U.S. patent application number 12/227008 was filed with the patent office on 2012-06-07 for automated storage and distribution system.
Invention is credited to Munroe Chirnomas.
Application Number | 20120143726 12/227008 |
Document ID | / |
Family ID | 38595996 |
Filed Date | 2012-06-07 |
United States Patent
Application |
20120143726 |
Kind Code |
A1 |
Chirnomas; Munroe |
June 7, 2012 |
Automated Storage and Distribution System
Abstract
An automated storage (2) and distribution system (ASDS) for
storing and then distributing articles. The ASDS includes an entry
means for controlling entry into the system of a plurality of
closed shipping containers. A sensing means (10) determines the
position of at least a portion of an outside surface of each one of
the plurality of closed shipping containers that have entered into
the system. An automated forming means (12) uses the determined
position specific to each of the closed shipping containers to form
an opening in each of the plurality of the shipping containers. A
storing means (14) stores the plurality of opened shipping
containers inside a storage area of the system. A computer
controlled retrieving means (16) enters into selected ones of the
opened shipping containers located in the storage area, by passing
through the formed opening so as to retrieve an article from inside
one of the stored opened shipping containers, and a moving means
(18) moves the retrieved articles to an output of the system.
Inventors: |
Chirnomas; Munroe; (Morris
Township, NJ) |
Family ID: |
38595996 |
Appl. No.: |
12/227008 |
Filed: |
May 2, 2007 |
PCT Filed: |
May 2, 2007 |
PCT NO: |
PCT/US2007/010755 |
371 Date: |
November 3, 2008 |
Current U.S.
Class: |
705/27.1 ;
705/337; 705/39 |
Current CPC
Class: |
G06Q 30/0641 20130101;
G07F 11/26 20130101; G06Q 20/10 20130101; G07F 11/42 20130101; B65G
1/1373 20130101; G06Q 10/083 20130101; B65G 1/1376 20130101; G06Q
30/0601 20130101 |
Class at
Publication: |
705/27.1 ;
705/337; 705/39 |
International
Class: |
G06Q 50/28 20120101
G06Q050/28; G06Q 20/08 20120101 G06Q020/08; G06Q 30/00 20120101
G06Q030/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 2, 2006 |
US |
60796681 |
Claims
1. An automated storage and distribution system (ASDS) for storing
and then distributing articles, the ASDS receiving closed shipping
containers for storage, and for distributing articles, which
articles were retrieved from inside stored shipping containers,
comprising: A means for receiving into the system of a plurality of
closed shipping containers, with at least some of the plurality of
closed shipping containers having outer dimensions which are
different from the outer dimensions of other ones of the plurality
of closed shipping containers; a sensing means for determining the
position of at least a portion of an outside surface of each one of
the plurality of closed shipping containers that have entered into
the system; an automated forming means for using the determined
position specific to each of the closed shipping containers to form
an opening in each of the plurality of the shipping containers; a
storing means for storing the plurality of opened shipping
containers inside a storage area of the system; a computer
controlled retrieving means for entering into selected ones of the
opened shipping containers located in the storage area, by passing
through the formed opening so as to retrieve an article from inside
one of the stored opened shipping containers; and moving means for
moving the retrieved articles to an output of the system.
2. The ASDS of claim 1 or 48, further including a customer
interface which allows a customer of said ASDS to select a desired
one or more of the articles stored therein.
3. The ASDS of claim 2, further including a customer interface
which allows a customer of said ASDS to make a payment for the one
or more of the selected desired articles.
4. The ASDS of claim 2 or 3, wherein said customer interface
includes one or more of an Internet connected communication device
for allowing the customer to access said ASDS via the Internet, a
touch-screen or other selection and/or payment device located at
the site of the ASDS.
5. The ASDS of claims 1-4, where said housing includes means for
providing a secure environment for the shipping containers and the
above-recited means which operate the ASDS.
6. The ASDS of claims 1-5 and 46, where the entry means includes
authorizing means for authorizing the entry into the ASDS of only
authorized shipping containers.
7. The ASDS of claim 6, where the authorizing means includes means
for authorizing a delivery person, which delivery person, once
authorized, is deemed to supply authorized shipping containers to
said entry means.
8. The ASDS of claim 6, where the authorizing means communicates
with a database in order to confirm that specific shipping
containers were anticipated and pre-authorized for entry into the
housing.
9. The ASDS of claim 6, where the authorizing means communicates in
real time to a remote location and/or to a remotely located person
and/or computer.
10. The ASDS of claim 6, where the authorizing means includes a
shipping container identification (ID) device for determining the
identity of a type for the shipping container.
11. The ASDS of claim 10, where the shipping container ID) device
can access a database in order to determine one or more of what
articles are contained in the shipping container and how those
articles are arranged n the shipping container, based on its
determined identity.
12. The ASDS of claim 10, where the shipping container ID) device
cooperates with a manipulation device for manipulating the shipping
container in order enhance the ability of the shipping container
ID) device to determine the identity of the shipping container.
13. The ASDS of claim 12, where the manipulation device includes
one or more of, a gripper mechanism, a robot, a device that can
rotate the shipping container.
14. The ASDS of claim 10, where the shipping container ID device
includes a camera imaging system.
15. The ASDS of claim 14, where the camera imaging system uses
image or pattern recognition techniques to identify the shipping
container.
16. The ASDS of claim 15, where the camera imaging system includes
a color image sensor for sensing attributes of the shipping
containers, which attributes are then compared with information
that is stored on a database, either a local or remote location, so
as to identify the shipping container.
17. The ASDS of claim 10, where the shipping container ID device
using one or more of a Barcode Recognition system, an RFID system,
a Text reading system, an optical scanner.
18. The ASDS of claims 1, 46 and 48, where said housing is one of a
fixed structure, such as a stand-alone building, or a portable
structure, such as a trailer.
19. The ASDS of claims 18, where said housing is adapted to be
located at a position that is one of above ground or
underground.
20. The ASDS of claims 6 and 46, where said housing includes a
secure input system which permits only authorized entry to places
within the housing.
21. The ASDS of claim 20, where said secure input system includes
an interlock area having an exterior door for preventing entry into
the interlock area from locations exterior of the housing.
22. The ASDS of claim 21, where opening of said exterior door is
enabled when the authorizing means has authorized the entry into
the ASDS.
23. The ASDS of claim 22, where the authorized opening of the
exterior door is enabled by utilizing a physical lock and key or
other similar type of device.
24. The ASDS of claim 21, where said interlock area is adapted to
receive, and then automatically pass therethrough, without human
interventions, only authorized shipping containers.
25. The ASDS of claim 21, where said interlock area is an area
bounded by said exterior door and an internal door, where passage
of authorized containers past the internal door can only occur
after said exterior door has been closed and a sensor has
determined that only authorized persons or shipping containers are
in the interlock area.
26. The ASDS of claim 5, further including a conveyance system for
moving shipping containers that enter into the housing to places
further within the housing.
27. The ASDS of claim 11, where said forming means operates so as
to form said opening in said shipping container at a location and
with a dimension that is specific to the identified typed of each
of the plurality of shipping containers, so as to thereby ensure
that said computer controlled retrieving means can enter the opened
shipping container by passing through the formed opening.
28. The ASDS of claim 27, where said forming means forms said
opening by one or more of the following techniques: i. removing
from said shipping container one or more sides thereof, ii.
removing a portion of the outside surface of said shipping
container, iii. by opening/unsealing flaps of said container, and
then physically separating said flaps from said container or
securing said flaps to exterior sides of said container in a manner
so as to form said opening in said container.
29. The ASDS of claim 28, further including a disposing device for
disposing of material removed from said shipping containers to make
said opening.
30. The ASDS of claims 1, 46 and 48, wherein said storing means
also stores therein received shipping containers which have not
been opened, so that said not opened shipping containers can be
delivered to the output of the housing.
