GB2624513A

GB2624513A - Systems and devices for stock management

Info

Publication number: GB2624513A
Application number: GB2314340.7A
Authority: GB
Inventors: Sverker Ture Lindbo Lars; Ingram-Tedd Andrew
Original assignee: Ocado Innovation Ltd
Current assignee: Ocado Innovation Ltd
Priority date: 2022-09-30
Filing date: 2023-09-19
Publication date: 2024-05-22
Also published as: WO2024068369A1; GB202214365D0; GB202314340D0

Abstract

A vehicle 300 for handling storage containers / trays C, comprises a container storage section 303 with the storage containers in a vertical arrangement; and a container handling mechanism 305 that is arranged to convey a target storage container from the container storage section to a pick position at which the content of the target storage container can be accessed. The container storage section may further comprise a loading port 314 which is preferably positioned on the side that faces away from the pick position. The vehicle may be operated as an autonomous vehicle and an autonomous mobile robot (AMR) and may further comprise a robotic arm (315’, fig 6) to pick items from the storage container in the pick position and place them on shelving. The vehicle my comprise a body 310, mounted on a movement means / castors 302, comprising the storage section, the handling mechanism and a pick station section 304. A system for handling storage containers is also claimed.

Description

SYSTEMS AND DEVICES FOR STOCK MANAGEMENT

Field of the invention

The invention relates to systems and devices for managing stock in stores. In particular, the present invention relates to systems and devices for managing and replenishing stocks of items stored on shelving within a store, and systems and devices for handling storage containers containing items that are to be stored on shelving within a store.

Background

In traditional supermarket, grocery and other stores with stock that is relatively quick moving, the shelves need to be regularly replenished for the flow of customers through the store. Typically, store shelf replenishment is a manual task which is carried when the store is closed, or during quiet times when the store is open, to minimise the disruption to shoppers due to obstructing the shopping aisles. However, this means that shelf replenishment most often takes place at night, which increases costs as night workers are typically paid a higher rate to compensate for the unsociable hours. In addition, limiting replenishment activities to when the store is closed or during quiet times prevents replenishment during busier periods for items whose stock is already low or has run out.

It is against this background that the present invention has been devised. Summary of the invention According to a first aspect, there is provided vehicle for handling a plurality of storage containers, the vehicle comprising: a container storage section that is arranged to accommodate the plurality of storage containers in a vertical arrangement; and a container handling mechanism that is arranged to convey a target storage container from the container storage section to a pick position at which content of the target storage container can be accessed.

The pick position may be horizontally displaced relative to the container storage section, and the container handling mechanism may then be at least partially arranged to displace the target storage container horizontally.

The vehicle may comprise a body mounted on a movement means that is arranged to allow the body to be moved. The body may comprise the container storage section and the container handling mechanism.

The container storage section may further comprise a loading port that is arranged to allow more than one storage container to be loaded into and unloaded from the container storage section. Preferably, the loading port is provided in a side of the container storage section that faces away from the pick positon. The loading port may be arranged to allow a stack of storage containers to be loaded into and unloaded from the container storage section, such that multiple storage containers can be loaded/unloaded simultaneously.

The vehicle may be configured to operate as any of an autonomous vehicle and an autonomous mobile robot (AMR), and may then further comprise a robotic arm that is arranged to pick items from within a storage container presented at the pick position and place them on shelving. The vehicle may comprise a pillar on which the robotic arm is movably mounted such that the robotic arm is capable of moving vertically along the pillar. The vehicle may comprise a body mounted on a movement means that is arranged to allow the body to be moved, wherein the body comprises the container storage section and the container handling mechanism. The vehicle may comprise a base, the movement means being mounted to a bottom surface of the base, the body being disposed at a first end of a top surface of the base and the pillar being disposed at an opposite, second end of the top surface of the base. The pick position may be located between the first end of the base and the second of the base, and the loading port may be provided in a side of the container storage section that faces away from the pillar and the robotic arm.

The container storage section may be arranged to accommodate the storage containers in a vertical sequence and the container handling mechanism is arranged to convey the storage containers to the pick position section sequentially. The container storage section may be arranged to store a first in the sequence of storage containers bottommost in the container storage section and a last in the sequence of storage containers topmost in the container storage section, and the container handling mechanism may then be arranged to convey the bottommost storage container from the container storage section to the pick position.

The container storage section may be arranged to accommodate a vertical stack of storage containers, and the container handling mechanism may then be arranged to convey the storage containers to the pick position in the order in which they are stacked.

The vehicle may comprise a body mounted on a movement means that is arranged to allow the body to be moved, the body comprising the container storage section, the container handling mechanism, and a pick station section that is arranged to provide the pick position. The container storage section may be horizontally adjacent to the pick station section, and the container handling mechanism may then be arranged to convey a target storage container horizontally from container storage section to the pick station section. The pick station section may comprise an access opening provided in the body through which an inside of a storage container can be accessed when presented at the pick position provided by the pick station section. The access opening may be provided in the horizontal upper surface of the pick station section.

The container handling mechanism may be arranged to separate the bottommost storage container from the stack of storage containers within the container storage section, convey the storage container horizontally from the bottom of the container storage section to the bottom of the pick station section, and then convey the storage container vertically from the bottom of the pick station section to the access opening. The container handling mechanism may comprise: a container separation mechanism that is arranged to vertically separate the bottommost storage container from the stack of storage containers within the container storage section; and a container displacement mechanism that is arranged to convey the separated storage container horizontally from the bottom of the container storage section to the bottom of the pick station section, and to lift the separated storage container from the bottom of the pick station section towards the access opening and hold the storage container adjacent to or within the access opening.

The body may further comprise an outfeed port that is arranged to allow a storage container to be removed from the pick station section, and an infeed port that is arranged to allow a storage container to be placed at the top of a stack within the container storage section.

The container storage section may be arranged to accommodate a vertical stack of storage containers, and the container handling mechanism may then be arranged to separate a target storage container from the stack and move the target storage container between a stowed position and the pick position. The container handling mechanism may comprise: a container separation mechanism arranged to vertically separate a target storage container from at least a portion of the stack of storage containers within the container storage section; and a container displacement mechanism that is arranged to horizontally extract the target storage container out of the container storage section from the stowed position to the pick position.

The container displacement mechanism may be arranged to move the target storage container vertically upwards before moving the target storage container horizontally.

The container storage section may be arranged to accommodate a plurality of storage containers in a vertically spaced arrangement, and the container handling mechanism may then be arranged to move a target storage container between a stowed position and the pick position. The container handling mechanism may comprise a container displacement mechanism for each of the plurality of storage containers that are accommodated in the container storage section, and each container displacement mechanism may then be arranged to horizontally extract target storage container out of the container storage section from the stowed position to a pick position.

According to a second aspect, there is provided a system for handling storage containers. The system comprises: a vehicle comprising a body arranged to accommodate a stack of storage containers and a loading port that is arranged to allow a stack of storage container to be loaded into and unloaded from the body; and a container handling apparatus comprising a first container handling unit arranged to load a stack of storage containers into the vehicle through the loading port, and a second container handling unit for unloading a stack of storage containers from the vehicle through the loading port.

The first container handling unit may comprise a container loading conveyor that is arranged to support multiple stacks of storage containers and to convey a stack into the body of the vehicle; and the second container handling unit may comprise a container unloading conveyor that is arranged to support multiple stacks of storage containers and to convey stack away from the body of the vehicle.

The first container handling unit may be arranged to be able to convey a stack of storage containers in a loading direction (i.e. towards a vehicle), whilst the second container handling unit may be arranged to be able to convey a stack of storage containers in an opposite, unloading direction (i.e. away from a vehicle).

The vehicle may comprise a container handling mechanism that is arranged to receive a stack of storage containers from the first container handling unit, convey the stack into the body of the vehicle, convey the stack out of the body of the vehicle and transfer the vertical stack to the second container handling unit. The container handling mechanism of the vehicle may be arranged to be able to convey a vertical stack of storage containers through the loading port in both the loading and unloading directions. The system may comprise a vehicle according to the third aspect.

There is also provided a system for managing shelving stock. The system comprises: one or more movable shelving units arranged in rows extending in a first direction and that are arranged to be movable in a second direction perpendicular to the first direction; each movable shelving unit having a front and a rear that are at least partially open and comprising a plurality of shelves that are open from the rear to the front of the movable shelving unit; and each movable shelving unit is arranged to be movable between a first position in which a rearward separation of the movable shelving unit is at a minimum and a frontward separation is at a maximum and a second position in which the rearward separation of the movable shelving unit is at a maximum and a frontward separation is at a minimum; wherein each movable shelving unit is arranged such that the frontward separation of the movable shelving unit defines a front aisle when in both the first position and the second position and such that the rearward separation of the movable shelving unit defines a rear aisle when in the second position.

In addition, there is also provided a method of managing shelving stock, the shelving comprising one or more movable shelving units arranged in rows extending in a first direction and that are arranged to be movable in a second direction perpendicular to the first direction. Each movable shelving unit having a front and a rear that are at least partially open, and comprising a plurality of shelves that are open from the rear to the front of the movable shelving unit. The method comprises: i) moving at least one of the movable shelving units from a first position to a second position in which the rearward separation of the movable shelving unit defines a rear aisle; ii) using the rear aisle to access the rear of the movable shelving unit and to deposit items on one or more of the shelves through the at least partially open rear of the movable shelving unit; and iii) moving the at least one movable shelving unit from the second position to the first position.

