The delivery container station 60 comprises a delivery container conveyor unit 68 configured for transferring a delivery container in a second direction and the combined station 62 which receives or feeds a combined delivery container and storage container to and from the merge/separation station comprises a combination conveyor unit 70 which is configured for transporting a combined delivery container and storage container in a third direction. The merge/separation station 64 comprises merge/separation conveyor unit 72 which is configured for feeding or receiving a storage container and/or delivery container to and from their respective storage container station 58, the delivery container station 60 and the combined station 62. The merge/separation conveyor unit 72 is shown in
One or more of the stations are arranged in different vertical levels in the apparatus 64 such that the storage container station 58, the delivery container station 60, the combined station 62 and the merge/separation station 64 all lie in the same vertical plane. As a result, the first, second and third directions shown by the arrows in
To combine and separate a delivery container and a storage container in the merge/separation station, the merge/separation station comprises a clamping device and a lifting device that is arranged to clamp the delivery container whilst the storage container is being lifted towards or away from the delivery container. To facilitate easy removal of the delivery container from the storage container, it is necessary that the delivery container is clamped by the clamping device when combined with the storage container. In one example of the present invention as shown in
In order for the pins 82 of the clamping device 74 to be received in the openings 84 in the delivery container 78 when combined with the storage container, it is essential that the pins 82 are correctly aligned with the corresponding openings 84 in the delivery container 78. To correctly position the delivery container 78 relative to the clamps 80, the merge/separation station 64 further comprises an alignment mechanism 86 that is configured to engage with at least one exterior or interior wall of the delivery container 78 to position the delivery container 78 relative to the clamps 80. In an exemplary embodiment of the present invention, the clamping device is arranged to clamp the delivery container when the delivery container is centred with respect to the walls of the storage container. To centre the clamps, the alignment mechanism comprises a centring device comprising one or more guides that are arranged to engage or interact with the delivery container when nested within the storage container. In the particular embodiment of the present invention, the centring device comprises a plurality of locating pins or guides 88 that are configured to engage with diagonally opposed corners of the delivery container 78. Four locating pins 88 are shown configured to engage with the corners of the delivery container (see
In contrast to the transfer mechanism being the conveyor unit to transport a storage container and/or combined delivery container and storage container to and from the merge/separation station, in the case of the delivery container station, the transfer mechanism is arranged to move the clamping device between the merge/separation station and the delivery station. The frame 90 supporting the clamping device 74 and the alignment mechanism 86 is moveably mounted to a substantially horizontal rail or track 92 extending between the delivery station 60 and the merge/separation station 64 and guides the frame 90 sideways between the merge/separation station and the delivery station. A drive mechanism is arranged to move the frame 90 supporting the clamping device 74 between the merge/separation station and the delivery station. In this case, the delivery conveyor unit 68, in particular the rollers are passive, i.e. freely rotating such that the transfer mechanism is configured to move a delivery container on the passive rollers of the delivery container conveyor unit 68. The drive mechanism can be belt drive or hydraulic drive. In the particular embodiment of the present invention, the frame 90 is driven sideways by a belt driven mechanism. However, other transfer mechanisms known in the art for conveying a container between different stations are applicable in the present invention. For example, the conveyor unit itself can have an integrated drive mechanism to move a container. Different combinations of the transfer mechanism for transporting delivery container and/or storage containers between the different stations in the apparatus is applicable in the present invention. For example, the delivery container conveyor unit 68 need not necessarily be passive and can be configured to transport the delivery container between the delivery container station 60 and the merge/separation station 64. Equally, plausible in the present invention is that the transfer mechanism can comprise a clamping device moveably mounted to a track or rail that is arranged to transport a delivery container and/or the storage container between the merge/separation station and the different stations in the apparatus.