31. The ASDS of claims 1, 46 and 48, wherein said storing means
includes a plurality of storage areas for receiving for storage
therein said shipping container, said storage areas including an
arrangement of one or more bins or racks.
32. The ASDS of claim 31, further including a shipping container
positioning system for moving said opened shipping containers into
said storage areas.
33. The ASDS of claims 1, 46 and 48, wherein said article
retrieving device includes a robotic article grasping device, which
uses a vision system and pattern recognition to guide the retrieval
apparatus for retrieving said articles from said shipping
containers.
34. The ASDS of claims 1, 46 and 48, wherein said article
retrieving device includes a robotic article grasping device, which
uses vacuum sensing for determining when said article retrieving
device has grasped an article.
35. The ASDS of claims 1, 46 and 48, wherein said article
retrieving device includes one or more of a robotic device,
gantries, and grippers of different sizes and shapes.
36. The ASDS of claim 35, wherein said said grippers can be of the
type which use one of more of suction cups or electro-mechanical
gripping devices.
37. The ASDS of claims 2, 46 and 48, wherein said article
retrieving device cooperates with said customer interface so as to
retrieve the customer selected article from the storage area.
38. The ASDS of claims 10, 46 and 48, where said forming means
accesses a database having information therein which allows the
forming means to determine how to form said opening in the shipping
container, which opening is positioned and dimensioned in a manner
that is specific to an identified type for each of the plurality of
shipping containers.
39. The ASDS of claim 38, where said database information allows
said forming means to form said opening based on specific
parameters of the identified type of the shipping container.
40. The ASDS of claim 31, where the storing means includes racks
that are situated so as to present the shipping containers to the
article retrieving device at an angle so that the opening faces one
of either upward or frontward with respect to the expected
direction from which said article retrieving device will approach
said stored shipping containers.
41. The ASDS of claim 1, where the storing means includes a memory
device having database information stored therein, said storing
means determining the location of where to store said opened
shipping containers based on database information which specific to
the identified type of each of the shipping containers.
42. The ASDS of claim 1, further including a packaging system which
cooperates with said customer interface so as to receive the
desired articles retrieved from the stored shipping containers, and
generate therefrom a customer package having the customer selected
articles therein, said customer package being moved by said moving
means to said output of the housing.
43. The ASDS of claims 2, 42, 46 and 48, further including an
article identification system for identifying articles moved by
said moving means to said output of the housing, so as to confirm
delivery of the customer of the selected article or articles.
44. The ASDS of claims 5, 46 and 48, where said output of the
housing includes an interlock area having an exterior door for
preventing entry into the interlock area from locations exterior of
the housing.
45. The ASDS of claim 1, further including a system controller for
enabling all of the operations performed by each of the entry means
sensing means, to be controlled in a fully automatic manner and
without any human intervention.
46. An ASDS for storing and then distributing articles, the ASDS
having a housing for receiving a plurality of different types of
closed shipping containers into the housing for storage, each of
the closed shipping containers having a plurality of articles
contained therein, and for distributing said articles to an output
of the housing articles which were retrieved from inside stored
shipping containers, CHARACTERISED BY: a sensing means for
determining the position of at least a portion of an outside
surface of each one of the plurality of closed shipping containers
that have been received into the housing; and a computer controlled
forming means which uses the determined position specific to each
of the closed shipping containers to form an opening in each of the
plurality of the shipping containers, which formed opening is
positioned and dimensioned in a manner so as to allow automated
retrieval of articles from inside of the opened shipping
containers.
47. The ASDS of claim 1, where said sensing means includes a
shipping container identification (ID) device for determining the
identity of a type for a plurality of the received the shipping
containers, said container type indicating specific attributes for
the container, which attributes relate to the size of the container
and/or the articles and their arrangement as contained in the
container, and said computer controlled forming means forms said
openings at positions and with dimensions that are specific to the
identified type of each of the plurality of shipping
containers.
48. A fully secured ASDS for storing and then distributing
articles, the ASDS having a housing which is sealed and operated by
computer control so that no people are required to be inside of the
housing for receiving closed shipping containers into the housing
for storage, and for distributing articles to an output of the
housing, which articles were retrieved from inside of stored ones
of the shipping containers, comprising: a computer controlled
secure entry means for receiving a plurality of closed shipping
containers at an entry point thereof, said entry means controlling
entry into the housing of so that only closed shipping containers
which are authorized are passed into the housing, where at least
some of the plurality of closed shipping containers which are
entered into the housing have outer dimensions which are different
from the outer dimensions of other ones of the plurality of closed
shipping containers which are entered into the housing; an
automated forming means for forming an opening in a plurality of
the shipping containers which entered into the housing; a storing
means for storing the plurality of opened shipping containers
inside a storage area of the housing; a computer controlled
retrieving means for entering into selected ones of the opened
shipping containers located in the storage area, by passing through
the formed opening so as to retrieve an article from inside one of
the stored opened shipping containers; and moving means for moving
the retrieved articles to an output of the housing.
49. A method of operating an ASDS for storing and then distributing
articles, the ASDS having a housing for receiving closed shipping
containers into the housing for storage, and for distributing
articles to an output of the housing, which articles were retrieved
from shipping containers stored inside the housing, comprising the
following steps: controlling entry into the housing of a plurality
of various different types of closed shipping containers, with at
least some of the plurality of closed shipping containers having
outer dimensions which are different from the outer dimensions of
other ones of the plurality of closed shipping containers;
developing information which identifies at least one of the
position and type of a plurality of the closed shipping containers;
using the developed position and type information to form an
opening in the container, which opening is positioned and
dimensioned for allowing automated retrieval of articles from
inside of the container; storing the container inside the housing;
and retrieving selected articles from said stored containers, and
distributing them to an output of the housing.
50. The method of claim 48, wherein said above-names steps are
performed in the order in which they are mentioned.
51. The method of claim 48, including the further step of allowing
a customer of said ASDS to select a desired one or more of the
articles stored therein by using a customer interface.
52. The method of claim 48, including the further step of allowing
a customer of said ASDS to make a payment for the one or more of
the selected desired articles by using a customer interface.
53. The method of claims 50 and 51, including the further step of
allowing the customer to access said ASDS via the Internet, a
touch-screen or other selection and/or payment device located at
the site of the ASDS.
54. The method of claim 48, including the further step of
authorizing the entry into the ASDS of only authorized shipping
containers.
55. The method of claim 53, where said authorizing step includes
determining the identity of a type for a plurality of the shipping
containers.
56. The method of claim 54, where said authorizing step accesses a
database in order to determine one or more of what articles are
contained, in the shipping container and how those articles are
arranged n the shipping container, based on the determined identity
of the shipping containers.
57. The method of claim 54, where said authorizing step includes
means for manipulating the shipping containers in order enhance the
ability of the authorizing step to determine the identity of the
shipping containers.
58. The method of claim 54, where said forming step operates so as
to form said opening in said shipping container at a location and
with a dimension that is specific to the identified typed of each
of the plurality of shipping containers, so as to thereby ensure
that said computer controlled retrieving means can enter the opened
shipping container by passing through the formed opening.
59. The method of claim 54, where said forming step forms said
opening by one or more of the following techniques: i. removing
from said shipping container one or more sides thereof, ii.
removing a portion of the outside surface of said shipping
container, iii. by opening/unsealing flaps of said container, and
then physically separating said flaps from said container or
securing said flaps to exterior sides of said container in a manner
so as to form said opening in said container.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to an automated
storage and distribution system (ASDS) for order picking articles,
and more particularly in one embodiment, to a system for
automatically receiving, opening and storing shipping containers
and retrieving articles from the shipping containers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 illustrates one embodiment of an automated storage
and distribution system (ASDS) in accordance with the
invention.
