WO2008140293A1

WO2008140293A1 - Warehouse system

Info

Publication number: WO2008140293A1
Application number: PCT/NL2007/000127
Authority: WO
Inventors: Martin Van Esschoten; Richard Ian Mcintosh
Original assignee: Martin Van Esschoten; Richard Ian Mcintosh
Priority date: 2007-05-14
Filing date: 2007-05-14
Publication date: 2008-11-20
Also published as: EP2164781A1

Abstract

The present invention relates to a method for storing and retrieving items in a warehouse which comprises at least one storage row for accommodating carriers, each storage row comprising at least one entry position, the carriers supporting the items, the method comprising: - each time adding a carrier to the at least one storage row at an entry position, such that a plurality of carriers are added to the row via the same entry position; - at times moving at least one of the carriers in the storage row away from said entry position for creating free space at said entry position; - selecting a carrier to be retrieved from the storage row; - retrieving the selected carrier from the storage row by moving the carrier away from the storage row. The present invention also relates to a warehouse system, a carrier and a shop or supermarket.

Description

Warehouse system

Field of the invention

The present invention relates to a method and device for rapidly storing and retrieving items in a warehouse system. Warehouse systems are known in the field of the art. The present invention further relates to a method and device for sorting items.

Description of the related art

There are many known systems for automated storage and retrieval. JP20040123244 discloses a system for storing and retrieving plants, fruit and vegetables in a warehouse system. A disadvantage of the system of JP2004123244 is that the plants are generally supported directly by a storage assembly. This is disadvantageous, because the handling of the plants by the system is difficult. Each plant may have significant different physical characteristics which are to be dealt with by the system.

Other warehouse systems are known in which items are stored and retrieved by a same device. The systems generally have comparatively long response times. Also, in existing warehouse systems, an increased warehouse size generally leads to longer response times. This is problematic for large warehouse systems in which many items are to be stored.

An especially demanding potential application for an automated storage and retrieval system is that of a retail supermarket. In such a situation there could be for example 20,000 different types of items. In order to meet demand, the storage system should store for instance 50 identical products for each item type, e.g. 50 tubes of a specific kind of toothpaste. At peak times there could be 250 or more customers. A customer could on average buy 25 separate items. Once a customer has selected all his desired products, he wants to check out, pay and leave within a relatively short time, e.g. within few minutes and preferably within less than a minute. 25 customers might be waiting for their items at a given instant. The storage and retrieval system would in this instance preferably then be capable of retrieving 25 times 25, i.e. 625 specific items from the warehouse and rapidly deliver the selected items to the associated customer. Simultaneously, the retrieved items should be replaced at a similar average rate into the storage system, in order to warrant a continuous supply.

No automated system is currently available which can satisfactorily meet these high demands for storage and retrieval. As a consequence traditional supermarkets play a dominant role in the market. These supermarkets have disadvantages such as a need for large numbers of costly staff. Customers must also pick items from the racks themselves. Other disadvantages also exist, such as theft, packaging waste and the problem of managing products which have an ultimate sell date. Further, price differentiation in traditional supermarkets is cumbersome.

Summary of the invention

It is an object of the present invention to provide a relatively fast and reliable warehouse system, and a method of storage and retrieval of items for such a warehouse system. It is another object of the invention to substantially- overcome, or at least ameliorate, at least one disadvantage of existing warehouse systems. At least one object is achieved in a method for storing and retrieving items in a warehouse which comprises at least one storage row for accommodating carriers, each storage row comprising at least one entry position, the carriers supporting items of different kinds, the method comprising: - each time adding a carrier to the at least one storage row at an entry position, such that a plurality of carriers is added to the row via the same entry position;

- at times moving at least one of the carriers in the storage row away from said entry position for creating free space at said entry position;

- selecting a carrier to be retrieved from the storage row, wherein the selected carrier is not necessarily the last carrier in the storage row, but may also be another carrier in the storage row; - retrieving the selected carrier from the storage row by moving the carrier away from the storage row.

According to the method, items can be added to the storage rows on a continuous basis or intermittently. Simultaneously, items can be retrieved on a continuous basis or intermittently. Because of the use of carriers, handling is easy and items of very different size, shape, weight and nature can be stored and retrieved.

When retrieving the carrier, the carrier is moved in a different direction than the direction in which the storage row extends at the position of the carrier.

In a suitable embodiment, the method has a high volume capability, i.e. a large number of items can be stored and retrieved per unit of time. In a suitable embodiment, more than one carrier can be retrieved simultaneously. Further, in a suitable embodiment, more than one carrier can be stored simultaneously.