Other variations and advantages will become apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the invention will now be described, by way of example only, and with reference to the accompanying drawings, in which: Figure 1A is a perspective view of a system for managing shelving stock in a first mode of operation; Figure 18 is a perspective view of the system of Figure 1A in a second mode of operation; Figure 1C is an alternative perspective view of the system of Figure 1A in the second mode of operation; Figure 2A is a perspective view of a shelving unit suitable for use with the system of Figures 1A to 1C; Figure 2B is a cutaway side view of the shelving unit of Figure 2A; Figure 3A is a cutaway side view of an alternative shelving unit suitable for use with the system of Figures 1A to 1C; Figure 38 is a perspective view of the shelving unit of Figure 3A; Figure 3C is a partial cutaway view of the shelving unit of Figure 3A; Figure 4 is a perspective view of a conventional vehicle that is used to perform replenishment; Figure 5 is a perspective view of a vehicle for handling a plurality of storage containers; Figure 6 is a perspective view of a first alternative vehicle for handling a plurality of storage containers; Figure 7 is a perspective view of a system for handling storage containers; Figures 8A and 8B are perspective views of a second alternative vehicle for handling a plurality of storage containers; Figures 9A and 9B are perspective views of a third alternative vehicle for handling a plurality of storage containers; Figure 10 is a perspective view of a fourth alternative vehicle for handling a plurality of storage containers; Figure 11 is a perspective view of a fifth alternative vehicle for handling a plurality of storage containers; and Figure 12 is perspective view of the system of Figure 1A in the second mode of operation. In the figures, like features are denoted by like reference signs where appropriate.

Detailed description

The following embodiments represent preferred examples of how the invention may be practiced, but they are not necessarily the only examples of how this could be achieved. These examples are described in sufficient detail to enable those skilled in the art to practice the invention. Other examples may be utilised and structural changes may be made without departing from the scope of the invention as defined in the appended claims. Moreover, direction references and any other terms having an implied orientation are given by way of example to aid the reader's understanding of the particular examples described herein. They should not be read to be requirements or limitations, particularly as to the position, orientation, or use of the invention unless specifically set forth in the appended claims. Similarly, connection references (e.g., attached, coupled, connected, joined, secured, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other, unless specifically set forth in the appended claims. Similarly, wording such as "movement in the n-direction" and any comparable wording, where n is one of x, y or z, is intended to mean movement substantially along or parallel to the n-axis, in either direction (i.e., towards the positive end of the n-axis or towards the negative end of the n-axis).

Figures 1A to 1C illustrate a system 100 for managing stock (i.e. a supply/quantity of items) stored on shelving within a store. The system 100 comprises a number of movable shelving units 101 that are arranged in rows extending in a first direction (X) and that are arranged to be movable in a second direction (Y) perpendicular to the first direction.

Each movable shelving unit 101 has a front 101A and a rear 101B and is arranged to be movable between a first position and a second position. In the first position, a rearward separation (DR) of the movable shelving unit 101 is at a minimum and a frontward separation (DF) is at a maximum. In the second position, the rearward separation (DR) of the movable shelving unit 101 is at a maximum and a frontward separation (DF) is at a minimum. To illustrate this, Figure 1A shows four movable shelving units 101 that are all in the first position, whilst Figures 1B and 1C show the two left-hand shelving units 101 in the second position whilst the two right hand shelving units 101 have remained in the first position.

In Figures 1A to 1C, each of the movable shelving units 101 is arranged with the rear of the movable shelving unit adjacent to, and facing towards the rear 101B of another of the movable shelving units 101 such that the rearward separation (DR) of the movable shelving unit 101 is a distance between the rear 101B of the movable shelving unit 101 and the rear 101B of the nearest adjacent movable shelving unit 101. However, the rearward separation (DR) of a movable shelving unit 101 more generally refers to the distance between the rear 101B of the movable shelving unit 101 and any adjacent object, such as a wall or an adjacent shelving unit. Similarly, the frontward separation (DF) is the distance between the front 101A of the movable shelving unit 101 and any opposing object, such as a wall or an opposing shelving unit.

Each movable shelving unit 101 is also arranged such that the frontward separation (Dr) of the movable shelving unit 101 defines a front aisle 102 when in both the first position and the second position, and such that the rearward separation (DR) of the movable shelving unit 101 defines a rear aisle 103 when in the second position. To enable this, each movable shelving unit 101 can be provided with at least one front stop (not shown) that prevents movement of the movable shelving unit 101 beyond the second position, with the location of the front stop being arranged to ensure that the frontward separation (Dr) defines a front aisle 102 when the movable shelving unit 101 is in the second position.

Whilst not essential, it is preferable that the rearward separation (DR) of the movable shelving unit 101 does not define a rear aisle 103 when in the first position so as to maximise the size of the front aisle 102. In other words, it is preferable that, when in the first position, the rearward separation (DR) of the movable shelving unit 101 is negligible. Each movable shelving unit 101 can therefore also be provided with at least one rear stop (not shown) that prevents movement of the movable shelving unit 101 beyond the first position, with the location of the rear stop being arranged to ensure that the movable shelving unit 101 does not collide with any adjacent object.

The front aisle 102 provides a passage between the front 101 of the movable shelving unit 101 and an adjacent object through which users (i.e. shoppers/customers) can access the stock of items on the shelving units 101 in order to remove items. In contrast, the rear aisle 103 provides a passage between the rear 101B of a movable shelving unit 101 and an adjacent object through which the stock of items on the shelves can be replenished. For example, Figure 1C shows a user with a trolley passing through the rear aisle 103 defined between two movable shelving units 101 that are in the second position, with the trolley being used as a vehicle for transporting storage containers containing additional items of stock for replenishing the shelves from the rear. The front aisle 102 can therefore be referred to as a shopping or depletion aisle whilst the rear aisle 103 can be referred to as a replenishment aisle. In a preferable arrangement, the rearward separation (DR) of the movable shelving unit 101 when in the second position is sufficient to allow a vehicle to move along the rear aisle 103 so that items transported on the vehicle can be deposited on one or more of the shelves of the movable shelving unit 101.

Each movable shelving unit 101 comprises a plurality of shelves 105 that are open from the rear 10113 to the front 101A of the movable shelving unit 101, such that each shelf 105 is open across the full width of the shelving unit 101. The front 101A and rear 101B of each movable shelving unit 101 is then at least partially open such that both the front 101A and rear 10113 of each shelf 105 can be accessed in order to allow depletion from the front 101A and replenishment from the rear 101B.

In Figures 1A to 1C, the movable shelving units 101 are arranged in pairs, with each pair comprising a first shelving unit 101 and a second shelving unit 101, with a rear 101B of the first shelving unit 101 adjacent to and facing towards a rear 10113 of the second shelving unit 101. Consequently, within each pair, a front 101A of the first shelving unit 101 faces away from the second shelving unit 101 and a front 101A of the second shelving unit 101 faces away from the first shelving unit 101. As a result, if the plurality of shelving units 101 are arranged in a number of parallel rows, then the front 101A of each shelving unit 101 faces towards the front 101A of the nearest shelving unit 101 of any neighbouring shelving unit pair. For each pair of shelving units, the first shelving unit 101 is moveable between a first position in which the rearward separation (DR) between first shelving unit 101 and the second shelving unit 101 is at a minimum and a second position in which the rearward separation (DR) between first shelving unit 101 and the second shelving unit 101 is at a maximum.

Whilst Figures 1A to 1C show a system 100 in which all of the shelving units are movable, in an alternative arrangement the system 100 could comprise one or more stationary shelving units. These stationary shelving units would essentially be the same as the movable shelving units 101 but without the ability to move. Each stationary shelving unit would then be arranged with the rear of the stationary unit adjacent to the rear 101B of one of the movable shelving units 101 such that the rearward separation (DR) of the movable shelving unit 101 would be the distance between the rear 101B of the movable shelving unit 101 and the rear of the stationary shelving unit. In other words, the shelving units could be arranged in pairs, with each pair comprising a first shelving unit and a second shelving unit, with one of the first and second shelving units being movable and the other of the first and second shelving units being stationary. Movement of the movable shelving unit 101 from the first position to the second position would then result in the opening of a rear aisle 103 between the stationary shelving unit and the movable shelving unit 101 through which a the stock of items on both the stationary shelving unit and the movable shelving unit 101 can be replenished.

In Figures 1A to 1C, the system 100 comprises, for each movable shelving unit 101, a number of guide rails or tracks 106 that are configured to guide movement of the moveable shelving unit 101 between the first position and the second position. The moveable shelving units 101 are partially supported by the guide rails 106 during movement between the first position and the second position. In this example, each movable shelving unit 101 is provided with wheels or rollers (not shown) that rest upon and are retained by the guide rails 106 such that they can only move along the path defined by the guide rails 106. In an alternative arrangement, each movable shelving unit 101 is provided with wheels, continuous tracks, or rollers that rest upon the floor, and are also provided with corresponding rails that cooperate with the guide rails 106 to restrict the movement of the movable shelving unit 101 to the path defined by the guide rails 106.