[0003] FIG. 2 illustrates a typical shipping container of the type
to be received and stored in the storage and distribution system of
FIG. 1.
[0004] FIGS. 3-5 illustrate various openings formed in various
shipping containers.
[0005] FIG. 6 illustrates one embodiment of the storage and
distribution system of FIG. 1, having an input port, including a
shipping container sensor/scanner/ID device 62, an interlock area
64, a container storage area 66, an output area 68 and a container
conveyor system 70 located between input 64 and output 68. A user
interface 72 is also shown, including a touch screen 74 and article
selection and payment interface devices 76
[0006] FIG. 7 illustrates a more detailed view of the input port
and user interface of the storage and distribution system of FIG.
6.
[0007] FIG. 8 illustrates a view of the interior of the housing at
the input end, where the shipping containers pass through a secure
portal/interlock area 80, have an opening formed in the containers
by a robotic box opening mechanism 82, are conveyed to a storage
area 86, and finally showing a user container 88 which contains
articles which were ordered by a user, being moved by a further
conveyor 89 toward an output of the housing 4.
[0008] FIG. 9 illustrates one embodiment of an article retrieval
device 84 for the invention, which uses a first robotic device 90
for positioning the opened containers 29 into and out of the
storage area 86, and a second robotic device 92 for retrieving
articles from inside the opened containers by using the openings as
shown in FIGS. 3, 4 and 5.
[0009] FIG. 10 shows one embodiment of a conveyor system for use in
the housing of FIG. 1, having a first conveyor 102 for transporting
the authorized containers into the interior of the housing, a
second conveyor 104 for transporting the containers to the opening
means, as well as to the storage means 86, and a third conveyor 106
for transporting the selected articles and containers through the
interlock area 68 to an output port leading to the exterior of the
housing. Note internal and external doors 108 and 110,
respectively, for the interlock areas.
DESCRIPTION OF THE INVENTION
[0010] FIG. 1 shows one embodiment of a system which is an
automated storage and distribution (ASDS) system 2 for storing and
or distributing articles. The automated storage and distribution
system having a housing 4 for receiving closed shipping containers
(29 of FIG. 2) into the housing for storage, and for distributing
articles 32 of FIG. 3, to an output 20 of the housing which
articles 32 were retrieved from inside stored shipping container
29.
[0011] In one embodiment, a storage and distribution system
including an entry means 8, 80 for controlling entry into the
housing 4 of a plurality of closed shipping containers 29, with at
least some of the plurality of closed shipping containers having
outer dimensions which are different from the outer dimensions of
other ones of the plurality of closed shipping containers.
[0012] The embodiment shown in FIG. 1 also shows a sensing means 10
for determining the position of at least a portion of an outside
surface of each one of the plurality of closed shipping containers
that have entered into the housing.
[0013] The embodiment of FIG. 1 shows an automated forming means 12
(and 82 of FIG. 8) for using the determined position specific to
each of the closed shipping containers to form an opening in each
of the plurality of the shipping containers
[0014] The embodiment of FIG. 1 shows a storing means 14 (and 86 of
FIG. 8) for storing the plurality of opened shipping containers
inside a storage area of the housing.
[0015] The embodiment of FIG. 1 furthermore shows a computer
controlled retrieving means 16 (and 84 of FIG. 8 and 90, 92 of FIG.
9) for entering into selected ones of the opened shipping
containers located in the storage area, by passing through the
formed opening so as to retrieve an article from inside one of the
stored opened shipping containers; and
[0016] The embodiment of FIG. 1 furthermore shows moving means 18
(and 88 of FIG. 8 and 106 of FIG. 10) for moving the retrieved
articles to an output 20 of the housing. Element 6 represents the
delivery of the shipping containers to the housing 4, element 22
illustrates the controller for the elements within housing 4 and
element 24 is a user/user interface for making selections and
payments for obtaining articles from the automated storage and
distribution system.
[0017] FIGS. 6 and 7 show further details of the automated storage
and distribution system described in FIG. 1, further including a
user interface 72 which allows a user of said automated storage and
distribution system to select a desired one or more of the articles
stored therein. The user interface can also allow a user of said
automated storage and distribution system to make a payment for the
one or more of the selected desired articles. An Internet connected
communication device for allowing the user to access said automated
storage and distribution system via the Internet, a touch-screen 74
or other selection and/or payment device 76 located at the site of
the automated storage and distribution system can also be included
in the system. The housing described herein can also include means
for providing a secure environment for the shipping containers and
the other recited means herein which operate the automated storage
and distribution system. The entry means can include authorizing
means for authorizing the entry into the automated storage and
distribution system of only authorized shipping containers.
Furthermore, the authorizing means can include means for
authorizing a delivery person, which delivery person, once
authorized, is deemed to supply authorized shipping containers to
said entry means. The authorizing means can include the means to
communicate with a database in order to confirm that specific
shipping containers were anticipated and pre-authorized for entry
into the housing. The authorizing means can be enabled to
communicate in real time to a remote location and/or to a remotely
located person and/or compute. The authorizing means includes a
shipping container identification (ID) device for determining the
identity of a shipping container. The shipping container ID device
can access a database in order to determine one or more of what
articles are contained in the shipping container and how those
articles are arranged n the shipping container, based on its
determined identity.
[0018] The shipping container ID device can further cooperate with
a manipulation device for manipulating the shipping container in
order to enhance the ability of the shipping container ID device to
determine the identity of the shipping container. The manipulation
device can include one or more of, a gripper mechanism, a robot, a
device that can rotate the shipping container. The shipping
container ID device can include a camera imaging system. The camera
imaging system can use image or pattern recognition techniques to
identify the shipping container and also can recognize and identify
the articles located inside the opened shipping container. The
camera imaging system can include a color image sensor for sensing
attributes of the shipping containers, which attributes are then
and compared with information that is storage and distribution
stored on a database, either a local or remote location, so as to
identify the shipping container. The camera system or other sensor
type system can be utilized by the computer control system to
enable the guiding of the manipulation device or the article
retrieval device. This database can contain information which is
specific to a given shipping container and or a specific article or
package which information can be utilized by the system in
conjunction with information generated by the sensors or camera
system in order to facilitate the guidance of the retrieval
apparatus and or the manipulation apparatus. This same database can
also be utilized and/or integrated with the database which is used
in determining the whether a container or package is authorized to
be in the storage and distribution system. The shipping container
ID device using one or more of a Barcode Recognition system, an
RFID system, a Text reading system, an optical scanner.
[0019] The housing can be one of a fixed structure, such as a
stand-alone housing, a building, or a portable structure, such as a
trailer. The housing can also be adapted to be located at a
position that is one of above ground or underground. The housing
includes a secure input system which permits only authorized entry
OF CONTAINERS OR PEOPLE to places within the housing. The secure
input system includes an interlock area having an exterior door for
preventing entry into the interlock area. The opening of said
exterior door is can be enabled TO OPEN when the authorizing means
has authorized the entry into the automated storage and
distribution system. The authorized opening of the exterior door
can also be enabled by utilizing a physical lock and key or other
similar type of device.
[0020] The interlock area can be adapted to receive, and then
automatically pass there through, without human interventions, only
authorized shipping containers. The interlock area can be an area
bounded by the exterior door and an internal door, where passage of
authorized containers past the internal door can only occur after
said exterior door has been closed and a sensor has determined that
only authorized persons or shipping containers are in the interlock
area.
[0021] The system can include a conveyance system for moving
Shipping containers that enter into the housing to places further
within the housing.