Also shown in
To prevent the storage container crashing into the delivery container when being lifted or lowered towards the storage container, the merge conveyor unit further comprises a datum edge 94 which represents a reference point on the merge/separation conveyor station 72 such that when an edge of the storage container is positioned against the datum edge 94, the open end of the storage container is directly below the delivery container. To position an edge of the storage container against the datum edge 94, the merge conveyor unit 72 further comprises a datum clamp 96 that is configured to clamp the storage container on the merge conveyor unit against the datum edge 94 (see
Once combined, the combined delivery container and storage container is transferred into the combined station 62 via the combination conveyor unit 70 for subsequent dispatch at the dispatch facility. The merge/separation station 64 is interposed between the delivery container station 60 and the storage container station 58 such that in the raised position of the merge station conveyor unit 72, the merge conveyor unit 72, the delivery container conveyor unit 68 and the combination conveyor unit 70 are all on the same level to form a continuous conveying system as shown in
The same apparatus can be used to separate the delivery container and the storage container. Starting with the combined delivery container and storage container at the combined station 62 shown in
The ability of the apparatus to interchangeably be used as a combination apparatus and a separation apparatus permits one (first) apparatus to as function as a separation apparatus and another (second) apparatus to function as a combination apparatus. This allows an empty storage container separated from a first apparatus to be fed into the second apparatus to be subsequently combined with a fresh delivery container. Referring to an order processing or fulfilment system 40 shown in
Also shown in
Optionally, the delivery port column 106 and/or the pick-up port column 108 can each comprise at least one bin lift device (not shown) that is operative to lift or lower a combined storage container and delivery container at least partially along the height of the delivery port column and/or the pick-up port column. The least one bin lift device can be mechanically driven to lift or lower a combined delivery container and storage container vertically along their respective delivery port column and/or pick-up port column. Although not shown in
In a typical operation of the order processing system, a combined “full” delivery container and storage container is lowered to the first apparatus 54a via the drop-off port column 106. The “full” delivery container represents a delivery container containing items picked from the order picking station for fulfilling a customer order. The merge/separation apparatus separates the “full” delivery container and the “full” delivery container is fed to the dispatch facility via the conveyor system 110. The separated empty storage container from the first apparatus 54a is fed to the second apparatus via the bridge 100 to be combined with an “empty” delivery container fed into the second apparatus 54b via the conveyor system 112. The combined delivery container and storage container is taken away from the second apparatus 54b to be stored in the storage and retrieval system via the pick-up port column 108 until required to be transported to the order picking station to fulfil a customer order.
The combination and separation apparatus shown in
In another aspect of the present invention, the clamping device 74 and the alignment mechanism 86 comprising the centring device can function as an end effector 113 coupled to a robot arm 118 of a robot 114 as shown in
In this embodiment, the clamping device 74 and the alignment mechanism 86 comprising the centring device are mounted to the robot arm 118 via a frame 90 to define the end effector 113. The process of centring the delivery container relative to the storage container and/or frame 90 by the centring device discussed above comprising the one or more guides 88 for engaging or interacting with the external surface of the delivery container still applies. The movement of the robot arm 118 and the clamping device 74 is controlled by a control system. Using the same operation as the lifting mechanism in the merge/separation station discussed above, the control system is configured to control the movement of the robot arm 118 and thus, the end effector 113 such that the one or more guides 88 of the centring device engages or interacts with the external surface of the delivery container. Once the guides interacts with the delivery container, the process of centring the delivery container relative to the storage container and/or frame in order for the clamping device to clamp onto the delivery container nested within the storage container discussed above in the merge/separation station repeats, i.e. the pair of clamps of the clamping device is positioned to clamp the opposing walls of the delivery container through the cut-outs in the storage container.
To provide multiple degrees of freedom of movement of the robot arm and thus, the end effector, the robot arm comprises a plurality moveable segments connected together by a plurality of pivotable joints, each of the plurality of pivotable joints providing rotation of the segments about one or more predetermined rotational axes, e.g. rotation about an axis along the arm (roll joint) and rotation about an axis transverse to the arm (pitch joint). In the particular embodiment of the present invention shown in
One or more pressure sensors can be mounted on the clamps in order to provide a signal to the control system of engagement with the walls of the delivery container. Once clamped, the control system is then able to cause the robot arm 118 to lift the delivery container out of the storage container so as to separate the delivery container from the storage container. The separated delivery container can subsequently be placed on a conveyor to be transported to the dispatch area for dispatch into delivery vehicles. Alternatively, the separated delivery container can be loaded into a delivery vehicle for dispatch. The reverse is applicable when combining a delivery container and storage container. To combine the delivery container with the storage container, the control system is instructed to move the robot arm 118 such that the end effector 113 engages or interacts with the delivery container. The one or more guides 88 of the centring device centres the delivery container relative to the storage container and/or frame 90 so as to enable the clamping device 74 to clamp the delivery container. The robot arm 118 can then be instructed to pick up the delivery container and move the delivery container towards an empty storage container, where it can subsequently lower the delivery container into the mouth of the storage container. Once the delivery container is positioned into the storage container, the clamping device can release so combining the delivery container with the storage container. One or more position sensors can be mounted to the frame of the end effector to provide a signal to the control system once the delivery container is combined with the storage container
In the case where the robot 114 is mounted to a grid cell via the robot base 116 shown in
The combination and separation apparatus may also include a camera mounted to the robot arm for viewing the area in which the end effector will operate. The camera may include any suitable camera or cameras, such as one or more infrared cameras, and may include a 3-dimensional depth camera. The camera may be provided with lighting elements to illuminate the interior of the grid cell when combining or separating a delivery container and storage container. Images from the camera are fed to the control system where the images are processed so as to assist in the identification and/or clamping the delivery container nested within the storage container. For example, the camera can identify the areas of the delivery container exposed by the cut outs in the storage container walls so as to enable to the clamping device to correctly position the clamps onto the walls of the delivery container. The use of a camera mounted to the robot arm or frame of the end effector to guide and position the clamping device on the delivery container may remove the need to have the centring device comprising the guides 88 to centre the delivery container relative to the storage container as the alignment mechanism can simply be provided by the camera.