In Figures 1A to 1C, the guide rails 106 are embedded in the floor beneath the movable shelving units 101, and do not protrude beyond the surface of the floor in order to minimise the risk that they will obstruct passage through the front and rear aisles 102, 103. In an alternative embodiment, the guide rails could be provided above the movable shelving units 101, attached to or suspended from a ceiling. The moveable shelving units 101 could then either be suspended from the guide rails during movement or could move on wheels, continuous tracks or rollers that contact the floor beneath the movable shelving units 101 whilst the guide rails restrict the movement of the movable shelving unit 101 to the path defined by the guide rails.

During a first mode of system operation, the movable shelving units 101 are in the first position, with the rearward separation (DR) of the movable shelving units 101 at a minimum and the frontward separation (Dr) at a maximum, so as to maximise the size of the front aisles 102. In this first mode, users (e.g. customers) can pass through the front aisles 102 and access items on the shelves 105 through the front 101A of the shelving units 101. Then, when any of the shelving units 101 require replenishment, the system changes in to a second mode operation. In this second mode, at least one of the movable shelving units 101 is moved from the first position to the second position in which the rearward separation (DR) of the movable shelving unit 101 is at a maximum and a frontward separation (Dr) is at a minimum, such that rearward separation (DR) of the movable shelving unit 101 defines a rear aisle 103. In this second mode, the rear aisle 103 enables access to the rear 101B of the shelving units 101 so that items can be deposited onto the shelves 105 through the rear 101B of the shelving units 101. In this second mode, whilst the frontward separation (DR) is at a minimum, the frontward separation (Dr) still defines a front aisle 102 through which users (e.g. customers) can pass and access items on the shelves 105 through the front 101A of the shelving units 101. Consequently, users can continue to access items on the shelves 105 even when they are being replenished and, whilst the front aisle 102 will be narrowed, can do so without any obstructions in the front aisle 102. When replenishment has been completed, and there are no longer any users (i.e. staff) and/or vehicles in the rear aisle 103, the system 100 can return to the first mode by moving the at least one movable shelving unit 101 from the second position to the first position.

Figures 2A and 2B illustrate a shelving unit 101 suitable for use with the system 100 of Figures 1A to 1C. In Figure 2, the shelving unit 101 comprises a plurality of shelves 105 that are vertically spaced, substantially horizontal and that are supported between first and second vertical end members 107. The shelving unit 101 further comprises a plurality of vertical divider members 108 that divide up each shelf 105 into a plurality of horizontal sections. Dividing each shelf 105 into horizontal sections provides that, if required, each section can be used to store a different type of item. In an alternative arrangement (not shown), each shelving unit could comprise a framework comprising vertical members and horizontal members which are supported by the vertical members, with substantially horizontal shelf surfaces supported upon the horizontal members.

As shown in Figure 2B, the shelves 105 of the shelving unit 101 are arranged to slope relative to horizontal such that items placed away from the front 101A of the shelving unit 101 are encouraged towards the front 101A of the shelving unit 101 by gravity. Specifically, the shelves 105 are fixed to slope downwards, at an acute angle 0, from the rear 101B of the shelving unit 101 towards the front 101A of the shelving unit 101. The front 101A of the each shelf 105 is then provided with a ridge or barrier 109 that prevents items placed on the shelf 105 from falling off the front edge. The shelves are therefore capable of conveying items placed away from the front 101A of the shelving unit 101 towards the front 101A of the shelving unit 101. To support this, the surface of the shelves 105 may be low friction. Alternatively, the sloped shelf 105 could be provided by a gravity roller such that items placed away from the front 101A of the shelving unit 101 will roll under gravity towards the front 101A of the shelving unit 101.

Figures 3A to 3C illustrate an alternative shelving unit 101' suitable for use with the system 100 of Figures 1A to 1C. In this alternative arrangement, rather than the shelves being sloped, the shelving unit 101' comprises a motorized shelf conveyor system 110' that is capable of conveying items placed away from the front 101A' of the shelving unit 101' towards the front 101A' of the shelving unit 101'.

In the arrangement shown in Figures 3A to 3C, the motorized shelf conveyor system 110' comprises a belt conveyor system in which items stored on a shelf 105' rest upon a shelf belt 111' of the belt conveyor system. A head pulley (not shown) of the shelf belt 111' is then driven by a motor 112' provided at an end of the shelving unit 101'. In this example, the motor 112' drives a driving pulley (not shown) that in turn drives a driver belt 113'. The driver belt 113' then drives a number of driven pulleys 114' disposed at the end of each shelf 105' and that are each mounted to the same shaft (not shown) as the head pulley of the shelf belt 111'. The motor 112' can then be activated in order to drive the shelf belt 111' forward and thereby convey items on the shelves 15' towards the front 101A' of the shelving unit 101'. Once again, the front of the each shelf 105' is provided with a ridge or barrier 109' that prevents items placed on the shelf 105' from falling off the front edge.

The motor 112' of the motorized shelf conveyor system 110' can be controlled by a shelf conveyor controller (not shown). The shelf conveyor controller could then be configured to activate the motor 112' at regular intervals. Alternatively, the shelving unit 101' can also be provided with shelf sensors (not shown) that can be used to detect when there are no items at the front of each shelf 105', and the shelf conveyor controller could then be configured to activate the motor 112' when there are no items at the front of one or more of the shelves 105'. For example, the shelf sensors could comprise a contact or proximity sensor for each shelf 105', with each sensor being arranged to detect the presence or absence of an item at the front of the shelf 105'. As an alternative example, the shelf sensors could comprise image sensors that observe each shelf 105' and that are provided as part of a vision system. The vision system could then be configured to determine, from images captured by the image sensors, whether or not there are items at the front of one or more of the shelves 105'.

In grocery retail, inbound items normally arrive at a distribution location on a pallet, stacked closely together. These pallets of inbound items are then separated and placed, individually or in groups corresponding to their stock keeping unit (SW) into separate storage containers for storage and subsequent distribution to retail stores. Replenishment operations therefore usually require the use of a vehicle to transport these storage containers containing additional items of stock around the store. Figure 4 illustrates an example of a conventional vehicle that is used to perform replenishment.

In Figure 4, the vehicle takes the form of a manually operated trolley 200. The trolley 200 comprises a rack 201 mounted on castors 202, the rack 201 comprising a framework 203 of interconnected vertical members and horizontal members. The rack 201 also comprises a plurality of horizontal support rails 204 mounted to the framework 203 that are arranged in vertically spaced pairs, each pair of support rails 204 being configured to support a storage container (C). In use, a storage container (C) containing additional items of stock is inserted horizontally onto a pair of support rails 204 of the trolley 200. An operator then pushes the trolley 200 around the store to reach shelves that require replenishment, at which point the operator slides one of the storage containers along the pair of support rails 204 until it is at least partially out of the framework 203 to access the contents of the storage container, removes items from the storage container and places the items on a shelf before sliding the storage container back until it is fully supported by the pair of support rails 204. This approach is entirely manual, relying on the operator to move storage containers in and out of the framework 203 and to support a storage container whilst picking and placing items. It also requires the operator to bend down to reach into the lower storage containers and/or stretch to reach into the upper storage containers stored in the rack 201.

Figure 5 then illustrates an improved vehicle 300 for handling a plurality of storage containers (C). The vehicle 300 comprises a body 301 mounted on a movement means 302 that is arranged to allow the body 301 to be moved. The body 301 comprises a container storage section 303, a pick station section 304 and a container handling mechanism 305. The container storage section 303 is arranged to accommodate a plurality of storage containers in a vertical arrangement such that the plurality of storage containers are arranged one above the other in vertical alignment. The pick station section 304 is arranged to present one of the plurality of storage containers to a pick position at which the content of the storage container can be accessed so as to allow items to be picked (i.e. removed) from within the storage container. The container handling mechanism 305 is arranged to convey a storage container from the container storage section 303 to the pick position.

In the arrangement shown in Figure 5, the container storage section 303 is arranged to accommodate a vertical stack of storage containers, in which all but the bottom storage container rests upon a storage container below. However, in an alternative arrangement each storage container could be supported upon one of plurality of vertically spaced shelves or rails. Carrying the storage containers vertically (i.e. relative to a horizontal surface upon which the vehicle is supported), minimises the footprint of the vehicle 300. The provision of a separate pick station section 304 and a container handling mechanism 305 that conveys storage containers from the container storage section 303 to the pick station section 304 then reduces the manual effort required to access items in the storage containers. The provision of a separate pick station section 304 also provides that the height of the container storage section 303 can be greater than the height of the pick station section 304, which in turn provides that the height of the container storage section 303 is not necessarily restricted by the height of the operator such that the number of the storage containers that can be transported on the vehicle 300 is greater than on a conventional trolley.

In the arrangement illustrated in Figure 5, the container storage section 303 is arranged to accommodate a vertical stack of storage containers and the container handling mechanism 305 is then arranged to convey the storage containers to the pick station section 304 in the order in which they stacked. The container storage section 303 therefore accommodates the storage containers in a vertical sequence and the container handling mechanism 305 conveys the storage containers to the pick station section 304 sequentially. Specifically, the container storage section 303 is arranged to store a first in the sequence of storage containers bottommost in the container storage section 303, and a last in the sequence of storage containers topmost in the container storage section 303. The container handling mechanism 305 is then arranged to convey the bottommost storage container from the container storage section 303 to the pick station section 304. The vehicle 300 therefore further comprises a container handling controller (not shown) for controlling the container handling mechanism 305. In particular, the container handling controller is configured to activate the container handling mechanism 305 so as to move a first in the sequence of storage containers to be presented at the pick position provided by the pick station section 304.

