GB2565883A

GB2565883A - Smart container and multi-layer supply chain automation thereof

Info

Publication number: GB2565883A
Application number: GB1809977.0A
Authority: GB
Inventors: Charles Martin Sanders Jeremy; Ramaswami Krishnan; Maurer Angela
Original assignee: Tesco PLC
Current assignee: Tesco PLC
Priority date: 2017-06-16
Filing date: 2018-06-18
Publication date: 2019-02-27
Also published as: GB201809977D0; GB201709611D0

Abstract

The application discloses an automated warehouse retrieval or fulfillment system comprising picking robots 205-n, containers 100-n and a server 220. The server comprises a modules for assigning tasks to the plurality of robots 235, for communicating and monitoring the containers 225 and devising optimal routes 230. The containers are divided into a plurality of compartments (see figure 1). The container preferably comprises a sensor for monitoring the weight, temperature, expiry date or space within the container. The containers can move on guides or lanes (310, figure 3) within the warehouse. The containers may be arranged in an optimal way on a racking that may also be reconfigurable. The racking maybe stationary or in a transportation vehicle (315, figure 3).

Description

SMART CONTAINER AND MULTI-LAYER SUPPLY CHAIN AUTOMATION THEREOF

Field of the invention

The present invention generally relates to a smart container and a system and method for multilayer supply chain automation.

Background of the invention

Product picking, shipping, merchandising and distribution of goods from supplier to retailer and further to a consumer are processes that are labor intensive, and exhausts good amount of time and money. Conventional procedures have tried to solve this problem through standard product packet sizes and standard shelving in stores to minimize product handling. Various solutions are available that solve these deficiencies.

By way of an example, US9378607 discloses a personalized commerce system for providing automated product placement in a residential building structure having a plurality of residential locations, each residential location configured to be populated by at least one human. A disadvantage of the prior art is that it doesn’t monitor attributes of the products.

By way of another example, US6622127 discloses a warehouse management system that allocates inventory to orders by selecting a pod in order to maximize throughput. If there are multiple locations within the pod that stock the same inventory item, then the method chooses one of those locations based upon the expiration date. Finally, if multiple of these locations have units that expire within the same expiration period, the location with the fewest units is chosen. Major drawback of the prior art pertains to lack of a central monitoring system that controls placing and sorting of one or more items at multiple locations within the pod.

By way of another example, US6061607 discloses an automated storage and retrieval system (ASRS) wherein individual identical articles are disposed in vertical stacks stored in cells of movable totes. However, the prior art lacks execution of algorithms for identifying the most economical paths for movement of movable totes.

Thus, there is a need for an efficient universal product delivery system that facilitates automation of such distribution and sale of products.

Summary of the invention

This summary is provided to introduce a selection of concepts in a simplified format that are further described in the detailed description of the invention. This summary is not intended to identify key or essential inventive concepts of the claimed subject matter, nor is it intended for determining the scope of the claimed subject matter.

A smart container and a multi-layer supply chain automation system is disclosed. In some embodiments, the system for multi-layer supply chain automation comprises, a smart container comprising a plurality of standardized compartments adapted to receive one or more standardized products, one or more product placing robots configured for placing the one or more standardized products within the plurality of standardized compartments, and an automation server. The automation server further comprises, a database, a container monitoring module, in communication with the smart container for managing the smart container, a passage processing module configured for determining at least an optimal path for the smart container, and robot control module configured for at least assigning a product picking and placing task to the one or more product placing robots, wherein the smart container is configured for moving from a source to a destination in the multi-layer supply chain via a grid of guide lanes.

During operation, the smart container is automatically filled with products by the product placing robots in the warehouse. That is, the automation server creates a delivery task, the container monitoring module assigns a container for that particular task, the passage processing module determines the optimal path for picking the products within the warehouse and an optimal path for delivering the products to the end terminals, and the robot control module assigns the product picking and placing task to the one or more product placing robots within the warehouse. The one or more product placing robots then automatically places the one or more products in the one or more compartments of the container. Then the one or more smart containers (performing one or more delivery tasks) are joined with each other to create any arrangement facilitated by a racking system such that the smart containers are moved to an optimum position within any storage area for example the delivery vehicle, warehouse.

In another embodiment, the smart racking system allows the stacking and horizontal and/or vertical movement of the smart containers such that a first smart container may join a second smart container to create an arrangement that enables efficient usage of space within any storage area for example delivery vehicle, warehouse. For this purpose, the smart racking system comprises an identifying means to identify the smart containers and a moving means to move the smart containers within the storage area, vertically and/or horizontally.

The automation system enables transportation of the smart containers loaded with the products to various terminals for example production plants, distribution centres, vehicles, retail outlets and homes by identifying a most economical path through the PPS.