[0022] The forming means can operate so as to form said opening in
said shipping container at a location and with a dimension that is
specific to the identified typed of each of the plurality of
shipping containers, so as to thereby ensure that said computer
controlled retrieving means can enter the opened shipping container
by passing through the formed opening. The system can determine
where to create an opening location into the box based on
information on specific parameters of the box, including for
example based on the physical layout of the insides, The forming
means forms said opening by removing from the shipping container a
side thereof, removing a portion of the outside surface of said
shipping container, by removing tape which is sealing the opening
and thereby unsealing and lifting up flaps of said container, and
then alternatively on other embodiments physically separating said
flaps from said container or securing said flaps to exterior side
of said container, for example using tape to tape the flaps to the
sides of the box in the opened position in a manner so as to form
said opening in said container. The system can further include a
disposing device for disposing of material removed from said
shipping containers to make said opening.
[0023] The automated storage and distribution system can have
storing means also to storage and distribution system therein
received shipping containers which have not been opened, so that
said not opened shipping containers can be delivered to the output
of the housing. The system can also deliver to a user a combination
of articles which were retrieved from opened shipping containers as
well as delivering unopened shipping containers to the user.
[0024] The storage and distribution system has storing means for
storing containers which can include a plurality of storage areas
for receiving for storage therein said shipping container. The
storage areas can include an arrangement of one or more bins or
racks. The storage means can storage and distribution system the
opened or closed shipping containers in a position which is best
suited for the article retrieving device to retrieve articles from
the container. This may include storing the shipping container with
the opening facing upward or towards the retrieval mechanism or in
another direction which is suitable to the successful retrieval of
the articles inside the shipping containers. This can include racks
that are situated to present the containers to the retrieval
apparatus, or at an angle, or with the opening facing upward, or
with opening frontward with facing towards the retrieval apparatus,
or stored in a position which keeps track of the location of the
inside layout or positions of the articles based on the database
information relating to that specific type of container type and/or
article type stored in that container type. The shipping container
can be in a specific position and with a specific orientation so
that, for example, not only is the opening facing a certain
direction in the storage location but container may be also
positioned so that specific sides of the container may be facing in
a certain direction, so that the system can determine where to
place the retrieval apparatus in order to be able to grip to one of
the packages.
[0025] The system can further include a shipping container
positioning system for moving said opened shipping containers into
said storage areas.
[0026] The article retrieving device can include a robotic article
grasping device, which uses a vision system, and/or pattern
recognition to guide the retrieval apparatus for retrieving said
articles from said shipping containers. The article retrieving
device may include a robotic article grasping device, which uses
vacuum sensing for determining when said article retrieving device
has grasped an article. The article retrieving device can include
one or more of a robotic device, gantries, and grippers of
different sizes and shapes, and methods, for example, the grippers
can be of the type with use one of more of suction cups or
electro-mechanical gripping devices.
[0027] In one embodiment of the invention, an enclosed and secure
structure or housing which can limit people from gaining access
into the housing, and more particularly from gaining access to any
of the articles or containers located inside the housing, includes
a loading port for receiving a plurality of closed shipping
containers, the plurality of shipping containers can include a
variety of differently shaped or differently dimensioned shipping
containers which contain articles therein and/or articles to be
transported into the housing, a security authorization means for
ensuring that only authorized shipping containers are allowed to
either enter into the housing or additionally or alternatively to
be stored in the system, a shipping container detection means that
enables the system to detect the position and/or location of at
least a portion of the outside surface of the shipping containers
which have been loaded into the housing, an opening means for
forming an opening in the shipping containers, a conveyance means
for conveying the opened shipping containers to storage locations
for storing at least some of the shipping containers, a retrieval
means for retrieving articles, and/or packages containing articles,
from inside the shipping containers, a conveyance means for
allowing containers and/or articles to be transported from within
shipping containers located inside the housing to a user of the
system who is outside of the housing and the user of the system can
access and remove the articles being distributed from the system.
In addition, the system can have a user interface such as a
touch-screen video system, typically located outside of the secure
housing, in order for the user to communicate with the system and
for inputting data such as order selections into the system.
Additionally, the system can utilize computer controlled sensors
and other technology including electromechanical sensors, pattern
and or image recognition hardware and/or software in order to
identify a specific shipping container, a specific article or
package type, and or the location and orientation of a specific
shipping container or the location and orientation of a specific
article or package which is located inside a shipping container The
system has a computer control means for controlling some or all of
the various apparatus within the system including some or all of
the apparatus described herein.
[0028] In other embodiments, the system can also include the
ability to retrieve one of a plurality of articles from inside
various shipping containers which are stored inside the housing and
move the plurality of articles into a single user container which
is supplied from within the housing and can include containers such
as a paper bag, a plastic bag or a cardboard box.
[0029] In another embodiment, the ASDS can have no housing. In that
embodiment, the other operative the components of the system can
work together without having a secure environment. This can be used
inside a standard warehouse building where people are also able to
work in proximity to the ASDS. This embodiment would be useful as
an adjunct or as a total solution within a currently standard
people based warehouse operation.
[0030] It is noted that it is not required that the loading port or
user access port be structures that are separate from the housing,
and in some embodiments of the invention, the loading and user
access port s can utilize the same or different structures as the
housing. It is also noted that the loading or user access port can
be formed using a separate structure which is connected to the
housing. The port may include conveyance apparatus which can
include conveyor belts, elevator systems, pneumatic tube structures
that are connected to or part of the housing. Additionally, in
another embodiment, the port can be a secure door through which
containers or packages are placed or retrieved manually.
Article Handling
[0031] In accordance with the invention, the housing includes
apparatus for providing automatic handling of articles to be
located therein.
[0032] One type of such automatic handling apparatus includes a
conveyance apparatus for transporting a plurality of containers
into the housing via the loading port and a conveyance apparatus
for transporting the containers (or articles that were located
inside the container), via the user access port, to a user of the
housing who is located outside of the housing. These conveyance
apparatuses can be totally separate from one another, or can
comprise a combined or even the same apparatus. It is noted that IN
SOME INSTANCES, THE TERM SHIPPING CONTAINER COULD mean VARIOUS
typeS of containing deviceS or packaging, such as a boxES, cartonS,
bagS, tubeS, etc. Such containers can have one article or item
stored or contained within them and/or can have a plurality of
items stored within them. In most embodiments, the shipping
containers being received by and or loaded into the system are of a
wide variety in size and or shape and or material thicknesses and
may be made of various types of materials such as cardboard
corrugated material or for example paperboard or other types of
packaging materials.
[0033] In accordance with an aspect of the invention, the ASDS
includes a container identification (ID) system which can identify
a container being presented to the housing and which can then
enable a control system of the ASDS to determine whether the
container is authorized to be conveyed into the housing or into the
storage area within the housing. This determination by the control
system can be based on many factors, such as whether the control
system was anticipating that specific type of container or even the
specific unique package at that time. Additionally, the
determination to allow the container into the housing can be based
on whether the control system determines that there is sufficient
space in the housing to warehouse system the container. The ID
system can include a bar code scanner, an RFID device, a camera, an
optical sensor, mechanical sensors or other sensors.
[0034] The housing may also include an apparatus for automatically
creating an opening in a portion of a container which may include
the removal of a portion of a container in a manner so as to not
damage the articles located therein, the opening created in the
container being of sufficient dimension and location in the
container so that articles located in the container may be removed
from the container. Alternatively, the container may never be
opened by the opening apparatus, and transported to the second
storage location in an intact and unopened state.
[0035] It is noted that various types of known systems can be used
for manipulating the container, and/or the cutting instruments for
creating the opening in the container, such as rotating and/or
stationary blades, laser beam cutters, etc. Such cutting devices
are know in the industry, see for example U.S. Pat. No.
6,863,486.
[0036] A conveyance apparatus is used for bringing the container to
a storage location in the housing, which storage location can
include a shelf, rack or bin The conveyance apparatus may include a
traditional type of conveyor belt or chain driven transport system
(powered by a device such as a motor, a hydraulic or pneumatic
system, a screw feed, a rack and pinion, or a piston mechanism or
some other mechanical device), and may or may not be used in
conjunction with further article handling mechanisms, such as a
gantry robot, a multi axis articulated arm robot, or some other
mechanically based article handling system.