In the arrangement illustrated in Figure 5, the container storage section 303 is horizontally adjacent to the pick station section 304. Consequently, the container handling mechanism 305 is arranged to convey a storage container horizontally from the bottom of the container storage section 303 to the bottom of the pick station section 304.

The pick station section 304 comprises an access opening 308 provided in the body 301 through which an inside of a storage container can be accessed when presented at the pick position provided by the pick station section 304. As shown in Figure 5, a suitable storage container (C) typically comprises an open box, i.e. having a base, sides and an open top through which the inside of the storage container can be accessed. Such a storage container could also have a lid that covers the open top, with the lid being removable or hinged to allow the open top of the storage container to be exposed. Consequently, when using such a storage container, the access opening 308 should be arranged so as to allow the open top of a storage container to be accessed. In the arrangement illustrated in Figure 5, the access opening 308 is provided on the horizontal upper surface of the pick station section 304.

However, in an alternative arrangement, the access opening 308 could be provided towards the top of a non-horizontal surface of the pick station section 304. For example, in an alternative arrangement the container storage section 303 and pick station section 304 could be the same height, with the access opening 308 then being provided in a vertical side surface of the pick station section 304 so that the contents of a storage container can be accessed by reaching through the access opening 308.

In the arrangement illustrated in Figure 5, the container handling mechanism 305 is therefore arranged to separate the bottommost storage container from the stack of storage containers within the container storage section 303, convey the storage container horizontally from the bottom of the container storage section 303 to the bottom of the pick station section 304, and then convey the storage container vertically from the bottom of the pick station section 304 to the access opening 308. The container handling mechanism 305 therefore comprises a container separation mechanism 310, and a container displacement mechanism 311.

The container separation mechanism 310 is arranged to vertically separate the bottommost storage container from the stack of storage containers within the container storage section 303, either by lifting the rest of the stack away from the bottommost storage container or by lowering the bottommost storage container away from the rest of the stack. In this example, the container separation mechanism 310 comprises container engagement members (not shown) that are vertically movable (using known means such as a ball screw mechanism or a belt drive) on one or more vertical rails 306 provided within the container storage section 303 and that are arranged to releasably engage a storage container. The container separation mechanism 310 can then be operated to move the container engagement members to the vertical position of the storage container immediately above the bottommost storage container. The container engagement members can then engage the storage container and move vertically upwards to lift the engaged storage container (and any storage containers that are stacked on top) away from the bottommost storage container. In Figure 5, it can be seen that the bottommost container has been vertically separated from the storage containers above.

The container engagement members may comprise any suitable mechanism for engaging a storage container. For example, the container engagement members may comprise one or more engaging features configured to move towards and away from the stack to engage and release corresponding features on a storage container. For example, the engaging features of the container engagement members may comprise one or more apertures, recesses, protrusions, rims, etc. arranged to engage corresponding apertures, recesses, protrusions, rims, etc. provided on each storage container. The container separation mechanism may then comprise one or more actuators for moving the engaging features towards and away from the stack. The engaging features may be moved relative to a portion of the container engagement members, or the container engagement members may move as a whole towards and away from the stack. The actuator may be a linear actuator. The actuator may be any suitable type of actuator, e.g. pneumatic, hydraulic, electric, etc. The container displacement mechanism 311 is then arranged to convey the separated storage container horizontally from the bottom of the container storage section 303 to the bottom of the pick station section 304, and to then lift the separated storage container from the bottom of the pick station section 304 towards the access opening 308 and hold the storage container adjacent to or within the access opening 308. In this example, the container displacement mechanism 311 comprises a container conveyor (e.g. a roller conveyor or a belt conveyor) that is arranged to convey the separated storage container horizontally from the bottom of the container storage section 303 to the bottom of the pick station section 304. The container displacement mechanism 311 then further comprises a container lifting mechanism 312 that is essentially the same as the container separation mechanism 310 described above in that it comprises container engagement members (not shown) that are vertically movable (using known means such as a ball screw mechanism or a belt drive) on one or more vertical rails 307 provided within the pick station section 304 and that are arranged to releasably engage a storage container. The container engagement members can then engage a storage container at the bottom of the pick station section 304 and move vertically upwards to lift the engaged storage container. In Figures, it can be seen that a storage container has been lifted to and is held within the access opening 308 of the pick station section 304.

In the arrangement illustrated in Figure 5, the access opening 308 also provides an outfeed port 309 that is arranged to allow a storage container to be removed from the pick station section 304. The body 301 then further comprises an infeed port 313 that is arranged to allow a storage container to be placed at the top of stack within the container storage section 303 (i.e. at an end of the sequence).

The infeed port 313 is therefore provided towards a top of the container storage section 303 and is arranged to allow a storage container to be inserted into the container storage section 303. Specifically, the infeed port 313 is provided in a side of the container storage section 303 that faces towards the pick station section 304. This arrangement provides that a storage container that is removed from the body 301 through outfeed port 309 can then be easily returned to container storage section 303 by inserting the storage container through the infeed port 313.

The container storage section 303 then further comprises a loading port 314 that is arranged to allow more than one storage container to be loaded into and unloaded from the container storage section 303. The loading port 314 is provided in a side of the container storage section 303 that faces away from the pick station section 304. In the arrangement illustrated in Figure 5, the loading port 314 is provided in the side of the container storage section 303 that is opposite to the side that faces the pick station section 304. However, in an alternative arrangement, the loading port 314 could be provided in one of the two sides that are perpendicular relative to the side that faces the pick station section 304. As described above, in the arrangement shown in Figure 5 the container storage section 303 is arranged to support a vertical stack of storage containers. The loading port 314 is therefore arranged to allow a stack of storage containers to be loaded into and unloaded from the container storage section 303, such that multiple storage containers can be loaded/unloaded simultaneously (i.e. in a single action).

As shown in Figure 5, the body 301 comprises a framework of interconnected vertical members and horizontal members and a casing that at least partially covers the framework. The framework partially defines both the container storage section 303 and the pick station section 304 of the body 301. The casing then comprises a number of casing panels that cover the majority of the exterior of the framework, with some of the casing panels being provided with openings that form the access opening/outfeed port 308, 309, the infeed port 313 and the loading port 314. The movement means 302 then comprises a number of castors mounted to the bottom of the framework, such that the vehicle 300 therefore takes the form of a manually operated trolley. However, in alternative arrangements the movement means could equally comprise any other movement means such as wheels, continuous tracks or rollers.

At the start of a replenishment operation, a vertical stack of storage containers is loaded on to the vehicle 300 by inserting the stack through the loading port 314. At this point, the storage containers would typically be at least partially filled with items that are intended to be transported to and deposited on the shelving. Prior to loading the storage containers, the sequence of the storage containers in the vertical stack would be determined based on the efficient routing of the vehicle 300 through the shelving. For example, a storage container containing items that are to be placed on the first in a row of shelves would be located at the bottom of the vertical stack, and therefore first in the sequence, whilst a storage container containing items that are to be placed on the last in a row of shelves would be located at the top of the stack, and therefore last in the sequence. The vehicle 300 is then used to transport the storage containers around the store to reach a shelf that requires replenishment, and the container handling mechanism 305 conveys the next in the sequence of storage containers to be presented at the pick position provided by the pick station section 304. An operator then removes items from the storage container presented at the pick position and places the items on a shelf. When no further items are required from the storage container, or the storage container is empty, the operator then removes the storage container from the pick station section 304 through the outfeed port 309 and returns it to the end of the sequence by inserting it through the infeed port 313. At the end of a replenishment operation, the storage containers are unloaded from the vehicle 300 by removing them through the loading port 314. At this point, the number of items in the storage containers would be less than at the start, with most if not all being empty.

Figure 6 illustrates a first alternative arrangement of an improved vehicle for handling a plurality of storage containers. The vehicle of Figure 6 is similar to that of Figure 5 and corresponding reference numerals have therefore been used for like or corresponding parts or features. However, in the arrangement of Figure 6 the vehicle 300' is capable of autonomously performing replenishment operations. The vehicle of Figure 6 therefore further comprises a robotic arm 315' that is arranged to pick items from within a storage container presented at the pick position provided by the pick station section 304' and place them on shelving. The vehicle 300' is also configured to operate as an automated or autonomous vehicle, e.g. an automated guided vehicle (AGV) which is capable of following fixed routes, or an autonomous mobile robot (AMR) which is capable of planning its own routes.

In the arrangement illustrated in Figure 6, the vehicle 300' comprises a pillar or stand 316' on which the robotic arm 315' is movably mounted such that the robotic arm 315' is capable of moving vertically along the pillar 316'. The robotic arm 315' then comprises an end effector 317' at a distal end, the end effector 317' being arranged to enable the robotic arm 315' to pick/remove items from within a storage container. The vehicle 300' then comprises a base 320', with the body 301' comprising the container storage section 303' and the pick station section 304' being disposed at a first end of the base 320' and the pillar 316' being disposed at an opposite, second end of the base 320'. The movement means 302' then comprises a number of motorized wheels mounted to the bottom of the base 320' that are configured to allow the vehicle to move in a plurality of directions. However, in alternative arrangements the movement means could equally comprise any other motorized movement means such as motorized continuous tracks or rollers.