Above all, an advantage of the present invention is that it gives a universal solution that can work across all geographies and for all kinds of suppliers, retailers and consumers. The system and methodology of the present invention deliver levels of stock management and availability. The invention overcomes the drawbacks of prior art by monitoring attributes of the products, provides a central monitoring system that controls placing and sorting of products and a passage processing system that executes algorithm for identifying the most economical paths for movement of the smart container loaded with products.

Brief description of the drawings:

To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawing. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings in which:

Figure 1A illustrates an exemplary smart container 100 in accordance with an embodiment of the present disclosure.

Figure IB illustrates an exemplary container and base unit arrangement in accordance with an embodiment of the present disclosure.

Figure 2 illustrates an exemplary multi-layer supply chain automation system in which various embodiments of the present disclosure may be seen.

Figure 3 schematically illustrates operation of the automation system (100) in a multi-layer supply chain in accordance with an embodiment of the present disclosure.

Figure 4 illustrates a flow chart (400) of the method for multi-layer supply chain automation, in accordance with an embodiment of the present disclosure.

It may be noted that to the extent possible, like reference numerals have been used to represent like elements in the drawings. Further, those of ordinary skilled in the art will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help to improve understanding of aspects of the invention. Furthermore, the one or more elements may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skilled in the art having benefit of the description herein.

Detailed Description of the Invention

It should be understood at the outset that although illustrative implementations of the embodiments of the present disclosure are described below, the present invention may be implemented using any number of techniques, whether currently known or in existence. The present disclosure should in no way be limited to the illustrative implementations, drawings, and techniques described below, including the exemplary design and implementation illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.

More specifically, any terms used herein such as but not limited to “includes,” “comprises,” “has,” “consists,” and grammatical variants thereof do NOT specify an exact limitation or restriction and certainly do NOT exclude the possible addition of one or more features or elements, unless otherwise stated, and furthermore must NOT be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated with the limiting language “MUST comprise” or “NEEDS TO include.”

Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility and non-obviousness. Use of the phrases and/or terms such as but not limited to “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or variants thereof do NOT necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

Figure 1A illustrates an exemplary smart container 100 in accordance with an embodiment of the present disclosure. As shown, the smart container (100) comprises a plurality of standardized compartments (101) configured to store different types of products or product containers (depicted by a dotted lines). The smart container (100) may have any number of standardized compartments (101-1, 101-2, to 101-N) For the sake of brevity only four standardized compartments (101-1 to 101-4) are being depicted in the figure. In one embodiment, the smart container (100) may be a bi-level structure, such that the compartments are divided into two sections, for example one lower set of compartments and one upper set of compartments. Herein the word “smart container (100)” and “container (100)” are interchangeably used. Similarly, the word “standardized compartment(s)” and “compartment(s)” are interchangeably used in the further description.

In one embodiment of the present disclosure, the smart container (100) comprises one or more sensors (sensing mechanism) (not shown in figure) for monitoring the products stored within the plurality of standardized compartments (101). The one or more sensors detect various attributes of the stored products such as count, weight, temperature, humidity, date, provenance and location, for example. Further, each compartment comprises a belt drive (105) installed so as to accurately eject the products from the compartment for vending the products. Furthermore, each compartment comprises a latch door (110) that can be opened during vending and creates a chute that dispenses the products from the belt drive (105) to a vending collection tray.

In one embodiment of the present disclosure, the container (100) is detachably attachable to a base unit which facilitates the movement of the container within the warehouse, for example. Figure IB illustrates an exemplary container and base unit arrangement in accordance with an embodiment of the present disclosure. As shown, the container 100 can be placed on the base unit (115) and the base unit (115) enables easy movement of the container (100) within the warehouse or the shipping area. The base unit (115) is typically power by a battery unit and comprises two or more wheels which engage with the rails for movement. Such implementation enables base unit (115) and the container (100) to be moved to any position in the trail matrix. The battery unit also provides required power to the container (100), that is, to the various elements of the container such as processing unit, drive belts, one or more sensors, etc.

Furthermore, the smart container (100) comprises a location tracking mechanism (not shown) for example Global Positioning System (GPS) for locating the smart container (100) within a geographical area, for example within a warehouse.

Figure 2 illustrates an exemplary multi-layer supply chain automation system in which various embodiments of the present disclosure may be seen. As shown, the system comprises a plurality of smart containers (100), a plurality of product placing robots (205), one or more guide lanes (210), a communication network (215) and an automation server (220), wherein the automation server further comprises a container monitoring module (225), a passage processing module (230), a robot control module (235) and a database (240).

In one embodiment of the present disclosure, the plurality of smart containers (100) are communicatively connected with the automation server via the communication network (215). Similarly, the plurality of product placing robots (205) are communicatively connected with the automation server via the communication network (215). Further, the one or more guide lanes (210) are communicatively connected with the plurality of product placing robots (205) and the automation server (220).

