Automated container storage and delivery system

Abstract

A material storage and delivery system includes an individual container storage and delivery system (ICSDS). A palletizer is provided for placing containers from the ICSDS on a pallet. A layer storage and delivery system (LSDS) places full layers of containers on a pallet. A robotic container delivery system (RCDS) places individual containers on a pallet. A conveyor system conveys containers and pallets between at least two of the ICSDS, the palletizer, the LSDS and the RCDS. A method for storing and delivering containers is also disclosed.

1 . A method for storing and delivering containers, comprising: 
 providing an individual container storage and delivery system;    providing a palletizer for forming a group of containers from said individual container storage and delivery system into a layer or a partial layer, and placing this layer or partial layer onto a pallet;    providing a layer storage and delivery system for taking full layers of containers from a storage area and placing said full layers onto a pallet;    maintaining inventory data comprising position data for at least some containers in said system;    receiving customer order data;    determining at least one pallet configuration from said order data and said inventory data, said pallet configuration including layers of containers for said pallet configuration; and,    if said configuration of containers includes layers of homogeneous SKUs, placing said homogeneous SKU containers on a pallet with said layer storage and delivery system;    if said configuration requires layers of homogeneous package type, placing said homogeneous package type containers on said pallet with said individual container storage and delivery system and said palletizer; and,    if said configuration requires heterogeneous package types, placing said heterogeneous package types onto a pallet.    
   
   
       2 . The method of  claim 1 , further comprising providing a system for placing containers onto a pallet.  
   
   
       3 . The method of  claim 2 , wherein the system for placing containers onto a pallet comprises a robotic delivery system for placing individual containers onto a pallet.  
   
   
       4 . The method of  claim 3 , further comprising determining layer configurations for heterogeneous layers of containers and causing said robotic delivery system to place said heterogeneous layers onto a pallet according to said layer configuration.  
   
   
       5 . The method of  claim 4 , wherein said heterogeneous layers comprise at least one selected from the group consisting of incomplete layers and full layers having at least two different package types.  
   
   
       6 . The method of  claim 1 , wherein said individual container storage and delivery system is a vertically accumulating storage and dispensing apparatus.  
   
   
       7 . The method of  claim 1 , further comprising replenishing said individual container storage and delivery system with containers from a pallet storage area.  
   
   
       8 . The method of  claim 1 , Further comprising determining if full pallets of goods are necessary, and obtaining such full pallets from a storage area.  
   
   
       9 . A method for storing and delivering containers, comprising: 
 providing an individual container storage and delivery system;    providing a palletizer for forming a group of containers from said individual container storage and delivery system into a layer or a partial layer, and placing this layer or partial layer onto a pallet;    providing a layer storage and delivery system for taking full layers of containers from a storage area and placing said full layers onto a pallet;    providing a container delivery system for placing individual containers onto a pallet;    maintaining inventory data comprising position data for at least some containers in said system:    receiving customer order data;    determining at least one pallet configuration from said order data and said inventory data, said pallet configuration including layers of containers for said pallet configuration; and,    if said configuration of containers includes layers of homogeneous SKUs, placing said homogeneous SKU containers on a pallet with said layer storage and delivery system;    if said configuration requires layers of homogeneous package type, placing said homogeneous package type containers on said pallet with said individual container storage and delivery system and said palletizer; and,    if said configuration requires heterogeneous package types, placing said heterogeneous package types onto a pallet;    wherein, if said number of layers of homogeneous SKUs exceeds a predetermined threshold and said layers are available from said layer storage and delivery system, causing said layer storage and delivery system to place said homogeneous layers of homogeneous SKUs on a pallet and, if additional containers are required to complete said pallet configuration, directing said pallet from said layer storage and delivery system to the container delivery system and causing the container delivery system to place said containers onto said pallet; and,    if said number of layers of containers does not exceed said predetermined threshold or if said layers are not available from the layer storage and delivery system, causing said individual container storage and delivery system to deliver containers to said palletizer and causing said palletizer to place said containers onto a pallet and, if additional containers are required to complete said pallet configuration, causing said conveyor system to direct said pallet to said container delivery system for placing said additional containers onto said pallet.    
   
   
       10 . The method of  claim 9 , wherein the container delivery system for placing containers onto a pallet comprises a robotic container delivery system for placing individual containers onto a pallet.  
   
   
       11 . The method of  claim 10 , further comprising determining layer configurations for heterogeneous layers of containers and causing said robotic container delivery system to place said heterogeneous layers onto a pallet according to said layer configuration.  
   
   
       12 . The method of  claim 11 , wherein said heterogeneous layers comprise at least one selected from the group consisting of incomplete layers and full layers having at least two different package types.  
   
   
       13 . The method of  claim 9 , wherein said individual container storage and delivery system is a vertically accumulating storage and dispensing apparatus.  
   
   
       14 . The method of  claim 9 , further comprising replenishing said individual container storage and delivery system with containers from a pallet storage area.  
   
   
       15 . The method of  claim 9 , further comprising determining if full pallets of homogenous SKU's are necessary, and obtaining such full pallets from a storage area.  
   