The vehicle 300' of Figure 6 then further comprises a control system (not shown) that is configured to enable the vehicle 300' to autonomously perform replenishment operations. To do so, the control system is configured to receive inputs from a number of sensors and to use these inputs to coordinate the movement of the vehicle 300', the operation of the container handling mechanism 305', and the operation of the robotic arm 315'. For example, the control system could be configured to receive inputs from one or more sensors that detect characteristics of the environment surrounding the vehicle 300', and one or more sensors that detect the presence of a storage container at the pick station section 304' and the contents of the storage container. These sensors could be either on-board or off-board sensors such as image sensors, proximity sensors, collision sensors, motion sensors etc. The control system could therefore also be provided with a receiver for receiving data from off-board sensors. The control system further comprises a motion controller for controlling the movement means 302' and thereby controlling autonomous movement of the vehicle 300', a robotic controller for controlling the robotic arm 315', a container handling controller for controlling the container handling mechanism 305', and a master controller for coordinating control between the robotic controller, the motion controller and the container handling controller.

In the arrangement illustrated in Figure 6, the robotic arm 315' is arranged to remove a storage container from the pick station section 304' through the outfeed port 309' and return it to the end of the sequence by inserting it through the infeed port 313'. However, in an alternative arrangement, the container handling mechanism 305' could be arranged to return a storage container from the pick station section 304 to the container storage section 303'. In such an alternative arrangement, container storage section 303' and the pick station section 304 could be the same height, with the container handling mechanism 305' then being arranged to lift a storage container to the top of the pick station section 304' before moving the storage container horizontally through the infeed port 313' into the container storage section 303'. The access opening 308' could then be provided in a vertical side surface of the pick station section 304' so that the contents of a storage container can be accessed by the robotic arm 315' reaching through the access opening 308'.

Figure 7 then illustrates a system for handling storage containers, the system comprising a container handling apparatus 400 and a vehicle 300 such as those illustrated in Figures 5 and 6. As described above, the vehicle 300 comprises a body 301 arranged to accommodate a vertical stack of storage containers and a loading port 314 that is arranged to allow more than one storage container to be loaded into and unloaded from the body 301. The container handling apparatus 400 then comprises a first container handling unit 401 arranged to load a plurality of storage containers into the vehicle 300 through the loading port 314, and a second container handling unit 402 for unloading a plurality of storage containers from the vehicle 300 through the loading port 314.

In the arrangements shown in Figures Sand 6, the body 301 of the vehicle 300 is arranged to support a vertical stack of storage containers. The loading port 314 is therefore arranged to allow a stack of storage containers to be loaded into and unloaded from the body 301, such that multiple storage containers can be loaded/unloaded simultaneously (i.e. in a single action). The first container handling unit 401 therefore comprises a container loading conveyor 403 that is arranged to support multiple vertical stacks of storage containers and to convey a vertical stack of storage containers into the body 301 of the vehicle 300. The second container handling unit 402 then comprises a container unloading conveyor 404 that is arranged to support multiple vertical stacks of storage containers and to convey a vertical stack of storage containers away from the body 301 of the vehicle 300. Consequently, the first container handling unit 401 is arranged to be able to convey a vertical stack of storage containers in a loading direction (i.e. towards a vehicle 300), whilst the second container handling unit 402 is arranged to be able to convey a vertical stack of storage containers in an opposite, unloading direction (i.e. away from a vehicle 300).

The container handling mechanism 305 of the vehicle 300 is then arranged to be able to receive a vertical stack of storage containers from the first container handling unit 401, convey the vertical stack into the body 301 of the vehicle 300, convey the vertical stack out of the body 301 of the vehicle 300 and transfer the vertical stack to the second container handling unit 402. The container handling mechanism 305 of the vehicle 300 is therefore arranged to be able to convey a vertical stack of storage containers through the loading port 314 in both the loading and unloading directions.

In the arrangement shown in Figure 7, the container conveyors of both the first and second container handling units 401, 402, and the container handling mechanism 305 of the vehicle 300, comprise roller conveyors that are arranged to convey vertical stacks of storage containers horizontally. However, they could equally comprise any other suitable form of conveyor system, such as a belt conveyor Figures 8A and 85 illustrate a second alternative arrangement of an improved vehicle 500 for handling a plurality of storage containers. The vehicle 500 of Figures 8A and 85 is similar to that of Figure 5 in that in comprises a container storage section 503, a pick station section 504 and a container handling mechanism 505. However, in the arrangement of Figures 8A and 85 the vehicle 500 is capable of receiving and handling storage containers (C) that are stacked on a dolly (D).

In the arrangement shown in Figures 8A and 88, the vehicle 500 comprises a body 501 mounted on a movement means 502 that is arranged to allow the body 501 to be moved. The body 501 comprises the container storage section 503, the pick station section 504 and the container handling mechanism 505. The container storage section 503 is arranged to retain a plurality of storage containers in a vertical arrangement such that the plurality of storage containers are arranged one above the other in vertical alignment. The pick station section 304 is arranged to present one of the plurality of storage containers to a pick position at which the content of the storage container can be accessed so as to allow items to be picked (i.e. removed) from within the storage container. The container handling mechanism 505 is arranged to convey a storage container from the container storage section 503 to the pick position.

In the arrangement shown in Figures 8A and 8B, the container storage section 503 is arranged to accommodate a dolly (D) supporting a stack of storage containers (C). The container handling mechanism 505 is then arranged to convey the storage containers to the pick station section 504 in the order in which they stacked. Specifically, the container handling mechanism 505 is arranged to convey the bottommost storage container from the container storage section 503 to the pick station section 504. The vehicle 500 therefore further comprises a container handling controller (not shown) for controlling the container handling mechanism 505. In particular, the container handling controller is configured to activate the container handling mechanism 505 so as to move a first in the sequence of storage containers to be presented at the pick position provided by the pick station section 504.

In the arrangement shown in Figures 8A and 8B, the container storage section 503 is horizontally adjacent to the pick station section 504. Consequently, the container handling mechanism 505 is arranged to convey a storage container horizontally from the bottom of the container storage section 503 to the bottom of the pick station section 504.

The pick station section 504 comprises an access opening 508 provided in the body 501 through which an inside of a storage container can be accessed when presented at the pick position provided by the pick station section 504. In the arrangement illustrated in Figures 8A and 8B, the access opening 508 is provided on the horizontal upper surface of the pick station section 504. However, in an alternative arrangement, the access opening 508 could be provided towards the top of a non-horizontal surface of the pick station section 504. For example, in an alternative arrangement the container storage section 503 and pick station section 504 could be the same height, with the access opening 508 then being provided in a vertical side surface of the pick station section 504 so that the contents of a storage container can be accessed by reaching through the access opening 508.

In the arrangement illustrated in Figures 8A and 8B, the container handling mechanism 505 is therefore arranged to separate the bottommost storage container from the stack of storage containers within the container storage section 503, displace the bottommost storage container away from the dolly and convey the storage container horizontally from the bottom of the container storage section 503 to the bottom of the pick station section 504, and then convey the storage container vertically from the bottom of the pick station section 504 to the access opening 508. The container handling mechanism 505 therefore comprises a container separation mechanism 510 and a container displacement mechanism 511.

The container separation mechanism 510 is arranged to vertically separate the bottommost storage container from the stack of storage containers within the container storage section 503. To do so, the container separation mechanism 510 can be arranged to either lift the rest of the stack away from the bottommost storage container or lift the entire stack away from the dolly and then lower the bottommost storage container away from the rest of the stack. In this example, the container separation mechanism 510 comprises container engagement members (not shown) that are vertically movable (using known means such as a ball screw mechanism or a belt drive) on one or more vertical rails 506 provided within the container storage section 503 and that are arranged to releasably engage a storage container. The container separation mechanism 510 can then be operated to move the container engagement members to the vertical position of the storage container immediately above the bottommost storage container. The container engagement members can then engage the storage container and move vertically upwards to lift the engaged storage container (and any storage containers that are stacked on top) away from the bottommost storage container.

The container displacement mechanism 511 is then arranged to displace the bottommost storage container away from the dolly and convey the storage container horizontally from the bottom of the container storage section 503 to the bottom of the pick station section 504, and then convey the storage container vertically from the bottom of the pick station section 504 to the access opening 508. In this example, the container displacement mechanism 511 comprises displacement members (not shown) that are horizontally moveable to allow the displacement members to engage and horizontally extract the bottommost storage container out of the container storage section 503. In particular, at least a portion of each displacement member is horizontally moveable between an extended position that is at least partially within the container storage section 503 and a retracted position that is entirely within the pick station section 504. For example, each displacement member could comprise a retractable arm configured to linearly extend and retract in a horizontal direction between the inserted position and the extracted position.

Each displacement member is configured to releasably engage the bottommost storage container in the container storage section 503 so that once engaged, the storage container can be horizontally moved by horizontally moving the displacement member. Similar to the container engagement members, the displacement members may comprise any suitable mechanism for engaging the bottommost storage container. For example, each displacement member may comprise one or more engaging features configured to move toward and away from the stack to engage and release corresponding features on a storage container. The engaging features may, for example, be one or more protrusions (e.g. extending in a horizontal direction towards the stack), recesses, apertures, etc. The displacement members may comprise one or more actuators for moving the engaging features towards and away from the stack. The engaging features may be moved relative to a portion of the displacement members, or the displacement members may move as a whole towards and away from the stack. The actuator may be a linear actuator. The actuator may be any suitable type of actuator, e.g. pneumatic, hydraulic, electric, etc. Once the displacement members have engaged the target storage container, the arms of the displacement members are then configured to retract from the extended position to the retracted position and thereby horizontally extract the bottommost storage container out of the container storage section 503. Before horizontally moving the bottommost storage container out of the container storage section 503, the displacement members may be configured to first move vertically upwards so that the bottommost storage container is clear of the dolly below it. This may be required if the storage containers comprise interlocking stacking features, for example.

