Method and apparatus for container storage and container retrieval

Abstract

Apparatus for use in a storage and retrieval system for product held in containers is provided. The apparatus includes multiple, parallel spaced-apart support members ( 41 ) defining a plurality of rows ( 20 ), each adapted to support a base of a plurality of containers thereby forming a container store. One or more conveying means ( 44 ) is engageable with containers in a row ( 20 ) to transport the containers longitudinally within that row, the conveying means ( 44 ) movable transverse and below the rows. One or more loading means ( 45 ) is movable transverse to the rows ( 20 ) along an end of the rows to enable loading of one or more containers into a selected row. A computer control system automatically controls operation of the loading means and conveying means. The loading means ( 45 ) may include a transfer conveyor ( 49 ) extending beneath at least a portion of said rows and moveable transverse to said rows below said rows. Product may be stored in a bulk storage zone ( 27 ) in which containers of product are stored in frames ( 50 ), an intermediate storage zone ( 40 ) and a low storage zone ( 65 ). A first automated retrieval system retrieves selected stacks of containers from the intermediate storage zone ( 40 ), and a second automated retrieval system retrieves individual containers, partial stacks or stacks of containers from the low storage zone ( 65 ). Product orders are collated at a collation zone ( 34 ) and a conveying means ( 19 ) is in communication with each zone for delivering product between zones. Methods of storage and retrieval are also claimed.

What is claimed is:  
     
         1 . Apparatus for use in a storage and retrieval system for product held in containers, said apparatus including: 
 multiple, parallel spaced-apart support members defining a plurality of rows, each adapted to support a base of a plurality of containers thereby forming a container store;    one or more conveying means engageable with one or more containers in a row to transport it or them longitudinally within that row, wherein said one or more conveying means is movable transverse to said rows below said rows to enable selective engagement with containers in said rows;    one or more loading means movable transverse to said rows along an end of said rows to enable loading of one or more containers into a selected row; and    a computer control system that in use automatically controls operation of the loading means and conveying means.    
     
     
         2 . The apparatus of  claim 1 , wherein the one or more loading means includes a transfer conveyor extending beneath at least a portion of said rows.  
     
     
         3 . Apparatus for use in a storage and retrieval system for product held in containers, said apparatus including: 
 multiple, parallel spaced-apart support members defining a plurality of rows, each adapted to support a base of a plurality of containers thereby forming a container store;    one or more conveying means engageable with one or more containers in a row to transport it or them longitudinally within that row;    one or more loading means movable transverse to said rows along an end of said rows to enable loading of one or more containers into a selected row, wherein the loading means includes a transfer conveyor extending beneath at least a portion of said rows and moveable transverse to said rows below said rows; and    a computer control system that in use automatically controls operation of the loading means and conveying means.    
     
     
         4 . The apparatus of  claim 3 , wherein said one or more conveying means is movable transverse to said rows below said rows to enable selective engagement with containers in said rows.  
     
     
         5 . The apparatus of any one of  claims 2  to  4 , wherein the or each transfer conveyor is substantially the length of a frame of containers, the frame including at least three stacks.  
     
     
         6 . The apparatus of any one of  claims 1  to  5 , wherein the or each loading means has a length sufficient to support at least one frame of containers including at least three stacks and transport said at least one frame of containers transverse to said rows along an end of said rows.  
     
     
         7 . The apparatus of any one of  claims 1  to  6 , wherein the length of the or each conveying means is substantially the length of at least two frames of containers, each frame including at least three stacks.  
     
     
         8 . The apparatus of any one of the preceding claims, wherein said one or more loading means is separate from said one or more conveying means and the one or more conveying means is moveable below and transverse to said rows independently of the one or more loading means.  
     
     
         9 . The apparatus of any one of the preceding claims, wherein said one or more loading means and/or said one or more conveying means each include an index conveyor locatable at a first and a second level, wherein at the first level, the index conveyor is located below said support members and at the second level, the index conveyor extends between said support members to contact said one or more containers to enable the index conveyor to convey it or them to a required location.  
     