[0037] This conveyance to the storage location can be done before
or after any opening is made in the container.
[0038] In the event the container is to be opened, once the opening
in a container is provided, an article retrieving device located in
the housing can access the opening for removing the articles from
inside the container, thereby enabling the articles to be
transported to a second location. Such transportation of the
article to the second location can be done by the article
retrieving device, or can be done in combination with a further
conveyance apparatus.
[0039] In one embodiment the removal of an article from a container
can be accomplished using a gripper. The gripper can include a
vacuum based suction cup or mechanical claw type gripper or other
material handling mechanism, all of which are commonly know in the
art. In order to facilitate the proper retrieval of items from the
container, a robotic device utilizing optical, vision, vacuum or
other sensors can be used.
[0040] It is noted that in a preferred embodiment, a disposal
apparatus is provided for securing to the material, if any, which
may have been removed from the container to form the opening, so as
to transport any such material to a disposal or recycling area.
Such securing apparatus can include a mechanical or suction-type
gripper, a robotic arm, or some other material handling device. A
portion of the apparatus that removes a portion of the container
and creates or forms the opening, can also form part of the
apparatus used to remove and dispose of that material removed to
form the opening.
[0041] It is also noted that the housing could have multiple
storage locations therein so as to accommodate a plurality of
containers of similar or different shape and/or size. Each
container may have similar or different items or articles inside
them. A container could have only one item contained inside, while
another container could have a plurality of items or articles
contained inside.
[0042] It is noted that the article retrieving device which removed
the article from the container, could be all or part of the
conveyance apparatus that puts the article in the second storage
location. Alternatively, e the article can be moved with a separate
conveying apparatus to the second location.
[0043] In accordance with another aspect of the invention, the
second location can be or have co-located therewith, a further
container, such as a non-returnable bag or box, that is delivered
to an end user. Such further container is hereinafter called a
delivery container. In one embodiment, the delivery container can
move with the article retrieving device so as to be positioned to
directly receive one or a plurality of articles from the article
retrieving device, which articles were removed from one or a
plurality of containers. Once the article is in the delivery
container, the system can dispense that container with one or a
plurality of items requested by the user, to be conveyed out of the
user access port of the housing and to the end user end user (or a
package delivery service). Alternatively, the delivery container
can be held for an indeterminate period of time in order to receive
additional items and/or to be held for a few hours, days, or more
for later pick-up by end user (or a package delivery service).
Thus, the delivery container receives the items requested by the
end user. In the event that the items requested are unopened
containers, then it is possible that no delivery container would be
used. How about add description of a "palletizer for making larger
containers for passing out to the user/user . . . ?
[0044] The delivery container may be of the type which is preformed
before being located in the housing, or it may be of the type which
is formed within the housing, such forming can be accomplished
using any one of known carton or bag forming devices, and the
carton or bag can be formed so as to have handles to assist the
user or a delivery service for the transportation and/or movement
of the container to the end user.
[0045] In another embodiment of the invention, there is no delivery
container, and the stored articles are delivered directly and
individually to the user waiting at the user access port, via the
conveyance apparatus without the use of a bag or carton.
[0046] In a preferred embodiment of this aspect of the invention,
the system can seal the delivery container, using for example an
adhesive tape. Additionally, automatic means can be provided so as
to be print or otherwise affix to the container addressee/user
information so that the delivery container is ready to be received
by a package delivery service for delivery to the end user.
[0047] It is noted that the housing of the ASDS can comprise
various sections, each section having, for example, a different
environmental condition, such as a different temperature or
humidity. Such conditions can be attained by the use of
air-conditioning or other refrigeration system located in, on, or
near the housing, thereby enabling at least a portion of the inside
of the housing to be kept air conditioned, refrigerated, frozen
and/or in an ambient environmental condition.
[0048] In accordance with a further aspect of the invention, a
payment mechanism is associated or otherwise included with the
automated storage and distribution system, thereby configuring it
as an Automated Selling
[0049] Device. For example, when the system and structure comprises
a retail warehouse system for the storage and sale of goods, there
are several ways a user of the warehouse system can access the
payment system, such as by: [0050] i) using an internet/online
based access, [0051] ii) using an order entry interface device
which is located outside the housing, but in proximity thereto,
such as a touch screen, bar code scanner and menu/list system, or
other input device, to enable users to request one or more of the
articles in the warehouse system, or [0052] iii) using a user
supplied device when the user is in close proximity to the
warehouse system, such as a PDA or a cell phone.
[0053] Additionally, a variety of end user payment systems may be
used in conjunction with the automated selling device for enabling
the end user to pay for the articles delivered to him. The end user
payment can be made by cash, debit, credit or other electronic
method, and can be made at the site of the storage system or can be
processed via a remote link which can include use of the internet
or a cell phone.
[0054] The automated warehouse device can also be accessed using a
security code or other method which methods can include the use of
a magnetic card, a biometric device, a PIN number code or other
similar system. This will enable a deliver service to deliver or
remove articles or packages from the enclosure in a secure
manner.
[0055] Thus, the system can also be used as a sales system thereby
distributing goods in exchange for payment, or alternatively, it
can be used as a secure distribution system which prevents access
of stored items from being retrieved unless a person has
authorization to do so, such as a delivery service which is
retrieving a parcel from the enclosure for further
transportation.
[0056] In an even further alternative embodiment, the system can be
used as both an automated warehouse for controlling the access of
the goods inside for security purposes, and additionally can also
allow items to be sold from the system as the need may arise.
[0057] Therefore, it is possible that the very same system can
function at any given time as either a secure distribution
warehouse and or a retail or wholesale outlet. So for example, a
parcel delivery company can use the system as a distribution depot
for the transfer of goods from one distribution site to another one
or to a final user where, payments are not necessary for accessing
the goods or containers inside. In another scenario, the very same
system can be selling items from the housing to other persons who
are interested in purchasing goods from the system.
[0058] Additionally, the system can be utilized as a public
warehousing or distribution system enabling people to have items
warehouse stored in the housing and whereby they can retrieve the
items or packages at a time of their own choosing.
[0059] The above noted devices can be accessed by the user via a
drive-up or walk up window.
[0060] For enhanced services from the warehouse system, a user can
access a remote site via a remote video and/or audio link to a live
person, if the end user at the warehouse system needed
assistance.
[0061] In accordance with a further aspect of a further preferred
embodiment of the invention, the automated storage and distribution
system includes an imaging system. The imaging system can be used
to identify the orientation of the containers in the housing using
sensing mechanisms, such as mechanical sensors, a vision or image
or other optical device, as well as a bar code device or radio
frequency. ID tag device (RFID).
[0062] Such imaging system may cooperate with the robotic or
conveyor apparatus, in order to assist with re-orientation of the
container in a manner so as to prepare it for storage, or for
assisting with the forenoted manipulation so as to ensure the
container is properly placed before forming the opening
therein.
[0063] The forenoted article retrieval device uses the image
system, and additional sensors (such as suction sensor or further
image or proximity sensor) to identify where and how to grab or
otherwise secure to the articles to be removed from the container.
It is also noted that the article retrieval device may, if desired,
grab more than one articles when removing them from the
container.
[0064] Information relating to metrics of the container dimensions,
container contents, opening orientation and instruction set,
internal layout of articles within the container or carton, color
or shape of the articles or packages inside the container or
carton, whether the items contained inside are of a delicate or
rugged nature, can all be accessed by the system from a database
which can be stored at the site of the housing or can be remotely
updated to the system via a remote link, including using the
internet, a wireless system or a wired communication connection.