The container displacement mechanism 511 then further comprises a container lifting mechanism 512 that is essentially the same as the container separation mechanism 510 described above in that it comprises container engagement members (not shown) that are vertically movable (using known means such as a ball screw mechanism or a belt drive) on one or more vertical rails 507 provided within the pick station section 504 and that are arranged to releasably engage a storage container.

The container engagement members can then engage a storage container at the bottom of the pick station section 504 and move vertically upwards to lift the engaged storage container. In Figure 8A, it can be seen that a storage container has been lifted to and is held within the access opening 508 of the pick station section 504.

In the arrangement illustrated in Figures 8A and 8B, the access opening 508 also provides an outfeed port 509 that is arranged to allow a storage container to be removed from the pick station section 504. The body 301 then further comprises an infeed port 513 that is arranged to allow a storage container to be placed at the top of stack within the container storage section 503 (i.e. at an end of the sequence) The container storage section 503 then comprises a loading port 514 that is arranged to allow more than one storage container to be loaded into and unloaded from the container storage section 503.

The loading port 514 is provided in a side of the container storage section 503 that faces away from the pick station section 504. In the arrangement illustrated in Figures 8A and 8B, the loading port 514 is provided in the side of the container storage section 503 that is opposite to the side that faces the pick station section 504. As described above, in the arrangement shown in Figures 8A and 8B the container storage section 503 is arranged to receive and retain a dolly (D) supporting a stack of storage containers (C). The loading port 514 is therefore arranged to allow a dolly supporting a stack of storage containers to be loaded into and unloaded from the container storage section 503, such that multiple storage containers can be loaded/unloaded simultaneously (i.e. in a single action). The container storage section 503 then further comprises a dolly retention mechanism (not shown) that is arranged to releasably engage a dolly within the container storage section 503. When engaged by the dolly retention mechanism, the dolly is held in position within the container storage section 503 and will therefore move with the vehicle 500. At the end of a replenishment operation, the dolly retention mechanism can be disengaged so that the dolly and the stack of storage containers supported on the dolly can be unloaded from the container storage section 503.

In the arrangement shown in Figures 8A and 8B, the vehicle 500 further comprises an electronic visual display 521 arranged to present information to an operator of the vehicle. For example, the electronic visual display 521 could be arranged to display picking information (e.g. maps, routes, product images, location information etc.) that assists the operator in selecting an item and locating the correct shelf associated with that item. The information would be provided to the electronic visual display 521 by either an on-board or off-board computer-implemented stock management system.

Alternatively or additionally, the electronic visual display 521 could be arranged to display live images of the surroundings of the vehicle 500, and particularly the area in front of the vehicle 500, which then assists the operator in safely manoeuvring the vehicle 500. In such an arrangement, the vehicle 500 could further comprise an on-board video camera (not shown) that is arranged to capture images of at least the area in front of the vehicle 500 and provide the images to the electronic visual display 521. Alternatively, the vehicle 500 could comprise a receiver (not shown) that is arranged to receive images captured by one or more off-board video cameras, such that this off-board images can then be presented on the electronic visual display 521.

In the arrangement shown in Figures 8A and 88, the electronic visual display 521 is disposed on the side of the container storage section 503 that faces towards the pick station section 504. The electronic visual display 521 could be a touchscreen, or alternatively the vehicle 500 could be provided with a separate user input device, which would therefore allow the operator to interact with an on-board or off-board computer-implemented stock management system.

Alternatively or additionally, the vehicle 500 could further comprise a scanner or vision system that is arranged to select and/or verify an item picked by the operator. For example, the vehicle 500 could comprise a scanner that is arranged to read either a machine-readable optical label, such a barcode or OR code, or a radio-frequency identification (RFID) or near-field communication (NFC) tag that is applied or attached to an item presented to the scanner, and communicate with either an on-board or off-board computer-implemented stock management system to verify that the item is correct/as expected.

Figures 9A and 98 illustrates a third alternative arrangement of an improved vehicle 500' for handling a plurality of storage containers. The vehicle of Figures 9A and 98 is similar to that of Figures 8A and 88 and corresponding reference numerals have therefore been used for like or corresponding parts or features. However, in the arrangement of Figures 9A and 95 the vehicle 500' is capable of autonomously performing replenishment operations. The vehicle of Figures 9A and 9B therefore further comprises a robotic arm 515' that is arranged to pick items from within a storage container presented at the pick position provided by the pick station section 504' and place them on shelving. The vehicle 500' is also configured to operate as an automated or autonomous vehicle, e.g. an automated guided vehicle (AGV) which is capable of following fixed routes, or an autonomous mobile robot (AMR) which is capable of planning its own routes.

In the arrangement illustrated in Figures 9A and 9B, the vehicle 500' comprises a pillar or stand 516' on which the robotic arm 515' is movably mounted such that the robotic arm 515' is capable of moving vertically along the pillar 516'. The robotic arm 515' then comprises an end effector 517' at a distal end, the end effector 517' being arranged to enable the robotic arm 515' to pick/remove items from within a storage container. The vehicle 500' then comprises a body 501' comprising the container storage section 503' and the pick station section 504'. The container storage section 503' is disposed at a first end of the body 501' and the pillar 316' is disposed at an opposite, second end of the body 501', with the pick station section 504' being disposed between the container storage section 503' and the pillar 316'. The movement means 502' then comprises a number of motorized wheels mounted to the bottom of the body 501' that are configured to allow the vehicle to move in a plurality of directions. However, in alternative arrangements the movement means could equally comprise any other motorized movement means such as motorized continuous tracks or rollers.

The vehicle 500' of Figures 9A and 98 then further comprises a control system (not shown) that is configured to enable the vehicle 500' to autonomously perform replenishment operations. To do so, the control system is configured to receive inputs from a number of sensors and to use these inputs to coordinate the movement of the vehicle 500', the operation of the container handling mechanism 505', and the operation of the robotic arm 515'. The control system further comprises a motion controller for controlling the movement means 502' and thereby controlling autonomous movement of the vehicle 500', a robotic controller for controlling the robotic arm 515', a container handling controller for controlling the container handling mechanism 505', and a master controller for coordinating control between the robotic controller, the motion controller and the container handling controller.

In the arrangement illustrated in Figures 9A and 9B, the robotic arm 515' is arranged to remove a storage container from the pick station section 504' through the outfeed port 509' and return it to the end of the sequence by inserting it through the infeed port 513'. However, in an alternative arrangement, the container handling mechanism 505' could be arranged to return a storage container from the pick station section 504 to the container storage section 503'. In such an alternative arrangement, container storage section 503' and the pick station section 504' could be the same height, with the container handling mechanism 505' then being arranged to lift a storage container to the top of the pick station section 504' before moving the storage container horizontally through the infeed port 513' into the container storage section 503'. The access opening 508' could then be provided in a vertical side surface of the pick station section 504' so that the contents of a storage container can be accessed by the robotic arm 515' reaching through the access opening 508'.

Figure 10 illustrates a fourth alternative arrangement of an improved vehicle 600 for handling a plurality of storage containers. The vehicle 600 of Figure 10 is similar to those of Figures 6, 9A and 9B in that it is capable of autonomously performing replenishment operations. The vehicle of Figure 10 therefore comprises a robotic arm 615 that is arranged to pick items from within a storage container presented at a pick position and place them on shelving. The vehicle 600 is also configured to operate as an automated or autonomous vehicle, e.g. an automated guided vehicle (AGV) which is capable of following fixed routes, or an autonomous mobile robot (AMR) which is capable of planning its own routes.

The vehicle 600 of Figure 10 comprises a body 601 mounted towards a first end of the base 620, the base 620 being mounted on a movement means 602. The body 601 comprises a container storage section 603 and a container handling mechanism 605. The container storage section 603 is arranged to accommodate a plurality of storage containers in a vertical arrangement such that the plurality of storage containers (C) are arranged one above the other in vertical alignment. The container handling mechanism 605 is then arranged to convey a target storage container of the plurality of storage containers to a pick position so as to allow items to be picked (i.e. removed) from within the storage container.

A pillar or stand 616 is then mounted towards an opposite, second end of the base 620, with a robotic arm 615 movably mounted to the pillar 616 such that the robotic arm 615 is capable of moving vertically along the pillar 616. The robotic arm 615 then comprises an end effector 617 at a distal end, the end effector 617 being arranged to enable the robotic arm 615 to pick/remove items from within a storage container that is in a pick position. The movement means 602 then comprises a number of motorized wheels mounted to the bottom of the base 620 and that are configured to allow the vehicle to move in a plurality of directions. However, in alternative arrangements the movement means could equally comprise any other motorized movement means such as motorized continuous tracks or rollers.