     
         10 . The apparatus of  claim 9 , wherein the or each index conveyor is divided into a plurality of longitudinal segments, each segment able to transport one or more stacks and/or partial stacks of containers in a defined longitudinal region of its row.  
     
     
         11 . The apparatus of any one of the preceding claims further including picking means for removing a container, stack or partial stack of containers from a pick face defined by containers closest to the ends of the plurality of rows of the container store, said picking means including a picker gripper adapted to engage with one or more containers in a stack and movable in x, y axes in the plane of a row, thereby enabling engagement of the picker gripper with one or more containers, displacement of those gripped containers away from the row and depositing of it/them at a selected location, wherein said picking means is engaged with transportation means to transport the picking means transversely along the pick face.  
     
     
         12 . The apparatus of  claim 11 , wherein the picker gripper is further moveable parallel to said rows to enable selective engagement with containers not closest to the end of a row.  
     
     
         13 . The apparatus of any one of  claims 1  to  10  further including picking means for removing containers from a pick face defined by the upper surface of said container store, the picking means including one or more gantry systems, each adapted to relocate one or more containers from the container store to a required location, wherein once a space in said container store is created by the removal of containers, said conveying means is operable to move containers adjacent to said space into said space, thereby creating a loading space at an edge of the container store whereby a further container may be loaded into said loading space by said loading means.  
     
     
         14 . The apparatus of  claim 13 , wherein the container store in use stores a plurality of first containers each holding a plurality of second containers, wherein the picking means is further adapted to remove both selected second containers and selected empty first containers from said container store.  
     
     
         15 . The apparatus of  claim 14 , wherein the first containers are pallets and the apparatus further includes a pallet conveying means for conveying pallets and wherein at least one of said gantry systems is adapted to place said second containers onto pallets located on said pallet conveying means and transport pallets removed from the container store by said picking means onto said pallet conveying means.  
     
     
         16 . The apparatus of  claim 15 , wherein the picking means places containers removed from the container store onto a container conveying means and the apparatus includes a palletiser to receive containers and pallets from said container conveying means and said pallet conveying means respectively, wherein said one or more gantry systems in use load full layers of containers from the container store onto pallets on said pallet conveying means and relocate partial layers of containers from the container store onto said container conveying means for receipt by said palletiser and wherein the palletiser loads all or selected containers from said partial layers onto said pallets.  
     
     
         17 . The apparatus of  claim 15  further including a reordering system for reordering containers that have been relocated as a partial layer of containers into a required order for loading by said palletiser prior to reaching said palletiser.  
     
     
         18 . The apparatus of any one of  claims 15  to  17 , wherein the container store includes a first and a second store area located on opposing longitudinal sides of said pallet conveying means, wherein in use the picking means removes only full layers from the first store area and any partial layers are taken from the second store area.  
     
     
         19 . The apparatus of any one of  claims 14  to  18 , wherein said container store stores said first containers adjacent to each other in a grid pattern and wherein the container store extends at least three said first containers away from the peripheral edge of the container store.  
     
     
         20 . The apparatus of either  claim 18  or  claim 19 , wherein the space between containers in said grid pattern is substantially minimised according to the minimum space required by said picking means.  
     
     
         21 . A method of storage for product held in containers, said method including: 
 providing a container store having multiple, parallel spaced-apart support members defining a plurality of rows and each adapted to support a base of a plurality of containers;    loading containers on said support members by moving a loading means carrying one or more containers transverse to said rows and along an end of said rows to align the loading means with a selected row and moving containers into the selected row from said loading means;    moving one or more conveying means transverse to said rows below said rows for selective engagement with containers in said rows and conveying one or more containers longitudinally within a row as required to move containers to or from that row; and    providing automated control of the operation of said loading means and conveying means by a computer control system.    
     