END OF
[0065] It is noted that in accordance with a further aspect of a
preferred embodiment of the invention, a shipping container which
is stored in the housing, once opened, may be used as a storage
container for the articles, that is, the shipping container is
moved to a storage location with all the articles still positioned
inside the container, and then the article retrieval device
selectively removes articles from one or more of the stored
containers, in order to fill a request for articles from an end
user (i.e., user). In this way, there is no need to have a person
manually load the items discretely into a storage area within the
housing, since the container in which the items were transported to
the distribution system housing, also acts as the storage device
from which the individual items may be automatically retrieved by
the retrieval device.
[0066] A particular advantage of the present arrangement is that it
provides an automatic, i.e., non-human contact, process which
allows an end user to obtain individual ones of articles that are
shipped in bulk in a sealed container from a manufacturer. That is,
the shipping containers received into the housing could have been
"sealed" at the factory or warehouse of the manufacturer of the
articles, and an end user can obtain one or more of the articles
from inside one or more of the various containers stored inside the
housing, in a manner that does not involve human contact to the
articles.
[0067] As noted above, in another embodiment, the system can
distribute and or convey unopened containers as well as items from
opened containers to the user access port. This may be desirable
since some containers may only have one item inside, or a given
user may wish to retrieve or purchase a full carton of a specific
item.
[0068] In an even further aspect of a preferred embodiment of the
invention, once all the articles have been removed from the
shipping container, the disposal apparatus attends to disposal of
the container. In one embodiment, the apparatus may convey the
empty container to a disposal location with one or more compacting
devices that may be located in or attached to the housing.
[0069] In an even further aspect of a preferred embodiment of the
invention, metrics regarding the container are, in advance, and
either remotely or directly, input to a computer controller of the
automatic storage and distribution system, which metrics provide
information to the vision and/or opening devices. Once the
container and its contents have been identified, specific to
attributes of various ones of the containers and the articles
positioned therein can be used to determine and or control further
handling and transportation of the container and its contents into
and around the inside of the system.
[0070] Additional feature of a preferred embodiment can include
remote video monitoring of the system which can monitor any part of
the process within the housing so that if there is a malfunction, a
computer or a person at a remote location can assess the situation
and can even remotely take control of the system in order to
rectify a given problem.
[0071] Additionally, a person loading containers to the port or the
housing can be required to input an authorization code through one
of various electronic means, including a magnetic card, a PIN
number, a fingerprint reader or other method which would enable
that person to activate a secure port thereby enabling him to load
a container into the housing. Both the loading port and the user
access port can be designed to be secure, thereby not allowing any
person access into the housing area or the storage area. So, while
a person may be authorized to deliver packages or cartons to the
housing, that same delivery person has no access to the inside of
the housing and he cannot access any containers or packages which
are located inside the housing. In this way, the person delivering
the containers does not have to be a person who the owner of the
distribution system has any prior dealing and there is no need to
have any relationship of trust or otherwise in order for the
delivery person to facilitate the loading of containers or packages
into the housing of the distribution system.
[0072] A particular advantage of the above system and its various
embodiments, as compared with prior art storage and distribution
systems, or retail systems, is that a significant cost of such
prior art systems is due to the labor involved in moving cartons
(with or without further articles positioned therein) from the
manufacturer to an intermediate storage/distribution facility and
then to the location where the user will pick-up the articles
(i.e., such as onto the shelf of the retail system). Such shipping,
storage and handling costs experienced by the article manufacturer
and the system owner/operator are ultimately passed on to the end
user, as reflected in a higher final sale price of the article. On
the other hand, the system of the invention allows the storage and
distribution system (i.e., a retail warehouse system or a warehouse
distribution system built according to the present invention) to
leverage existing article transportation infrastructure and
services, such as the United Parcel Service (UPS) and Federal
Express (Fex Ex) or other general trucking and transportation
companies, to deliver the containers to the housing of the
inventive system. These existing transportation service company's
typically provide for article transportation to literally any place
on the globe at a highly efficient and competitive price. Thus, by
using such service company's for container transportation and
loading of a structure in accordance with the present invention,
this feature results in a significant savings over an article
manufacturer having to distribute his products on his own, thereby
requiring a fleet of trucks, drivers and a plurality of centrally
located distribution centers as well as all of trustworthy
personnel required to stock the shelves and or pick the
products.
[0073] The system of the invention also includes automated systems
inside the housing which attend to the initial sorting, final
storing and then ultimate distribution of the articles to the end
user, all without additional costs for employee labor or providing
the physical and financial infrastructures needed for employees.
Thus, many of the "manpower" and "real estate" costs involved in
the operation of a retail store or a distribution warehouse are
avoided. Such costs include: the requirement to provide an
environment "habitable" to employees, such as sufficient area for
them to work and sufficient light, air, heat etc., a place for them
to take care of personal needs, such as a bathroom, the provision
of vacation time, time off, administrative and management employees
to oversee lower level employees, etc. All these costs are avoided,
as well as all of the other overhead and indirect costs of
employees. Without employees, the size of the automated storage and
distribution systemsystem can be limited to not much more than is
need to actually automated storage and distribution systemsystem
and distribute the articles to be dispensed, and the real estate
required to meet such habitability needs of employees is
avoided.
[0074] A further advantage relating to the fact that the above
handling of the cartons and articles inside the housing is
accomplished in a mechanized and automated way, without human
intervention, is that: [0075] the loading of the housing with the
cartons can be accomplished by an unskilled person, such as the
truck driver/carton delivery person, [0076] employee and
third-party delivery person related issues, such as article and
monetary theft, as well as article damage due to mishandling, is
avoided. [0077] These advantages result in real cost savings for
the automated automated storage and distribution systemsystem
owner/operator, and allow for greater profit margins without
increasing the cost of the articles being dispensed as compared
with traditional warehouse systems.
[0078] While the present invention has been disclosed with
reference to certain embodiments, numerous modifications,
alterations and changes to the described embodiments are possible
without departing from the sphere and scope of the present
invention, as defined above. Accordingly, it is intended that the
present invention not be limited to the described embodiments, but
that it has the full scope defined by the above language, as well
as equivalents thereof.
[0079] In accordance with the above description, the present
invention includes, among other features: [0080] 1. an enclosure
[0081] 2. a port which enables transfer of packages into the
enclosure, this port can include a means for controllably blocking
access into the housing, [0082] 3. a port which enables transfer of
packages out of the enclosure, this port can also include a means
for controllably blocking access into the housing, and, [0083] 4.
means for removing of a portion of packages in the enclosure so as
to make an opening, so articles stored therein can be
automatically, and without human contact or intervention, removed
from the package.
[0084] In accordance with further aspects of the invention: [0085]
at least one package which has been transferred into the housing
though the port includes a plurality of "articles" therein. [0086]
the articles can include a further package that contains more
articles. [0087] the package opening device includes a cutting
device, for cutting the package to make the opening. [0088] Further
including an article retrieving device located in the enclosure for
removing articles from a package using the opening, and
transferring the articles to a further location. [0089] providing
to the user goods that are retrieved from a location in the
enclosure upon the users request. [0090] where the further articles
were received into the enclosure in one or more packages which were
sealed by the supplier of the articles, and the articles were
delivered to the end user at the retrieval of the housing by fully
automatic means in the housing, so that the articles are removed
from the sealed packages and then delivered to the user all without
human contact.
[0091] Furthermore: [0092] 1. the further location may be a
predetermined storage location in the enclosure, or [0093] 2. the
further location may be the user access port. [0094] 3. Where the
further location may be a "dispensing container" which is provided
to the user via the user access port [0095] 4. Transfer means are
located inside the housing to transfer at least one of the packages
from inside the housing to outside the housing through a port,
[0096] 5. Where an article retrieval device provides the articles
to the transfer means from a storage location inside the housing.
[0097] 6. Where that port can restrict access to the packages which
remain inside the enclosure. (I think this is redundant) [0098] 8.
where the in and out port are the same, or [0099] 9. where the in
and out port are different.