In the arrangement illustrated in Figure 10, the container storage section 603 is arranged to accommodate a plurality of storage containers (C) in a vertical stack. The container storage section 603 then further comprises a loading port 614 that is arranged to allow a stack of storage containers to be loaded into and unloaded from the container storage section 603, such that multiple storage containers can be loaded/unloaded simultaneously (i.e. in a single action). The loading port 614 is provided in a side of the container storage section 603 that faces away from the pillar 616 and the robotic arm 615. In the arrangement illustrated in Figure 10, the loading port 614 is provided in the side of the container storage section 603 that is opposite to the side that faces the pillar 616 and the robotic arm 615.

The container handling mechanism 605 is then arranged to separate a target storage container from the stack and move the target storage container between a stowed position and the pick position. The container handling mechanism 605 therefore comprises a container separation mechanism 610 and a container displacement mechanism 611.

The container separation mechanism 610 is arranged to vertically separate a target storage container from at least a portion of the stack of storage containers within the container storage section 603, either by lifting those storage containers above it away from the target storage container or by lowering the target storage container away from those above it. In this example, the container separation mechanism 610 comprises container engagement members (not shown) that are vertically movable (using known means such as a ball screw mechanism or a belt drive) on one or more vertical rails 606 provided within the container storage section 603 and that are arranged to releasably engage a storage container. The container separation mechanism 610 can then be operated to move the container engagement members to the vertical position of the storage container immediately above the target storage container. The container engagement members can then engage the storage container and move vertically upwards to lift the engaged storage container (and any storage containers that are stacked on top) away from the target storage container.

In this example, the container engagement members may comprise any suitable mechanism for engaging a storage container. For example, the container engagement members may comprise one or more engaging features configured to move towards and away from the stack to engage and release corresponding features on a storage container. For example, the engaging features of the container engagement members may comprise one or more apertures, recesses, protrusions, rims, etc. arranged to engage corresponding apertures, recesses, protrusions, rims, etc. provided on each storage container. The container separation mechanism may then comprise one or more actuators for moving the engaging features towards and away from the stack. The engaging features may be moved relative to a portion of the container engagement members, or the container engagement members may move as a whole towards and away from the stack. The actuator may be a linear actuator. The actuator may be any suitable type of actuator, e.g. pneumatic, hydraulic, electric, etc. In this example, the container displacement mechanism 611 comprises displacement members 612 that are vertically moveable along one side of the container storage section 603 to allow the displacement members 612 to reach the vertical position of the target storage container. Similar to the container engagement members, the displacement members 612 are vertically moveable on vertical rails 607 that are mounted on the outside of the container storage section 603. The displacement members 612 may move on the rails 607 using known means such as a ball screw mechanism or a belt drive. The displacement members 612 are also horizontally moveable to allow the displacement members 612 to engage and horizontally extract the target storage container out of the stack. In particular, at least a portion of the each displacement member 612 is horizontally moveable between an inserted position that is at least partially within the container storage section 603 and an extracted position that is entirely outside of the container storage section 603. In this example, each displacement member 612 comprises a retractable arm configured to linearly extend and retract in a horizontal direction between the inserted position and the extracted position.

Each displacement member 612 is configured to releasably engage a target storage container in the stack so that once engaged, the target storage container can be vertically and/or horizontally moved by vertically and/or horizontally moving the displacement member 612 respectively. Similar to the container engagement members, the displacement members 612 may comprise any suitable mechanism for engaging the target storage container. For example, each displacement member 612 may comprise one or more engaging features configured to move toward and away from the stack to engage and release corresponding features on a storage container. The engaging features may, for example, be one or more protrusions (e.g. extending in a horizontal direction towards the stack), recesses, apertures, etc. The displacement members 612 may comprise one or more actuators for moving the engaging features towards and away from the stack. The engaging features may be moved relative to a portion of the displacement members 612, or the displacement members 612 may move as a whole towards and away from the stack. The actuator may be a linear actuator. The actuator may be any suitable type of actuator, e.g. pneumatic, hydraulic, electric, etc. Once the displacement members 612 have engaged the target storage container, the arms of the displacement members 612 are then configured to retract from the inserted position to the extracted position and thereby horizontally extract target storage container out of the container storage section 603 to a pick position. Figure 10 shows a target storage container has been extracted to a pick position by the displacement members 612. Before horizontally moving the target storage container out of the container storage section 603, the displacement members 612 may be configured to first move vertically upwards so that the target storage container is clear of the container below it. This may be required if the storage containers comprise interlocking stacking features, for example.

The vehicle 600 further comprises a control system (not shown) configured to enable the vehicle 600 to autonomously perform replenishment operations. To do so, the control system is configured to receive inputs from a number of sensors and to use these inputs to coordinate the movement of the vehicle 600, the operation of the container handling mechanism 605, and the operation of the robotic arm 615. For example, the control system could be configured to receive inputs from one or more sensors that detect characteristics of the environment surrounding the vehicle 600, and one or more sensors that detect the presence of a storage container in a pick position and the contents of the storage container. These sensors could be either on-board or off-board sensors such as vision sensors, proximity sensors, collision sensors, motion sensors etc. The control system could therefore also be provided with a receiver for receiving data from off-board sensors. The control system further comprises a motion controller for controlling the motorized wheels and thereby controlling autonomous movement of the vehicle 600, a robotic controller for controlling the robotic arm 615, a container handling controller for controlling the container handling mechanism 605, and a master controller for coordinating control between the robotic controller, the motion controller and the container displacement controller.

Figure 11 illustrates a fifth alternative arrangement of an improved vehicle 700 for handling a plurality of storage containers. The vehicle 700 of Figure 11 is similar to that of Figures 6, 9A, 9B and 10 in that it is capable of autonomously performing replenishment operations. The vehicle of Figure 11 therefore comprises a robotic arm 715 that is arranged to pick items from within a storage container presented at a pick position and place them on shelving. The vehicle 700 is also configured to operate as an automated or autonomous vehicle, e.g. an automated guided vehicle (AGV) which is capable of following fixed routes, or an autonomous mobile robot (AMR) which is capable of planning its own routes.

The vehicle 700 of Figure 11 comprises a body 701 mounted towards a first end of the base 720, the base 720 being mounted on a movement means 702. The body 701 comprises a container storage section 703 and a container handling mechanism 705. The container storage section 703 is arranged to accommodate a plurality of storage containers in a vertical arrangement such that the plurality of storage containers (C) are arranged one above the other in vertical alignment. The container handling mechanism 705 is then arranged to convey a target storage container of the plurality of storage containers to a pick position so as to allow items to be picked (i.e. removed) from within the storage container.

A pillar or stand 716 is then mounted towards an opposite, second end of the base 720, with a robotic arm 715 movably mounted to the pillar 716 such that the robotic arm 715 is capable of moving vertically along the pillar 716. The robotic arm 715 then comprises an end effector 718 at a distal end, the end effector 718 being arranged to enable the robotic arm 715 to pick/remove items from within a storage container that is in a pick position. The movement means 702 then comprises a number of motorized wheels mounted to the bottom of the base 720 that configured to allow the vehicle to move in a plurality of directions. However, in alternative arrangements the movement means could equally comprise any other motorized movement means such as motorized continuous tracks or rollers.

The container storage section 703 then further comprises a loading port 714 that is arranged to allow a plurality of storage containers to be loaded into and unloaded from the container storage section 703. The loading port 714 is provided in a side of the container storage section 703 that faces away from the pillar 716 and the robotic arm 715. In the arrangement illustrated in Figure 11, the loading port 714 is provided in the side of the container storage section 703 that is opposite to the side that faces the pillar 716 and the robotic arm 715.

In the arrangement illustrated in Figure 11, the container storage section 703 is arranged to support a plurality of storage containers in a vertically spaced arrangement such that each storage container is vertically separated from those above and/or below it in the container storage section 703. The container handling mechanism 705 is then arranged to move a target storage container between a stowed position in which the target storage container is vertically aligned in the container storage section 703 and a pick position in which the target storage container is horizontally displaced relative to the container storage section 703. The container handling mechanism 705 therefore comprises a container displacement mechanism 711 for each of the plurality of storage containers that are supported in the container storage section 703.

In this example, the container storage section 703 comprises a plurality of horizontal support rails 704 that are arranged in vertically spaced pairs, each pair of support rails 704 being configured to support a storage container (C). Each container displacement mechanism 711 then comprises displacement members (not shown) that are horizontally moveable to allow the displacement members to engage and horizontally displace the respective storage container. In particular, each displacement member is horizontally moveable between an inserted position that is within the container storage section 703 and an extracted position that is at least partially outside of the container storage section 703. In this example, each displacement member comprises a retractable arm configured to linearly extend and retract in a horizontal direction between the inserted position and the extracted position. The displacement members may comprise one or more actuators for moving the retractable arms. The actuators may be linear actuators and may be any suitable type of actuator, e.g. pneumatic, hydraulic, electric, etc. The arms of the displacement members are configured to extend from the inserted position to the extracted position and thereby horizontally displace the respective storage container from the stowed position, out of the container storage section 703 to a pick position. Figure 11 shows a target storage container has been extracted to a pick position by the respective displacement members.