The communication network (215) may be a wireless network or a wired network or a combination thereof. Wireless network may include long range wireless radio, wireless personal area network (WPAN), wireless local area network (WLAN), mobile data communications such as 3G, 4G or any other similar technologies. The communication network (215) may be implemented as one of the different types of networks, such as intranet, local area network (LAN), wide area network (WAN), the internet, and the like. The communication network (215) may either be a dedicated network or a shared network. In one implementation, the communication network (125) is internet which enables communication between one or more elements of the system (100) as shown.

In one embodiment of the present disclosure, the automation server (220) may include, for example, a computer server or a network of computers or a virtual server which provides functionalities or services for other programs or elements of the system. In one implementation, automation server (220) comprises one or more processors, associated processing modules, interfaces and storage devices communicatively interconnected to one another through one or more communication means for communicating information. The storage associated with the payment transaction server (220) may include volatile and non-volatile memory devices for storing information and instructions to be executed by the one or more processors and for storing temporary variables or other intermediate information during processing.

In one embodiment of the present disclosure, the automation server (220) comprises a database (240) having information pertaining to the plurality of smart containers (100), for example, container ID, capacity, sensor information, current location within the warehouse, etc. and such information is updated in real-time or near-real time. Further, the database records the warehouse information, guide lanes information, product information within the warehouse such as product location, storage unit ID associated with the product, etc. Hence, in one embodiment of the present disclosure, the container monitoring module (225) periodically monitors the plurality of containers and updates the data such as current location, availability, etc., in the database (240). The robot control module (235) controls the operations of the one or more product placing robots (205) and the passage processing module (230) determines an optimal path for a given container within the warehouse and/or to the destination such as house/retail store. The functionalities of these modules are described in detail further in the description.

In one embodiment of the present disclosure, the plurality of product placing robots (205) facilitates loading of products to the container and unloading of products from the container (100). Hence, the product placing robots may comprise vertically and horizontally movable arms for arranging, loading and unloading the products or the containers. The manner in which the system operates in a multi-layer supply chain to fulfill an order described in detail further below.

Figure 3 schematically illustrates operation of the automation system (100) in a multi-layer supply chain in accordance with an embodiment of the present disclosure. As illustrated, typically, a warehouse comprises plurality of storage units (305-1 to 305-N), each identified with a unique ID, plurality of rails or guide lanes or conveyors (shown one guide lane 310) for guiding the containers to various locations within the warehouse, plurality of product placing robots (205-1 to 205-N) configured for facilitating picking and placing of products from the storage unit to the containers, and plurality of containers (shown one container 100-1), each identified with a unique identifier (container ID) for receiving the products. When an order is received from a consumer, the automation server (220) records the order in the database (240), assigns an order ID, and identifies the one or more product listed in the order and the location of the products within the warehouse, wherein the location may be identifies based on the information available at the warehouse SKU, storage unit IDs, etc., as well known in the art. Then the container monitoring module (225) identifies the one or more available containers, from example the container (100-1) from among the plurality of containers in the warehouse for fulfilling the order. Further, the passage processing module (230) determines an optimal path for the selected container (100-1) for receiving the one or more products listed in the order. In one implementation, the optimal path may be determined based on the current location of the container, one or more product locations within the warehouse, etc.

Furthermore, the robot control module (235) assigns picking and placing task to the one or more product placing robots (205-1 to 205-N) within the warehouse. For example, considering an order containing three products located at three storage units (305-1, 305-3 and 305-10), the robot control module (235) assigns the task to the corresponding product placing robots (205-1, 205-3 and 205-10), wherein the task comprises information such as number of units to be placed and the container ID. Then the automation server (220) triggers the container (100-1) to move to the product location where the first product needs to be picked and placed within the one of the compartment of the container (100-1). In one implementation, the base unit (115) of the container (100-1) comprises a controller that enables movement of the container (100-1). When the container (100-1) reaches the product location, the product placing robot identifies the container, for example by scanning a machine readable code on the container, and picks and places the product in the respective compartment of the container (100-1). For example, if the product needs to be preserved at a very low temperature, then the product placing robot identifies the compartment based on a unique compartment ID and places the product in that particular compartment of the container. In one embodiment, each compartment in the container 100-1 comprises an identifier that describes the type of the compartment. Hence, the container and the method of placing the products within the container ensure maintenance of frozen, chilled and ambient products at the correct temperature at all times till delivery. Upon completing the task, the container (100-1) loaded with the products is moved to a loading space of a delivery vehicle (315).