In a suitable embodiment, items can be retrieved quickly, i.e. without a long waiting time (or response time) between the moment of a retrieval instruction for the item and the moment of delivery of the item. In a suitable embodiment, the present invention is scaleable in terms of the number of items that are stored without a substantial deterioration in response time. For known systems, the response time generally deteriorates with a rise in the number of items that are stored. This scalability also applies for the number of simultaneous retrieval operations, to the sizes of the goods that are stored and to the range of goods that are stored.

The present concept is suitable for an automated supermarket, for an automated internet store such as a internet book store. Other applications of the concept are also possible.

Generally, the method will comprise the step of loading at least one item on a carrier prior to adding the carrier to the storage row. This step may be performed at the warehouse or at a location which is remote from the warehouse. Preferably, for the majority of carriers only one item is supported by each carrier.

The carriers may be retrieved manually or by a retrieval organ. Generally, the routes via which the carriers are loaded into the system and the route via which the carriers are retrieved are different. In one embodiment a portion of the routes are shared by carriers which are loaded and carriers which are shared. Generally, the carrier is retrieved from the storage row by- moving the carrier away from the storage row in a direction which is substantially different than the main direction of the storage row at the position of the carrier. Generally, this direction will be substantially perpendicular to the main direction of the storage row at the location of the retrieved carrier.

If the method is used for a shop, store or supermarket different types of items will be stored on the carriers.

In a preferred embodiment there will be a plurality of retrieval organs. Generally, the retrieval organs can act simultaneously and independently of one another.

In a preferred embodiment at least one carrier carrying an item of a first kind is positioned between two carriers each carrying an item of a second kind.

In this way, the same items can be spread at least to a certain degree over the available storage space. When the item is to be retrieved by a movable retrieval organ or a moveable retrieval person, the retrieval time can be kept short, because on average, the distance of a closest item to a position of the retrieval organ or a movable retrieval person will be shorter than in a situation in which the same items are stored together. The carrier carrying this item may thus be chosen. An optimisation of the response time can in addition be based on a travel distance between a carrier and a collecting station, i.e. by choosing a carrier which has a short travel distance compared to carriers with other same items and thus a short travel time period to a collecting station where a customer collects the item from the carrier.

The words Collecting station' indicate a location at which the carrier is delivered and subseguently collected by a user. The words ^Λdelivery station' are also used herein. A response time is defined as the time period between the moment at which an instruction for retrieval of an item is entered into the system and the moment at which the selected item is delivered to a delivery station. The response time may be divided into a retrieval time period and a travel time period. The retrieval time period is the time period required for moving the retrieval arm or person to the selected carrier and then moving the carrier from a storage row to a position on a discharge conveyor directly adjacent the storage row. The travel time period is the time period required for moving the carrier from the position on the storage conveyor to the allocated collecting station.

This spreading of the same items over the available storage space leads to an improved response time. Both the average retrieval time and the average travel time may improve as a result of spreading the same items over the available storage space.

The average retrieval time may improve because there will be more combinations of items and retrieval organs to choose from when a particular item is to be selected.

The average travel time will improve because when there are more carriers to select from, there are more possible routes from the carrier which is to be retrieved to the allocated collecting station to choose from. It is thus likely that a shorter route is available than in a situation wherein items of one kind are stored together, and these items have a substantially similar travel distance from their respective positions to the allocated collecting station, when the carrier is to be selected.

More than one of the same item may be retrieved from different positions within the system simultaneously.

In a preferred embodiment a retrieval system is provided comprising at least one retrieval organ, and wherein the retrieval organ retrieves a carrier from the storage row, and wherein prior to the retrieval of a selected carrier the retrieval organ is moved to the carrier. The retrieval organ will each time move to a selected carrier and retrieve it from the row. In this way, a limited number of retrieval organs are necessary. Alternatively, the carriers may be moved toward the retrieval organ.

Generally, the retrieval organ is moved along the storage row to a selected carrier.

In a preferred embodiment, for the retrieval of an item of a certain type the positions of a number of items in the storage row which are of the selected item type are known or determined, and the item is retrieved which has a preferred position. The positions are in particular determined or known:

- relative to the retrieval organ or retrieval person and/or - relative to the position of a collecting point.

This advantageously improves the response time of the system, because overall the most favourably positioned item may be retrieved.