An illustrative embodiment of a vision system for separation of a storage container 10 from a delivery container 78 is shown in
In the illustrated example, the apparatus 54 comprises a merge/separation station with a combined storage tote 10 and delivery tote 78. The next stage in the process is for the delivery container 78 to be grasped by the clamp and lifted out of the storage container 10, as described in detail earlier. A camera 87 is fixed in a position facing the combined storage container 10 and delivery container 78, such that the field of view 89 of the camera 87 includes a part of both the storage container 10 and the delivery container 78. The storage container 10 and the delivery container 78 can be distinguished by the camera, for example by being different colours. The camera is positioned such that the cut-out 76 of the storage container 10 can be seen, and the side of the delivery container 78 can be seen through the cut-out 76 in the storage container 10. The part of the side of the delivery container 78 that can be seen through the cut-out 76 includes one of the openings/engagement features 84. The camera locates the position of the opening 84 within the cut-out 76, and measures the distance between the opening 84 in the delivery container and the side of the cut-out 76 in the storage container 10. In other examples, a different kind of sensor could be used in the vision system as an alternative to or in addition to a camera.
As described above, the datum edge 94 represents a reference point on the merge/separation conveyor station 72 such that when an edge of the storage container 10 is positioned against the datum edge 94, the exact position of the storage container 10 is known. Therefore the position of the cut-out 76 in the storage container 10 is also known, and since the side of the cut-out 76 is within the field of view 89 of the camera 87, the position of the side of the cut-out 76 can be used as a datum or reference point for measuring the position of the delivery container 78 inside the storage container 10.
The apparatus 54 comprises a control system that facilitates full or semi-automated separation or combination of delivery containers 78 and storage containers 10. The control system comprises a processor. The camera 87 creates an image of the field of view 89, which is processed by the processor of the control system. Using the processed image, the control system can detect the opening 84 (in this illustration, the opening is a circular hole), and identify the centre point 91 of the opening 84. The processor can then determine the distance or separation 97 between the centre of the opening 84 in the delivery container 78 and the edge 97 of the cut-out 76 in the storage container 10.
The control system can then compare the distance 97 with a pre-determined distance or predetermined separation which represents the distance or separation 97 when the delivery container 78 is positioned centrally within the storage container 10. The predetermined distance is the distance between the centre of the opening 84 in the delivery container 78 and the edge 97 of the cut-out 76 in the storage container 10, when the delivery container 78 is positioned in the centre of the storage container 10. If the distance 97 is the predetermined distance or is within a given tolerance of the predetermined distance, then the control system determines that the delivery container 78 is positioned sufficiently centrally within the storage container 10, so no further alignment is required. However, if the distance 97 is not the same as the predetermined distance or not within a given tolerance of the predetermined distance, the control system determines that the delivery container 78 is not positioned centrally within the storage container 10. In this case the delivery container 78 is misaligned within the storage container 10, i.e. positioned farther towards one side rather than in the centre of the storage container 10. The control system can then adjust the distance that the clamping device 74 needs to move, in order to compensate for the delivery container 78 not being positioned centrally within the storage container 10.
It is important that the clamping device 74 is correctly positioned relative to the delivery container 78 so that the engagement features or pins 82 align with the engagement features or openings 84 in the delivery container 78, in order for the clamping device 74 to successfully engage with the delivery container 78 to effect the separation from the storage container 10.
The distance 97 is illustrated in
In other examples, the distance 97 may be measured in more than one direction, for example in a horizontal direction and/or a vertical direction. If there is variation in the vertical position of the delivery container 78 (for example vertical misalignment of the delivery container 78 within the storage container 10, or if the delivery containers vary in height), the control system can also adjust for vertical position as well as horizontal position. In some examples the clamping device 74 could move vertically as well as horizontally, and in other examples the merge/separation conveyor unit can vary the vertical distance by which it moves up/down.