[0100] In accordance with another embodiment, the present invention
includes: [0101] 1. an enclosure [0102] 2. a port which enables
transfer of packages into the enclosure [0103] 3. a port which
enables transfer of packages out of the enclosure, and [0104] 4.
Further including a conveyance system for transferring the packages
from the portal into the enclosure, the conveyance system
including: [0105] a. Means for identification of the package +/or
articles inside the package [0106] b. Apparatus for analysis of the
orientation of the package [0107] c. Apparatus for manipulation of
the package based on the orientation analysis [0108] d. Apparatus
for determination if the package is acceptable to enter the
enclosure [0109] i. where the Determination is based on bar
code/input scan of the package, [0110] ii. where the Determination
is based on what the housing was expecting via advance knowledge,
such as via a wireless connection
[0111] In another embodiment, the invention comprises: [0112] 1.
enclosure for storing packages therein, having a loading and user
access port [0113] 2. a conveyor for transporting packages into the
enclosure, [0114] 3. A system for removing a portion of a package
after being transported into the enclosure, the portion being
removed creating an opening in the package from which individual
articles may be removed, and [0115] 4. An article retrieving device
located in the enclosure for removing articles from the package via
the opening and transferring the articles to a further location.
[0116] a. Where the further location is a storage location in the
enclosure [0117] b. Where the further location is the user access
port.
[0118] Business methods in accordance with the invention include
using the above-noted enclosure and apparatus to make an automated
package/article storage and retrieval system which can use the
shipping facilities of "common carriers" to "load" the enclosure
with the packages and articles to dispensed to the end users.
[0119] This method allows multiple manufactures, each making a
different article, so ship their items in bulk to a given
enclosure, which enclosure can then "load itself" without human
intervention, thereby resulting in significant cost savings in
shipping, as well as reduced personnel costs at the enclosure.
[0120] by opening./unsealing flaps of said container, and then
physically separating said flaps from said container or securing
said flaps to exterior sides of said container in a manner so as to
form said opening in said container.
[0121] The Fully automated system can be sealed and no human
intervention to operate to allow containers having some of which
shipping containers having different external dimensions than
others of the shipping containers in, an opening means, and whereby
the opening means can adjust/be adaptable to opening shipping
containers having various outer dimensions, and having means for
adjusting the opening of the shipping container, and using the
attribute information for determining unless a proper an
authorization code is received by the system it will prevent a
container(s) from proceeding to the container opening means.
[0122] The following are some of the situations which the system
can operate as to: [0123] Where the plurality of packages within a
given box are of the same type (identical items) [0124] Where the
packages within a given box are of a variety or mixed product types
(bags of different flavors, size, type of product) [0125] Where the
retrieval device goes into the box to retrieve the packages [0126]
Where the plurality of packages are (pre-packed) positioned within
the box such that the (possibly without divider walls, possibly
random, organized in a pattern such as being organized into rows,
columns, stack and or layer.) [0127] Where packages are made from
flexible packaging materials, such as a bag or pouch (as opposed to
rigid packages, such as bottles, boxes, cans, rigid or semi-rigid
containers [such as yogurt or cottage cheese container type])
[0128] Where the flexible packages are easily deformable and tend
to shift within the box and therefore for the retrieval device to
determine the position to pick the product from can be challenging
due to the unpredictability of the package location within the box.
[0129] Where the packages are positioned in the box in a manner
that is at least somewhat disorganized and or stored in a random
manner. [0130] The retrieval apparatus itself, (or the conveyance
systems, or handling) can also cause the packages to become
disorganized or less organized than they were originally when they
were originally packed (Originally packed means for example how
they were packed into the box at the point when the box was shipped
from a different distribution point, such as at the factory where
the products were produced or at a remote warehouse where they were
packed into the carton.
[0131] The system can automatically opening a shipping carton, and
Using the shipping carton as the storage container from which
orders can be automatically picked and deal with the Tremendous
variety and variability of different shipping carton types, shapes
and sizes, different package types (bags, boxes, bottles), shapes
and sizes, and the tremendous variety of physical orientation of
packages within the shipping cartons, different temperature zones
these cartons must be stored in.
[0132] In some prior systems, there is a requirement for a person
to manually open up the shipping carton and transfer the packages
to a dispensing bin. Regardless of the type of product being
transferred and regardless as to how the packing arrangement was in
the shipping container, the packages then had to be arranged in a
specific manner required for the dispensing mechanism to operate
properly. So, packages of different types having different sizes
and shapes which were originally packed into their ORIGINAL
SHIPPING CARTONS, each different item type having been arranged in
a variety of ways and which
[0133] Packages are organized in an organized manner which is the
same from item type to item type. This loading pattern (including
random pattern or no pattern) is dictated by the dispensing or
retrieval mechanism.
[0134] Shipping container is able to be used as the storage
container from which articles are retrieved
[0135] The system combines Intelligent box opening combined with
intelligent box manipulation/positional storing which enables the
article retrieval device to have the ability to predetermine how
and where the retrieval device needs to be manipulated in order to
retrieve the articles.
[0136] The system can include a Package ID system for Authorizing
Package Input and Moving the loaded box/bag to the user retrieval
area, or sealing the box, or labeling box with shipping information
for destination, or storing box in a queue area within or
associated with the housing/system, and or an authorized person can
present ID to the machine and then can be authorized by the control
system to remove the container
[0137] The delivery to the system:
[0138] Can be a truck with a driver, or can be multiple delivery
agents, or can include a plurality of unrelated trucking or
transportation entities each with their own identification
codes
[0139] Can be offloaded from a truck by hand, By automatic conveyor
system, by pallet, with a forklift.
[0140] The Shipping container can be identified as a specific type
of container, or as having a Specific type of article contained
therein, or as having identification including bar code markings,
graphics, text, symbols, or an RFID tag.
[0141] The shipping container may have been closed or sealed using
tape, using glue, using staples. The shipping container can be a
box, made of paperboard, cardboard, plastic, corrugated material or
some other material. The shipping container can be a formed bag,
which can have different sizes and or shapes and can be made from
various materials including plastic, or including paper.
[0142] The shipping container can have a plurality of articles
therein, where the at least one article can be a package, and where
the package can have at least one article contained therein.
[0143] The packages which are stored in the shipping container can
be stored in an organized manner such as in rows, columns, layers,
whereby some of the packages are occluded by other packages and
where a plurality of packages within a specific container are
stored with the front facings of the plurality of packages facing
in various directions or wherein packages are stored in a manner
such that they could shift their position during transport or
further wherein where the articles are stored in the shipping
container in a random manner.
[0144] The Types of articles can be various and can include items
such as food, electronics, components, paper goods
[0145] The Types of packages can be various as well and can include
bottles, cans, bags, cylinders, pouches
[0146] The articles within the shipping container can be
identified, as a specific type of article or as being a specific
type of package, or as a package having a specific type of article
contained therein
[0147] The package can have an identification including bar code
markings, graphics, text, symbols, or RFID tag which the various
types of sensors and or cameras can detect to identify the packages
and their orientation or position within the opened shipping
container
[0148] The Housing can be one that houses the components and
systems of the described automated warehouse system, and provides a
secure environment for the containers and apparatus of related to
the system and can be a stand-alone building, or can be a portable
trailer, or can be above ground or underground, or be as small or
large, or can be housed in a cabinet the size of a room or a large
building, can be made of wood, metal, masonry, plastic or other
construction materials.
[0149] The Input port opening can be an opening in the housing for
allowing packages to enter into the housing which opening is large
enough to allow packages of various sizes and shapes to enter into
the housing
[0150] Computer Control System and can be PC, embedded controls,
mechanical and or electromechanical relays, at least partially
remote, and can have hardware which can be located fully within or
proximate to the housing, or Which can be at least partially
remote, and or which can communicate with computer systems at
remote locations, and which can be linked to a network or
communications link, and which can operate a video interface for
communicating with users of the system, and which can operate a
video and or audio communications link to enable people at the
automated storage and distribution system to communicate with
people or computers at a remote site.
