Automated container storage and delivery system

• US 20030176944A1
• Filed: 02/20/2003
• Published: 09/18/2003
• Est. Priority Date: 03/13/2002
• Status: Active Grant

• Current Assignee: System Logistics Corporation
• Original Assignee: Frederick J. Stingel III, James N. Smith, Jeffrey W. Stingel
• Inventors: Stingel, Frederick J. III, Stingel, Jeffrey W., Smith, James N.
• Granted Patent: US 7,200,465 B2
• Time in Patent Office: Days
• US Class Current: 700/215
• CPC Class Codes: B65G 1/08 the articles being fed by gravity braking arrangements for roller-ways B65G13/075; separating or stopping elements B65G47/88
• CPC Class Codes: B65G 1/1378 the orders being assembled on fixed commissioning areas remote from the storage areas
• CPC Class Codes: B65G 11/086 for articles

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.

Claims

1. A container storage and delivery system, comprising:

an individual container storage and delivery system;

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;

a layer storage and delivery system for taking full layers from a storage location and placing said full layers of containers onto a pallet;

a robotic container delivery system for placing individual containers onto a pallet;

a conveyor system for conveying containers and pallets bearing containers between at least two of said individual container storage and delivery system, said palletizer, said layer storage and delivery system, and said robotic container delivery system.

2. The material storage and delivery system of claim 1, wherein said individual container storage and delivery system is a vertically accumulating storage and retrieval apparatus.

3. The material storage and delivery system of claim 1, wherein said layer storage and delivery system comprises a full layer storage system for storing full layers of containers, and a gantry for taking full layers of containers and placing said full layers onto a pallet to be delivered.

4. The material storage and delivery system of claim 3, wherein said layer storage and delivery system comprises a pallet magazine for delivering empty pallets to a position for receiving said full layers.

5. The material storage and delivery system of claim 1, wherein said layer storage and delivery system is adapted to receive pallets from said palletizer and place layers onto said pallets.

6. The material storage and delivery system of claim 1, wherein said layers delivered by said layer storage and delivery system are homogeneous SKU layers.

7. The material storage and delivery system of claim 1, further comprising a depalletizing system for delivering containers to said individual container storage and delivery system.

8. The material storage and delivery system of claim 1, further comprising a control system for delivering containers from said individual container storage and delivery system to said palletizer, for sending pallets from said palletizer to at least one of said layer storage and delivery system and said robotic container delivery system, and for sending pallets from said layer storage and deliver system to said robotic container delivery system.

9. The material storage and delivery system of claim 8, wherein said control system receives inventory data and order data, said inventory data comprising container position data for containers in said individual container storage and delivery system, said layer storage and delivery system, and said robotic container delivery system.

10. The material storage and delivery system of claim 9, wherein said control system determines at least one pallet configuration from said order data, said pallet configuration comprising the number of homogeneous SKU layers of containers to be placed on said pallet.

11. The material storage and delivery system of claim 10, wherein said control system, if said number of homogeneous SKU layers to be placed on said pallet exceeds a predetermined threshold, and if said number of homogeneous SKU layers can be obtained from said layer storage and delivery system, directs said layer storage and delivery system to place said layers on a pallet.

12. The material storage and delivery system of claim 9, wherein said control system directs said pallet having homogeneous SKU layers of containers from said layer storage and delivery system to said robotic container delivery system, and causes said robotic container delivery system to place containers on said pallet.

13. The material storage and delivery system of claim 11, wherein said control system directs pallets from said palletizer to said robotic container delivery system and causes said robotic container delivery system to place containers on said pallet.

14. The material storage and delivery system of claim 10, wherein said control system, if said number of homogeneous SKU layers of containers does not exceed a predetermined threshold, and if there is at lest one homogeneous package type layer that is necessary, causes said individual container storage and delivery system to deliver an equivalent number of said containers to said palletizer and directs said palletizer to place said homogeneous package type containers onto a pallet.

15. The material storage and delivery system of claim 10, wherein said control system determines if heterogeneous package type containers are to be placed onto said pallet and, if so, directs said containers to be sent to said robotic container delivery system.

16. The material storage and delivery system of claim 10, wherein said control system determines the number of homogeneous SKU full layers of containers and, if said number is above a predetermined threshold, directs said layer storage and delivery system to place said homogeneous SKU full layers on said pallet.

17. The material storage and delivery system of claim 16, wherein said control system directs said pallet from said layer storage and delivery system to said robotic container delivery system and causes said robotic container delivery system to place containers on said pallet.

18. The material storage and delivery system of claim 1, wherein said robotic container delivery system places heterogeneous package type containers on a pallet.

19. The material storage and delivery system of claim 1, wherein said robotic container delivery system places incomplete layers of containers on a pallet.

20. A method for storing and delivering containers, comprising the steps of:

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 robotic 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 with said robotic container delivery system.

21. The method of claim 20 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 said robotic container delivery system and causing said robotic 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 robotic container delivery system for placing said additional containers onto said pallet.

22. The method of claim 20, further comprising the step of 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.

23. The method of claim 22, 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.

24. The method of claim 20, wherein said individual container storage and delivery system is a vertically accumulating storage and dispensing apparatus.

25. The method of claim 20, further comprising the step of replenishing said individual container storage and delivery system with containers from a pallet storage area.

26. The method of claim 20, wherein after containers have been placed on said pallet by said palletizer, directing said pallet to said layer storage and delivery system for placing full layers on said pallet.

27. The method of claim 26, wherein, after placing layers on said pallet in said layer storage and delivery system, directing said pallet to said robotic container delivery system for placing individual containers onto said pallet.

28. The method of claim 20, further comprising the step of determining high through-put containers, and maintaining full layers of said high through-put containers in said layer storage and delivery system.

29. The method of claim 20, further comprising the step of 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 at least one of said palletizer and said robotic container delivery system.

30. The method of claim 20, further comprising the step of determining if full pallets of goods are necessary, and obtaining such full pallets from a storage area.

31. A container storage and delivery system, comprising:

a fully automated individual container storage and delivery system;

a semi-automated individual container storage and delivery system;

a palletizer for placing containers from said fully automated container storage and delivery system and from said semi-automated individual container storage and delivery system; and

,

a conveyor system for transporting said containers from said fully automated individual container storage and delivery system and said semi-automated container storage and delivery system to said palletizer.

32. The container storage and delivery system of claim 31, wherein said fully automated individual container storage and delivery system and said semi-automated container storage and delivery system are vertically accumulating.

33. A container storage and delivery system, comprising:

a vertically accumulating, semi-automated container storage and delivery apparatus having an upper container input location; and

,

an elevated container storage station substantially adjacent to said upper container input location of said semi-automated storage and delivery apparatus, whereby an operator can remove individual containers from said storage area and place them into said vertically accumulating semi-automated storage and delivery apparatus at said upper container input location.

34. A container storage and delivery system, comprising:

an individual container storage and delivery system;

a depalletizer for removing layers of containers from pallets and placing said containers into said individual container storage and delivery system; and

,

an automated partial pallet storage and delivery system for taking partial pallets to and from said depalletizer.