   
       16 . A method for storing and delivering containers, comprising: 
 providing an individual container storage and delivery system;    providing a palletizer for forming a group of containers from said individual container storage and delivery system into a layer or a partial layer, and placing this layer or partial layer onto a pallet;    providing a layer storage and delivery system for taking full layers of containers from a storage area and placing said full layers onto a pallet;    maintaining inventory data comprising position data for at least some containers in said system;    receiving customer order data;    determining at least one pallet configuration from said order data and said inventory data, said pallet configuration including layers of containers for said pallet configuration; and,    if said configuration of containers includes layers of homogeneous SKUs, placing said homogeneous SKU containers on a pallet with said layer storage and delivery system;    if said configuration requires layers of homogeneous package type, placing said homogeneous package type containers on said pallet with said individual container storage and delivery system and said palletizer; and,    if said configuration requires heterogeneous package types, placing said heterogeneous package types onto a pallet;    wherein after containers have been placed on said pallet by said palletizer, placing full layers on said pallet from said layer storage and delivery system.    
   
   
       17 . The method of  claim 16 , further comprising providing a system for placing containers onto a pallet.  
   
   
       18 . The method of  claim 17 , wherein the system for placing containers onto a pallet comprises a robotic delivery system for placing individual containers onto a pallet.  
   
   
       19 . The method of  claim 18 , further comprising determining layer configurations for heterogeneous layers of containers and causing said robotic delivery system to place said heterogeneous layers onto a pallet according to said layer configuration.  
   
   
       20 . The method of  claim 19 , wherein said heterogeneous layers comprise at least one selected from the group consisting of incomplete layers and full layers having at least two different package types.  
   
   
       21 . The method of  claim 16 , wherein said individual container storage and delivery system is a vertically accumulating storage and dispensing apparatus.  
   
   
       22 . The method of  claim 16 , further comprising replenishing said individual container storage and delivery system with containers from a pallet storage area.  
   
   
       23 . The method of  claim 18 , wherein, after placing layers on said pallet in said layer storage and delivery system, directing said pallet to said robotic delivery system for placing individual containers onto said pallet.  
   
   
       24 . The method of  claim 16 , further comprising determining if full pallets of homogenous SKU's are necessary, and obtaining such full pallets from a storage area.  
   
   
       25 . A method for storing and delivering containers, comprising: 
 providing an individual container storage and delivery system;    providing a palletizer for forming a group of containers from said individual container storage and delivery system into a layer or a partial layer, and placing this layer or partial layer onto a pallet;    providing a layer storage and delivery system for taking full layers of containers from a storage area and placing said full layers onto a pallet;    maintaining inventory data comprising position data for at least some containers in said system;    receiving customer order data;    determining at least one pallet configuration from said order data and said inventory data, said pallet configuration including layers of containers for said pallet configuration; and,    if said configuration of containers includes layers of homogeneous SKUs, placing said homogeneous SKU containers on a pallet with said layer storage and delivery system;    if said configuration requires layers of homogeneous package type, placing said homogeneous package type containers on said pallet with said individual container storage and delivery system and said palletizer; and,    if said configuration requires heterogeneous package types, placing said heterogeneous package types onto a pallet with said container delivery system; and,    determining high through-put containers, and maintaining full layers of said high through-put containers in said layer storage and delivery system.    
   
   
       26 . The method of  claim 25 , including providing a container delivery system for placing individual containers onto a pallet.  
   
   
       27 . The method of  claim 26 , wherein the container delivery system for placing containers onto a pallet comprises a robotic delivery system for placing individual containers onto a pallet.  
   
   
       28 . The method of  claim 27 , further comprising determining layer configurations for heterogeneous layers of containers and causing said robotic delivery system to place said heterogeneous layers onto a pallet according to said layer configuration.  
   
   
       29 . The method of  claim 25 , wherein said heterogeneous layers comprise at least one selected from the group consisting of incomplete layers and full layers having at least two different package types.  
   
   
       30 . The method of  claim 25 , wherein said individual container storage and delivery system is a vertically accumulating storage and dispensing apparatus.  
   
   
       31 . The method of  claim 25 , further comprising replenishing said individual container storage and delivery system with containers from a pallet storage area.  
   
   
       32 . The method of  claim 25 , further comprising determining if full pallets of goods are necessary, and obtaining such full pallets from a storage area.  
   
   
       33 . A method for storing and delivering containers, comprising: 
 providing an individual container storage and delivery system;    providing a palletizer for forming a group of containers from said individual container storage and delivery system into a layer or a partial layer, and placing this layer or partial layer onto a pallet;    providing a layer storage and delivery system for taking full layers of containers from a storage area and placing said full layers onto a pallet;    maintaining inventory data comprising position data for at least some containers in said system;    receiving customer order data;    determining at least one pallet configuration from said order data and said inventory data, said pallet configuration including layers of containers for said pallet configuration; and,    if said configuration of containers includes layers of homogeneous SKUs, placing said homogeneous SKU containers on a pallet with said layer storage and delivery system;    if said configuration requires layers of homogeneous package type, placing said homogeneous package type containers on said pallet with said individual container storage and delivery system and said palletizer; and,    if said configuration requires heterogeneous package types, placing said heterogeneous package types onto a pallet; and,    determining low through put containers, and maintaining said low through-put containers in a semi-automated vertically accumulating storage and delivery apparatus, and directing containers from said semi-automated storage and delivery apparatus to said palletizer.    
   