Equal items having a different position along a same storage row are likely to have different response times. Equal items in different storage rows may also have different response times for retrieval. The item having the shortest response time may, in a suitable embodiment, thus be selected. Alternative selection strategies based on or incorporating other criteria are also possible. Selection criteria are likely to be different in particular where the warehouse system is used either additionally or separately for sorting purposes, including defining the sequence in which items are delivered. As well as a warehouse of a multiplicity of same items, the system is also applicable where there is a multiplicity of unique items, for example parcels at a postal sorting hub. In a preferred embodiment, carriers carrying the same items are supplied to at least two different storage rows by the supply system. This further spreads the items over the storage space thereby further improving the response time of the retrieval system.

In one aspect, a plurality of retrieval organs is configured to retrieve items from a same storage row. This is effective for long storage rows, because the distance of travel of the retrieval organs is thus limited, in particular if the storage row is divided in sectors, wherein each retrieval organ services a particular sector. Another advantage is the possibility of parallel simultaneous retrieval actions.

In one aspect a retrieval organ is configured to retrieve items from a plurality of storage rows, in particular by moving vertically from a storage row at one horizontal level to a storage row at a different horizontal level. It s also possible that a retrieval organ is disposed between two storage rows at a same horizontal level and is configured to retrieve carriers from both storage rows, e.g. in a back-to-back arrangement. In a preferred embodiment, each carrier is associated with an identification code, and wherein a control unit controls the storage and retrieval process on the basis of the identification code. This feature provides good control of the system. In one aspect, the method comprises:

- recording carrier data relating to the kind of items on each carrier;

- recording the actual position of each carrier, which may change over time; - recording retrieval organ position data relating to the position of the at least one retrieval organ;

- selecting a kind of item which is to be retrieved by a user;

- determining a preferred combination of a carrier and a

> retrieval organ for retrieving the item from the storage row. In this way, a short retrieval response time can be achieved. In the case when a carrier which is elsewhere pre-loaded with an item is entered into the system, the carrier data is typically recorded when that pre-loaded carrier is entered into the system. If the loading of an item on a carrier takes place within the system, the carrier data is typically recorded at the time of loading, shortly before or shortly after the loading. In either case carrier data thus links the identification code of the carrier to an item code which identifies the item loaded on the carrier. Other data, for example who was responsible for conducting the loading, may also be recorded.

Generally, prior to the retrieval of a carrier the identification code of the carrier is read by a reader in order to assert that the correct carrier is retrieved.

In one embodiment, the carrier data is regularly updated by reading the identification codes of the carriers in the storage row, in particular by a reader or sensor mounted to the retrieval organs as they move along the storage row. Advantageously, the data in the control unit, in particular relating to the respective carrier positions along the storage rows, is hereby kept correct and up to date.

In a preferred embodiment a storage row to which a carrier is to be added is selected in dependence of the locations of similar items which are already present on the different storage rows. This further improves spreading or scattering the same items over the available storage space, further shortening response times.

In one aspect carriers of different sizes are used. Products of shops or supermarket may have different sizes, and if carriers of for instance 2, 3, 4 or another limited number of sizes are used, more efficient handling and storage is possible.

The present invention also relates to a warehouse system for storing and retrieving items of different kinds which are supported by carriers, the warehouse system comprising: - a storage assembly defining a storage row;

- a supply system configured for adding a plurality of carriers to the storage row at a same entry position;

- a moving device for at times moving at least a portion of the carriers away from the entry position for creating free space at the entry position;

- a retrieval system for retrieving a selected carrier from the storage row by moving the carrier away from the storage row, wherein the selected carrier is not necessarily the last carrier in the storage row, but may also be another carrier in the storage row. Generally, the entry position will be located at one end of the storage row, and generally only one entry position will be used. It is conceivable however that a plurality of entry positions are provided for a single storage row.

Generally, the carriers will be added to the storage row one by one.

In one aspect, the warehouse system comprises a carrier loading device for loading at least one item onto a carrier prior to the entry of the carrier onto the storage row. The carriers may be automatically loaded with items in order to achieve a high throughput.

The loading device can be a system comprising different components, such as a gripping organ which takes the item from a package or tray, and places the item on the carrier. Sensors may be provided to ensure that the loading is performed correctly. The central control unit can be configured to control the loading process .