The processor of the control system can process the images captured by the camera 87 in order to distinguish between containers with different attributes. For example, the containers can be different colours, different materials, different textures, different shapes or sizes, or have identifying features such as bar codes or QR codes to assist in identifying and classifying the containers. The attributes can be used to distinguish between storage containers 10 and delivery containers 78 (for example, storage containers 10 could all be of one colour and delivery containers 78 could all be of another colour). Distinguishing between storage containers 10 and delivery containers 78 may be necessary in order to determine the position of a feature of the storage container 10 or delivery container 78, for example the edge 93 of the cut-out 76 of the storage container 10.
Alternatively or additionally, the attributes can be used to distinguish between different storage containers 10, e.g. storage containers 10 of different heights or different materials could be stored in different locations and/or at different temperatures, and/or the attributes can be used to distinguish between different delivery containers 78, e.g. delivery containers 78 with different bar codes could assigned to different consignments for shipping or delivery.
The control system may have a plurality of different algorithms for different kinds of container, and may select the appropriate algorithm depending on the attributes of the container. The camera 87 captures an image of the storage container 10 and delivery container 78, the processor processes the image, and the control system identifies the containers according to the attribute. The different algorithms for different kinds of container could, for example, require different predetermined distances and/or directions of movement, for example to accommodate different sizes or shapes of container. For example, consider a storage system with two different types of storage container 10, a first-type storage container 10 and a second-type storage container 10, where the first-type storage containers 10 are large storage containers for storing large items, and the second-type storage containers 10 are small storage containers for storing small items. The first-type and second-type storage containers 10 are merged with delivery containers 78 of a similar size to the storage containers 10, so the large first-type storage containers 10 contain large delivery containers 78, and the smaller second-type storage containers contain smaller delivery containers 78. When a combined storage container 10 and delivery container 78 arrives at the merge/separation station, the camera 87 captures an image of the field of view 89 including a part of both the storage container 10 and the delivery container 78. The image is sent to the processor for processing. After processing the image, the control system can determine whether the storage container 10 is a first-type storage container 10 or a second-type storage container 10, for example by the position of a feature or an edge of the storage container 10. If the storage container 10 is large, then the control system identifies the storage container 10 as a first-type storage container 10. The control system can then select a predetermined distance 97 that is appropriate for first-type storage containers 10. For example, the predetermined distance 97 may be a larger distance, since the first-type storage container 10 is a larger storage container 10 and the clamping device 74 may need to move farther in order to engage with the larger delivery container 78 within the first-type storage container 10. After the clamping device 74 has been moved by the appropriate distance, the delivery container 78 inside the first-type storage container 10 can grasped by the clamping device 74 and lifted out of the storage container 10. If, however, the storage container 10 is smaller in size, then the control system identifies the storage container 10 as a second-type storage container 10. The control system can then select a predetermined distance 97 that is appropriate for second-type storage containers 10. For example, the predetermined distance 97 may be a smaller distance, since the second-type storage container 10 is a smaller storage container 10 and the clamping device 74 may need to move less far in order to engage with the smaller delivery container 78 within the second-type storage container 10. After the clamping device 74 has been moved by the appropriate distance, the delivery container 78 inside the second-type storage container 10 can grasped by the clamping device 74 and lifted out of the storage container 10.
Alternatively or additionally, the control system can determine what should happen to the storage container 10 and/or the delivery container 78 at the next stage in the process. For example, after separating the storage container 10 and the delivery container 78, the control system can determine the next destination for the storage container 10 and/or the delivery container 78 depending on the attribute, e.g. directing one or both containers to a different location.
Consider a storage system with two different types of delivery container 78: a first-type delivery container for storing ambient temperature goods, black in colour, and a second-type delivery container which is insulated for storing frozen goods, and coloured white. When a combined storage container 10 and delivery container 78 arrives at the merge/separation station, the camera 87 captures an image of the field of view 89 including a part of both the storage container 10 and the delivery container 78. The image is sent to the processor for processing. After processing the image, the control system can determine whether the delivery container 78 is black in colour or white in colour. If the delivery container 78 is black in colour, then the control system identifies the delivery container 78 as a first-type delivery container. After the first-type delivery container 78 has been grasped by the clamping device 74 and lifted out of the storage container 10, the first-type delivery container 78 can be directed to a pick station for ambient-temperature goods in order to be used again for another customer order. If, however, the delivery container 78 is white in colour, then the control system identifies the delivery container 78 as a second-type delivery container. After the second-type delivery container 78 has been grasped by the clamping device 74 and lifted out of the storage container 10, the second-type delivery container 78 can be directed to a pick station for frozen goods in order to be used again for another customer order.