     
         22 . The method of  claim 21 , wherein the loading means includes a transfer conveyor extending beneath at least a portion of said rows and the method includes using said transfer conveyor as said one or more conveying means for the portion that it extends beneath.  
     
     
         23 . A container storage and retrieval system including: 
 a first storage zone in which containers of product are storable in frames, each frame including a plurality of stacks of containers;    a second storage zone in which containers of product are storable in stacks, including apparatus to receive, locate and store frames and including a first automated retrieval system to retrieve stacks of containers;    a third storage zone in which containers of product are storable in stacks, including apparatus to receive, locate and store stacks and including a second automated retrieval system to retrieve as required individual containers, partial stacks and stacks of containers; and    a conveying system in communication with each storage zone and including conveying means operable to deliver frames to the second storage zone, receive stacks retrieved from the second storage zone and deliver them to the low storage zone and to receive containers from each zone and deliver them to a collation zone at which product orders are collated.    
     
     
         24 . The container storage and retrieval system of  claim 23 , wherein the bulk storage zone is arranged to allow manual retrieval of frames of containers stored therein and the conveying system is suitable for receiving manually retrieved frames of containers.  
     
     
         25 . The container storage and retrieval system of either  claim 23  or  claim 24  including a fourth storage zone arranged to allow manual retrieval of individual items of product from the containers.  
     
     
         26 . The container storage and retrieval system of any one of  claims 23  to  25  including a manager computer including an inventory system for recording the flow and location of product within a controlled area defined by at least the second and third storage zones.  
     
     
         27 . The container storage and retrieval system of any one of  claims 23  to  26 , wherein the second and third storage zones each include: 
 a storage retrieval unit including multiple parallel spaced-apart support members, each defining a row and adapted to support a base of a plurality of containers; and  
 one or more index conveyors parallel to and beneath the rows, movable transverse to the rows, and including engagement means enabling engagement of the or each index conveyor with one or more stacks and/or partial stacks of containers in a row to transport it or them longitudinally within that row.  
 
     
     
         28 . The container storage and retrieval system of any one of  claims 23  to  27 , wherein one or both of the second and third storage zones further include at least one transfer conveyor, the or each transfer conveyor movable transverse to the rows, having a loading region parallel to the rows, and including engagement means enabling engagement with one or more stacks and/or partial stacks of containers in a row to transport it or them into or out of the storage zone.  
     
     
         29 . The container storage and retrieval system of  claim 26 , wherein the manager computer is operable to cause the container storage and retrieval system to replenish the third storage zone with one or more stacks of containers sourced from the second storage zone.  
     
     
         30 . A method of container storage and retrieval including: 
 in a first storage zone storing containers of product in frames, each frame including a plurality of stacks of containers;    in a second storage zone storing containers of product in rows of stacks, retrieving selected stacks of containers from the second storage zone using an automated retrieval system and replenishing containers by receiving frames;    in a third storage zone retrieving selected individual containers, partial stacks or stacks of containers using a second automated retrieval system and replenishing containers by receiving stacks from the second storage zone; and    collating containers retrieved from the storage zones into orders.    
     
     
         31 . The method of  claim 30  including manually retrieving frames of containers from the first storage zone.  
     
     
         32 . The method of either  claim 30  or  claim 31  including providing a fourth storage zone, manually retrieving individual items of product from the containers in the fourth storage zone and collating containers retrieved from the fourth storage zone into orders.  
     
     
         33 . The method of any one of  claims 30  to  32 , including using a conveying system to transfer containers between the second and third storage zones and to transfer containers from the first, second and third storage zones to a collation zone for collation into orders.  
     
     
         34 . A storage and retrieval system substantially as herein described with reference to FIGS.  1  to  8  or FIG. 9.  
     
     
         35 . A method of container storage and retrieval substantially as herein described with reference to FIGS.  1  to  8  or FIG. 9.