[0151] The system has software which has a database which can be
local or remote to the automated storage and distribution system,
and has ability to monitor inventory levels, and has ability to
control all of the apparatus within the system and or housing which
can send information over the internet to users, users, suppliers,
maintenance personnel, owners, investors, lenders in the automated
storage and distribution system, and other interested parties and
Can be operable to shut down part or all of the systems operations
in the event of a malfunction.
[0152] The Delivery Person Interface enables authorization for
proceeding with delivery and has the ability to identify (and or
validate identity) the Delivery person/entity and the ability to
confirm that the specific delivery was anticipated and
pre-authorized based on the order database of control system. Also
it can have the ability to communicate via email, video conference,
video phone, wireless voice etc. and in real time to a remote
location and or to a remotely located person and or computer for
example, for the purpose of dealing with any issues relating to the
delivery A badge, bill of laiding, pin code, biometrics, other code
etc. may be used to activate the authorization.
[0153] Shipping container identification/ID device can determines
what the shipping container is, its contents, its identity and can
determine the shipping container contents, type, packed quantity,
article size,
[0154] The system may be designed to manipulate the shipping
container in order to better sense the shipping container's
attributes by utilizing a gripper mechanism, or by using a robot,
or by using a device that can rotate the shipping container. It can
utilize a camera with image or pattern recognition software, or a
Barcode Recognition system, or an RFID system, or a Text reading
system, or An optical scanner, or other type of sensor, or a
mechanical or electromechanical switch, or light beam, or a color
recognition sensor, and by determining attributes of the shipping
containers and comparing that information with information that is
stored on a database, either a local or remote one it can Feed the
ID information to Control system database to determine whether
shipping container should be allowed to pass into the system.
[0155] The secure portal can be a secure input is restricted to
allow only authorized entry into the housing In order to gain entry
into the housing, a shipping container must move through a first
opening, and where entry through the opening is typically prevented
by an exterior door (barrier, gate, fencing, bars or other physical
security mechanism) which may be located near, adjacent to or
indirectly connected to the exterior of the housing and Whereby the
authorized opening of the exterior door is enabled by an
authorization code Whereby the authorized opening of the exterior
door is enabled by utilizing a physical lock and key or other
similar type of device etc, and Once a package passes through the
external opening, the package is situated in an interlocking
security holding area. This can utilize two doors that open and
close in conjunction with one another so as to prevent unauthorized
access into the system by a shipping container or person. Further
passage beyond the security holding area is typically blocked by an
internal door. The internal door will not open until and unless the
exterior door has been closed. This arrangement of at least two
doors together with a security holding area is intended to prevent
unauthorized entrance of a person, shipping container or other
object. Additionally, the system can utilize cameras, motion
sensors, infrared sensor and or specialized detection software and
or other similar devices for determining that no person is within
the security area before the system will enable the interior
security door to be opened. Additionally, the system can have
cameras monitoring the security area of the system so that a person
or computer at a remote site can monitor the activity in the
loading area or security area of the system.
[0156] The system has a security area for preventing unauthorized
objects or people from gaining entrance into the system. The portal
into the system has a security area beyond the portal opening where
one or a plurality of shipping containers can be located after the
shipping containers are placed onto the conveyance means delivery
person, whereby the system can close the external security door so
that a person cannot gain entrance into the system during package
loading.
[0157] Shipping containers are loaded onto a conveyance system for
moving package into the housing shipping containers can be loaded
into the system, and or onto a conveyor system, directly into a
security holding area, and by placing a container on a surface
within the housing, or by a transport device located in the housing
which picks up a container and moves transports it for example, by
a robot, by a gantry, by a crane or other means. And it can move
them by loading one shipping container at a time, or by loading a
plurality of containers at a time, or by placing a pallet of
shipping containers at the opening to the housing. And the system
may be equipped with means for moving shipping containers from a
pallet to a point within the housing and towards a container
opening means. The system can also be used in conjunction with a
de-palletizer.
[0158] Container opening device with an automated forming means for
using the determined position specific to each of the closed
shipping containers to form an opening in each of the plurality of
the shipping containers, which formed opening may include cutting
the container material, cutting the tape, opening the flaps, and or
cutting off the flaps. The opening is positioned and dimensioned in
a manner that is specific to the identified typed of each of the
plurality of shipping containers for allowing automated retrieval
of articles from inside of the opened shipping containers, ie.
where they are stored in rows, columns, removing from front, top
side etc., so for example it can be leaving a certain amount of lip
not cut off so as to act as a retainer or cut the box in some other
place or manner.
[0159] The system can use a disposing device for material removed
from me to make opening for recycling it.
[0160] The Article Retrieving Device for Removing the Articles from
the Container
[0161] Article retrieving device retrieving articles via opening An
Retrieval Apparatus for Retrieving articles from the opened boxes
for order picking, using robots, vision systems, Retrieval
apparatus using vision systems and pattern recognition to guide the
retrieval apparatus in picking, Retrieval apparatus which use
vacuum sensing for determining when they have secured to a package,
Robots, gantries, grippers, different sizes and shapes of suction
cups, electro-mechanical grippers.
[0162] The system can Cooperate with user selection system, for
retrieving selected articles and with the Packaging system inside
the system which can cooperate with user selection system, for
generating a User Package of user selected articles.
[0163] One of the advantages of the system is that various delivery
personnel, such as a plurality parcel services, trucking companies
etc. that do not have to have any particular relationship of trust
with the facility can "load" the system . . . in other words, the
concept where an automated system such as a vending system or
automated retail, which traditionally requires a trusted agent or
employee to go and gain access to prior systems in order to load
new articles into the system and where these employees are
dedicated specifically to loading the automated machines, and their
trucks and warehouses and logistical systems are all specifically
dedicated to dealing with and loading the prior machines, and since
these people; trucks and equipment are all dedicated only to
managing the equipment of a and a key requirement of the specific
retail or vending operator having dedicated resources, for example,
people and trucks to service and load the systems is that the
operator must have employees whom he can have significant trust in
and a formal business relationship with since, he needs to rely
upon the dedicated loading person to load carefully and properly,
load items in the correct place be honest and not to steal from the
system when the loading person to the operator or owner of the
automated retail or vending system, it is not possible to fully
benefit from the economies of scale that would occur if the system
was rather able to be loaded automatically and leverage the
existing efficient general transportation industry. By having the
box opening and loading into the system being fully automated, the
owner or operator of the system does not need to have a trusted
person "load" the machine since the only requirement is to have the
boxes be delivered to the system and placed on the conveyor system.
One of the many great advantages to this system is therefore to
enable an operator or owner to utilize common carriers or general
and non-dedicated transportation companies to deliver the boxes
since there is no longer a need to have a trusted person open
boxes, or load articles into the system.
[0164] Most prior systems in automated warehouse systems and or
automated vending systems utilize dispensing devices or retrieval
apparatus that are designed to dispense or retrieve articles from
highly organized rows or columns which are specific in nature to
the given system and which are intended to be loaded in a
particular way so as to enable the particular dispensing or
retrieval mechanism to properly dispense or retrieve the articles.
Due to this requirement of prior systems, a person must manually
remove the articles from their original shipping containers and
manually load them into the bins, compartments or other storage
systems of the particular vending or automated warehouse
system.
[0165] Therefore, except for situations where articles which are
packed into special shipping container which are specifically
designed to fit into a specific type of retrieval or dispensing
system, most shipping containers are not suitable to be simply put
into an automatic apparatus and retrieved from a typical vending or
automated warehouse system.
* * * * *