In a first step 200, the camera 87 captures an image of the camera's field of view 89. The field of view 89 includes part of the side of the storage container 10, with part of the side of the delivery container 78 visible through the cut-out 76 of the storage container 10. In the next step 202, the image captured by the camera 87 is processed by a processor. In step 204 the processed image is then used to identify a reference feature on the delivery container 78. In the example described above in relation to
In a step 210, the control system compares the distance 97 to a predetermined distance which represents the distance between the fixed feature and the reference feature when the delivery container 78 is perfectly aligned within the storage container 10. In examples where the distance 97 is measured in more than one direction, e.g. a horizontal distance and a vertical distance, the distance 97 can be compared with the predetermined distance in more than one direction, i.e. a horizontal distance 97 can be compared with a predetermined horizontal distance and a vertical distance 97 can be compared with a predetermined vertical distance. In a step 212, the control system determines whether the distance 97 is within a tolerance of the predetermined distance, e.g. whether the deviation between the distance 97 and the predetermined distance is greater than a maximum permissible deviation. Again, in examples where the distance 97 is measured in more than one direction, different tolerances can be set for different directions, e.g. the control system can determine whether the horizontal deviation between the horizontal distance 97 and the predetermined horizontal distance is greater than a maximum permissible horizontal deviation, and the control system can determine whether the vertical deviation between the vertical distance 97 and the predetermined vertical distance is greater than a maximum permissible vertical deviation.
If the control system determines at step 212 that the distance 97 is within the tolerance, the control system moves on to step 216. If the control system determines that the distance is not within the tolerance, however, at a step 214 the control system adjusts the position of the clamping device 74 to compensate for the deviation. For example, the control system can instruct the clamping device to move a greater or smaller distance in order to compensate for the deviation between the distance 97 and the predetermined distance. If for example the deviation is 1 cm measured horizontally, the clamping device 74 can be instructed to move 1 cm in order to compensate for the misalignment of the delivery container 78 within the storage container 10. This ensures that the engagement pins 82 of the clamps 80 of the clamping device 74 will be able to successfully engage with the engagement features or openings 84 of the delivery container 78. If the control system did not account for the misalignment of the delivery container 78 within the storage container 10, the engagement pins 82 of the clamps 80 of the clamping device 74 would not be in the same position as the openings 84 of the delivery container 78, so the clamping device 74 would not be able to engage with the delivery container 78.
At a step 216, if the clamping device 74 is not already positioned above the merge/separation station 64, the clamping device 74 moves into the merge/separation station 64 above the delivery container 78. If the control system at step 212 has determined that the distance 97 is not within tolerance of the predetermined distance, the position of the clamping device is adjusted to compensate for the deviation between the distance 97 and the predetermined distance. Once the clamping device 74 is in position above the merged storage container 10 and delivery container 78, the clamping device is lowered towards the delivery container 78.
The clamps 80 of the clamping device 74 then grip the delivery container 78, by means of the engagement pins 82 of the clamps 80 engaging with the openings 84 of the delivery container 78. The delivery container 78 can then be lifted out of the storage container 10.
Further features of the present invention comprise:
1. An end effector for a robot having a robot base and a robot arm coupled to the robot base, the end effector being configured for separating and combining a delivery container and a storage container, the storage container comprising at least one cut out extending below the height of the delivery container, the end effector comprising:
2. The end effector of feature 1, wherein the plurality of guides are configured for interacting with the corners of the delivery container.
3. The end effector of feature 1 or 2, wherein at least a portion of each of the plurality of guides is wedge shaped.
4. The end effector of any of the preceding features, wherein the clamping device comprises a pair of clamps configured for engaging with the side walls of a delivery container.
5. A combination and separation apparatus for combining and separating a delivery container and a storage container, the delivery container being containable within the storage container, the apparatus comprising a robot having a robot base, a robot arm coupled to the robot base, and an end effector as defined in any of the features 1 to 4 coupled to the robot arm, wherein the robot is configured to control movement of the end effector to combine and separate a delivery container and a storage container.
6. A system for combining and separating a delivery container and a storage container stored in a three dimensional grid framework structure, the system comprising:
| Number | Date | Country | Kind |
|---|---|---|---|
| 2114723.6 | Oct 2021 | GB | national |
| 2114725.1 | Oct 2021 | GB | national |
| 2118530.1 | Dec 2021 | GB | national |
| 2118537.6 | Dec 2021 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/078740 | 10/14/2022 | WO |