   
       34 . The method of  claim 33 , further comprising providing a system for placing containers onto a pallet.  
   
   
       35 . The method of  claim 34 , wherein the system for placing containers onto a pallet comprises a robotic delivery system for placing individual containers onto a pallet.  
   
   
       36 . The method of  claim 35 , further comprising determining layer configurations for heterogeneous layers of containers and causing said robotic delivery system to place said heterogeneous layers onto a pallet according to said layer configuration.  
   
   
       37 . The method of  claim 33 , wherein said heterogeneous layers comprise at least one selected from the group consisting of incomplete layers and full layers having at least two different package types.  
   
   
       38 . The method of  claim 33 , wherein said individual container storage and delivery system is a vertically accumulating storage and dispensing apparatus.  
   
   
       39 . The method of  claim 33 , further comprising replenishing said individual container storage and delivery system with containers from a pallet storage area.  
   
   
       40 . The method of  claim 33 , further comprising the step of determining if full pallets of the same SKU's are necessary, and obtaining such full pallets from a storage area.  
   
   
       41 . A method for storing and delivering containers, comprising: 
 (a) delivering individual containers from container storage;    (b) forming a group of containers from said individual containers into a layer or a partial layer, and placing this layer or partial layer onto a pallet;    (c) maintaining inventory data comprising position data for at least some containers;    (d) receiving customer order data;    (e) determining at least one pallet configuration from said order data and said inventory data, said pallet configuration including layers of containers for said pallet configuration; and,    (f) if said configuration of containers includes layers of homogeneous SKU containers, placing said homogeneous SKU containers on a pallet;    (g) if said configuration requires layers of homogeneous package type containers of different SKU's, placing said homogeneous package type containers on said pallet; and,    (h) if said configuration requires heterogeneous SKU containers or package types, placing said heterogeneous SKU containers or package types onto a pallet.    
   
   
       42 . The method of  claim 41 , wherein at least one of steps (b), (f), (g) or (h) is performed at least partially by a palletizer.  
   
   
       43 . The method of  claim 41 , wherein homogenous SKU containers are placed on said pallet vertically below heterogeneous SKU containers.  
   
   
       44 . The method of  claim 41 , wherein at least one container is delivered from container storage by a robotic system.  
   
   
       45 . The method of  claim 41 , wherein at least one container is placed on a pallet by a robotic system.  
   
   
       46 . The method of  claim 41 , wherein at least one container in step (h) is placed onto a pallet by a robotic system.  
   
   
       47 . The method of  claim 41 , wherein at least one layer of said pallet is formed of homogeneous SKU containers.  
   
   
       48 . The method of  claim 41 , wherein at least one layer of said pallet is formed of heterogeneous SKU containers or package types.  
   
   
       49 . The method of  claim 41 , wherein at least one pallet layer configuration is determined based on containers within a predetermined height range.  
   
   
       50 . A method for storing and delivering containers, comprising: 
 (a) receiving order data from a customer;    (b) comparing said order data to maintained inventory data to determine available containers in a container storage area for inclusion on at least one pallet for delivery to said customer;    (c) delivering said available containers from a container storage area to a pallet building area for inclusion on said at least one pallet;    (d) placing layers of available containers on said at least one pallet in said pallet building area; and,    (e) if said configuration of containers includes layers of homogeneous SKU containers, placing said homogeneous SKU containers on a pallet;    (f) if said configuration requires layers of homogeneous package type containers of different SKU's, placing said homogeneous package type containers on said pallet; and,    (g) if said configuration requires heterogeneous SKU containers or package types, placing said heterogeneous SKU containers or package types onto a pallet.    
   
   
       51 . The method of  claim 50 , wherein at least one of steps (d), (e), (f) or (g) is performed at least partially by a palletizer.  
   
   
       52 . The method of  claim 50 , wherein homogenous SKU containers are placed on said pallet vertically below heterogeneous SKU containers.  
   
   
       53 . The method of  claim 50 , wherein at least one container is delivered from container storage by a robotic system.  
   
   
       54 . The method of  claim 50 , wherein at least one container is placed on a pallet by a robotic system.  
   
   
       55 . The method of  claim 50 , wherein at least one container in step (g) is placed onto a pallet by a robotic system.  
   
   
       56 . The method of  claim 50 , wherein at least one layer of said pallet is formed of homogeneous SKU containers.  
   
   
       57 . The method of  claim 50 , wherein at least one layer of said pallet is formed of heterogeneous SKU containers or package types.  
   
   
       58 . The method of  claim 50 , wherein at least one pallet layer configuration is determined based on containers within a predetermined height range.