The vehicle 700 further comprises a control system (not shown) configured to enable the vehicle 700 to autonomously perform replenishment operations. To do so, the control system is configured to receive inputs from a number of sensors and to use these inputs to coordinate the movement of the vehicle 700, the operation of the container handling mechanism 705, and the operation of the robotic arm 715. For example, the control system could be configured to receive inputs from one or more sensors that detect characteristics of the environment surrounding the vehicle 700, and one or more sensors that detect the presence of a storage container in a pick position and the contents of the storage container. These sensors could be either on-board or off-board sensors such as vision sensors, proximity sensors, collision sensors, motion sensors etc. The control system could therefore also be provided with a receiver for receiving data from off-board sensors. The control system further comprises a motion controller for controlling the motorized wheels and thereby controlling autonomous movement of the vehicle 700, a robotic controller for controlling the robotic arm 715, a container handling controller for controlling the container handling mechanism 705, and a master controller for coordinating control between the robotic controller, the motion controller and the container displacement controller.

Figure 12 illustrates an example of a system for managing and replenishing shelving stock. In this example, the system 100 comprises a number of movable shelving units 101, such as those described in relation to Figures 1A to 1C, and a vehicle 300', 500', 600, 700 that is capable of autonomously performing replenishment operations, such as those described in relation to any of Figures 6, 9A, 9B, and 11. The system 100 then further comprises a control system (now shown) for controlling the management of shelving stock. To do so, the control system is configured to receive inputs from a number of sensors and to use these inputs to identify shelves that should be replenished, control the movement of the movable shelving unit 101, and coordinate the operation of the autonomous vehicle 300', 500', 600, 700. The control system may also be configured to control the operation of a motorized shelf conveyor system and/or control the loading of storage containers on to the autonomous vehicle 300', 500', 600, 700.

For example, the control system could comprise a vision system comprising a number of image sensors 107 that are configured to capture images of the shelving, and one or more processors (not shown) that are configured to analyse the images of the shelving to identify shelves that require additional stock (e.g. shelves on which there are no items, shelves on which the number of items is lower than a threshold or shelves on which there is space for additional items). The control system could then use this information to identify specific storage containers containing items require replenishment and to determine the order in which these storage containers should be loaded on to the autonomous vehicle. The control system would then control the movement of the movable shelves 101 such that they move from the first position to the second position to thereby define a rear aisle 103 through which the autonomous vehicle 300', 500', 600, 700 can pass. The control system would then coordinate the movement of the autonomous vehicle 300', 500', 600, 700 as it travels through the rear aisle, and the operation of a container handling mechanism and the robotic arm of the autonomous vehicle 300', 500', 600, 700 so as to pick items from particular storage containers on to appropriate shelves of the shelving units. Optionally, the shelving units 101 could be provided with an indicator lighting system or electronic shelf labels that the control system would be arranged to control in order to highlight the appropriate destination/location for the next item.

It will be appreciated that while the devices, apparatus, system and methods described herein are described using grocery systems as an example, the systems and devices for managing and replenishing stocks are not limited to systems directed to groceries. For example, the technology can be applied to shipping, baggage handling, vehicle parking, indoor or hydroponic greenhouses and farming, modular buildings, self-storage facilities, cargo handling, transport switchyards, manufacturing facilities, pallet handling, parcel sortation, airport logistics (ULD) and general logistics to name but a few possible applications. It will be appreciated that stock replenishment systems of different types will have different technical requirements.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and/or shown in the drawings, whether or not particular emphasis has been placed thereon.

It will be appreciated that a mechanism can be designed for a particular application using various combinations of devices and arrangements described above. It will be appreciated that the features described hereinabove may all be used together in a single system. In other embodiments of the invention, some of the features may be omitted. The features may be used in any compatible arrangement. Many variations and modifications not explicitly described above are possible without departing from the scope of the invention as defined in the appended claims.

For example, Figures 1A to It illustrate a system for managing and replenishing stock that comprises a number of movable shelving units. These movable shelving units can be moved forward in order to open up a rear aisle through which the shelves can be replenished whilst maintaining a front aisle through which the shelves can be depleted. When a replenishment operation has been completed, the movable shelving units can be reversed in order to close the rear aisle and increase the size of the front aisle. However, in an alternative system, each shelving units could be stationary but could be arranged to persistently define both a rear aisle and a front aisle. The front aisle would then be accessible to users who would be depleting the shelves (e.g. shoppers/customers) whilst the rear aisle would be accessible for replenishment operations, preferably with access to the rear aisle being restricted and/or controlled (e.g. by a permanent or temporary barrier). This arrangement has the advantage of allowing continuous replenishment without the complexity of movable shelving units. In addition, whilst a persistent rear aisle consumes space within a store, the ability to continuously replenish shelves provides that individual shelves can hold smaller quantities of each item and can therefore be smaller, thereby offsetting the space consumed by the rear aisle. Furthermore, the width of the rear aisle can be reduced when replenishment operations are conducted autonomously, by an autonomous robot such as those described in relation to Figures 6, 8 and 9.

As a further example, whilst the arrangements disclosed herein have been described with reference to their use in replenishing shelving stock, they could equally be used for reverse operations, wherein items are picked from the shelves into storage containers. In particular, the systems and vehicles described above could all be used to implement in-store fulfilment operations.

Claims

CLAIMS1. A vehicle for handling a plurality of storage containers, the vehicle comprising: a container storage section that is arranged to accommodate the plurality of storage containers in a vertical arrangement; and a container handling mechanism that is arranged to convey a target storage container from the container storage section to a pick position at which content of the target storage container can be accessed.
2. A vehicle according to claim 1, wherein the container storage section further comprises a loading port that is arranged to allow more than one storage container to be loaded into and unloaded from the container storage section, and preferably the loading port is provided in a side of the container storage section that faces away from the pick positon.
3. A vehicle according to claim 2, wherein the loading port is arranged to allow a stack of storage containers to be loaded into and unloaded from the container storage section.
4. A vehicle according to any of claims 1 to 3, wherein the vehicle is configured to operate as any of an autonomous vehicle and an autonomous mobile robot (AMR), and further comprises a robotic arm that is arranged to pick items from within a storage container presented at the pick position and place them on shelving.
5. A vehicle according to any of claims 1 to 4, wherein the container storage section is arranged to accommodate the storage containers in a vertical sequence and the container handling mechanism is arranged to convey the storage containers to the pick position sequentially.
6. A vehicle according to any of claims 1 to 5, wherein the container storage section is arranged to accommodate a vertical stack of storage containers, and the container handling mechanism is arranged to convey the storage containers to the pick position in the order in which they are stacked.
7. A vehicle according to any of claims 1 to 6, wherein the vehicle comprises a body mounted on a movement means that is arranged to allow the body to be moved, the body comprising the container storage section, the container handling mechanism, and a pick station section that is arranged to provide the pick position.
8. A vehicle according to claim 7, wherein the pick station section comprises an access opening provided in the body through which an inside of a storage container can be accessed when presented at the pick position provided by the pick station section.
9. A vehicle according to claim 8, wherein the container handling mechanism is arranged to separate the bottommost storage container from the stack of storage containers within the container storage section, convey the storage container horizontally from the bottom of the container storage section to the bottom of the pick station section, and then convey the storage container vertically from the bottom of the pick station section to the access opening.
10. A vehicle according to claim 9, wherein the container handling mechanism comprises: a container separation mechanism that is arranged to vertically separate the bottommost storage container from the stack of storage containers within the container storage section; and a container displacement mechanism that is arranged to convey the separated storage container horizontally from the bottom of the container storage section to the bottom of the pick station section, and to lift the separated storage container from the bottom of the pick station section towards the access opening and hold the storage container adjacent to or within the access opening.
11. A vehicle according to any of claims 1 to 5, wherein the container storage section is arranged to accommodate a vertical stack of storage containers, and the container handling mechanism is arranged to separate a target storage container from the stack and move the target storage container between a stowed position and the pick position.
12. A vehicle according to claim 11, wherein the container handling mechanism comprises: a container separation mechanism arranged to vertically separate a target storage container from at least a portion of the stack of storage containers within the container storage section; and a container displacement mechanism that is arranged to horizontally extract the target storage container out of the container storage section from the stowed position to the pick position.
13. A vehicle according to any of claims land 2, wherein the container storage section is arranged to accommodate a plurality of storage containers in a vertically spaced arrangement, and the container handling mechanism is arranged to move a target storage container between a stowed position and the pick position.
14. A vehicle according to claim 13, wherein the container handling mechanism comprises a container displacement mechanism for each of the plurality of storage containers that are supported in the container storage section, and each container displacement mechanism is arranged to horizontally extract the target storage container out of the container storage section from the stowed position to a pick position.
15. A system for handling storage containers, the system comprising: a vehicle comprising a body arranged to support a stack of storage containers and a loading port that is arranged to allow a stack of storage containers to be loaded into and unloaded from the body; and a container handling apparatus comprising a first container handling unit arranged to load a stack of storage containers into the vehicle through the loading port, and a second container handling unit for unloading a stack of storage containers from the vehicle through the loading port.
16. A system according to claim 15, wherein the first container handling unit comprises a container loading conveyor that is arranged to support multiple stacks of storage containers and to convey a stack into the body of the vehicle; and the second container handling unit comprises a container unloading conveyor that is arranged to support multiple stacks of storage containers and to convey stack away from the body of the vehicle.
17. A system according to any of claims 15 and 16, wherein the vehicle comprises a container handling mechanism that is arranged to receive a stack of storage containers from the first container handling unit, convey the stack into the body of the vehicle, convey the stack out of the body of the vehicle and transfer the vertical stack to the second container handling unit.
18. A system according to any of claims 15 to 17, wherein the vehicle is a vehicle according to any of claims 1 to 12.