In one embodiment of the present disclosure, the delivery vehicle (315) comprises a racking system (not shown in figure), typically a robot, that places the one or more such product carrying containers on the delivery vehicle (315) in an optimal way. That is, one or more containers are stacked in an arrangement at optimum positions to obtain efficient usage of the storage area of the delivery vehicle (315). Further, in another embodiment of the present disclosure, the one or more containers are stacked based on the delivery location of the one or more containers. For example, a container that needs to be unloaded first is placed near the door of the delivery vehicle (315). Hence, in one embodiment of the present disclosure, the delivery vehicle further comprises one or more guide lanes that enables stacking of products or product carrying containers within the delivery vehicle.

Hence, in one embodiment of the present disclosure, the smart racking system allows the stacking and horizontal and/or vertical movement of the smart containers such that a first smart container may join a second smart container to create an arrangement that enables efficient usage of space within any storage area for example delivery vehicle, warehouse. For this purpose, the smart racking system comprises an identifying means to identify the smart containers and a moving means to move the smart containers within the storage area, vertically and/or horizontally.

Hence, the automation system enables transportation of the smart containers (100) loaded with the products to various terminals/destinations for example retail outlets (320), homes (325), distribution centres, etc., by identifying a most economical path through the passage processing module (230). In one embodiment of the present disclosure, the terminal (320 or 325) is adapted to accept delivery of the smart container(s) (100) by automatically providing direct access for the smart container(s) (100) delivered or by providing any automated locker outside the home. Likewise, the terminal (325) may be re-purposed to have a space/storage area (330), for example.

Figure 4 illustrates a flow chart (400) of the method for multi-layer supply chain automation, in accordance with an embodiment of the present disclsoure.

At step (405), the smart containers (100) are automatically filled with products by the product placing robots (205-1 to 205-N) in the warehouse. That is, the automation server (220) creates a delivery task, the container monitoring module (225) assigns one or more containers, the passage processing module (230) determines the optimal path for picking the products within the warehouse and an optimal path for delivering the products to the end terminals, and the robot control module 235 assigns the product picking and placing task to the one or more product placing robots (205-1 to 205-10) within the warehouse. The one or more product placing robots then automatically places the one or more products in the one or more compartments of the containers.

At step (410), the smart containers (100) loaded with products are joined with each other to create any arrangement facilitated by the racking system such that the smart containers (100) are moved to an optimum position within any storage area for example the delivery vehicle, warehouse.

At step (415), the passage processing module 230, identifies the most economical paths for movement of the smart containers (100) to any terminal/destination. As such, passage processing module 230 may execute one or more algorithms, as known in the art, for identifying the most economical path.

At steps (420), subsets of the smart containers (100) can be formed for smaller deliveries to smaller destinations such as to home and then the subsets are delivered. At step (425), the smart containers (100) are regularly delivery to bigger places for example production plants, distribution centres, vehicles and retail outlets etc. The sensors and connectivity means of smart container (100) may increase the accuracy level of loading of the products to any storage area and optimal positioning of the smart container (100) facilitate efficient distribution. Also, an individual may have full visibility of all the products currently within the smart container (100).

Finally, at step (430) the old and empty smart container (100) will be taken out and replaced with a new smart container (100).

In one embodiment of the present disclosure, a plurality of smart containers (100) may be used in stationary automated vending systems wherein each of the one or more smart containers (100) loaded into the vending system comprise products according to the preferences of one or more users pre-registered with the automated vending system. Further, the smart containers (100) are replenished with products automatically at periodic intervals.

While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. The scope of embodiments is at least as broad as given by the following claims.

Claims

1. A multi-layer supply chain automation system, the system comprising;

a smart container comprising a plurality of standardized compartments adapted to receive one or more standardized products;

one or more product placing robots configured for placing the one or more standardized products within the plurality of standardized compartments; and an automation server comprising:

a database;

a container monitoring module, in communication with the smart container for managing the smart container;

a passage processing module configured for determining at least an optimal path for the smart container; and robot control module configured for at least assigning a product picking and placing task to the one or more product placing robots;

wherein the smart container is configured for moving from a source to a destination in the multi-layer supply chain via a grid of guide lanes.

2. The multi-layer supply chain automation system as claimed in claim 1, wherein the smart container comprises one or more sensors for monitoring at least a temperature, weight, expiry date, available space within the container, and the like.

3. The multi-layer supply chain automation system as claimed in claim 1, wherein the smart container is uniquely identified through a unique identification number.

4. The multi-layer supply chain automation system as claimed in claim 1, wherein the database comprises information pertaining to the smart container, the one or more product placing robots, the warehouse, the grid of guide lanes, warehouse SKU, and the like.

5. The multi-layer supply chain automation system as claimed in claim 1, wherein the system further comprises a smart racking system configured for stacking and horizontal and/or vertical movement of the smart containers to create an arrangement that enables efficient usage of space within a storage area.

6. The smart racking system claimed in claim 5 comprises an identifying means for identifying the smart containers and a moving means for moving smart containers within the storage area, vertically and/or horizontally.