Automatic loading of the carriers may also take place remote from the warehouse system. Loading could take place directly into carriers at the end of a manufacturing line. If loaded carriers are provided to the warehouse system, carrier data would generally be provided together with the carriers, preferably in electronic format. These data would be loaded into the control unit. Preferably, the warehouse system comprises a plurality of storage rows, wherein the supply system comprises a distribution system for supplying the carrier to a selected storage row. The distribution system is controlled by the control unit and comprises conveyors and routeing switches (or transfer devices) via which the carrier can be routed towards a selected storage row.

In one aspect, the at least one retrieval organ comprises a reader for reading the identification codes of the carriers. Prior to a retrieval operation, the identity of the carrier can thus be checked, in order to assert that the desired carrier is retrieved. Also, during the movement of the retrieval organ along the storage row, the positions of the carriers which are stored by the control unit can be checked and updated.

Preferably, a plurality of retrieval organs are provided and a control unit is provided, the control unit being configured to select which of the retrieval organs is in the most favourable position to retrieve a carrier carrying the selected item, and to control the selected retrieval organ in order to retrieve the selected carrier. A fast response is possible via this selection function. Preferably, a plurality of retrieval organs are provided and a control unit is provided, the control unit being configured to:

- determine for a retrieval organ the positions of carriers carrying items of the desired type relative to the position of the retrieval organ; and

- select which of the carriers should be retrieved by the retrieval organ;

- control the retrieval organ in order to retrieve the selected carrier.

A retrieval organ can thus be guided toward the most suitably positioned carrier, for instance the carrier nearest to the retrieval organ. It is possible that a retrieval organ has a certain retrieval sector and that one or more carriers are located outside the retrieval sector. The control unit will take account of this and will not select this carrier. Preferably, the supply system is configured to distribute items of a same type in a scattered or random fashion over the available storage space. The response time of the total system improves when the same items are not stored together, but stored separately, with carriers carrying other items in between carriers carrying the same items. Moreover, spreading carriers supporting the same items over different storage rows also improves response times, because statistically, the average distance between a carrier which is to be retrieved and a retrieval organ will be smaller, thus leading to a shorter response time.

In the present warehouse system, the supply system and the retrieval system generally are separate systems in order to allow the adding of a carrier to a storage row simultaneous with a retrieval of another carrier from the storage row. The separate systems advantageously have improved response times and a higher throughput capability in comparison to a system having a combined storage and retrieval system in which the same device and/or the same route is used for both loading and unloading.

One embodiment comprises the use of the collecting points as loading points. This embodiment further comprises two operation modes :

- in a retrieval mode the conveyors convey carriers to the collecting stations;

- in a loading mode the carriers convey carriers from the collecting stations into the system.

The route via which the carriers are conveyed into the system will branch off from the retrieval route at a branch point and extends from the branch point to the supply system of the warehouse system. Preferably, the carrier loading device, the supply system and the retrieval system are configured to handle carriers of different sizes .

Items can thus be stored in a suitable carrier, thus leading to more efficient use of storage space. Preferably, the storage rows extend substantially horizontally, and a plurality of storage rows extend in different horizontal planes and/or in different vertical planes. In this way, efficient use of the available volume in a warehouse is possible. The present warehouse system is substantially free of any trolleys or carts onto which the carriers are loaded and which in conventional systems are used for transporting the items, which further simplifies the system. This feature further saves space such as for corridors which are essential in typical existing warehouse systems .

Preferably, the device for moving carriers along a row comprises a conveyor, e.g. a belt conveyor or roller conveyor configured for supporting the carriers and for moving the carriers away from the entry position. In an alternative embodiment, rollers are provided which support the carriers and which allow the carriers to be moved along the storage row. Alternatively, a flat surface with a separate moving device may be provided or a different kind of moving device suitable for moving the carriers. A repeated surface element conveyor may also be used.

In one aspect, the retrieval system comprises at least one discharge conveyor for moving a carrier from the storage row towards a delivery station, which can be a collecting station (also referred to as a pickup station) . In a particular embodiment, a number of storage rows are arranged at different horizontal levels, and wherein at least one retrieval organ is movable from one storage row to a different storage row at a different horizontal level. The number of retrieval organs may thus be limited. Preferably the supply system comprises a receiving station configured for allowing a third party to supply carriers carrying items to the supply system. Item data, i.e. data relating to the items which are carried by the supplied carriers, are recorded into the system by recording means. These recording means may be provided at a remote location where the items are loaded onto the carriers, for example at the location of the third party.

Also, the receiving station may comprise at least one recording means (or sensor) for sensing the at least one received carrier and for recording the item data. The recorded item data may relate to any feature of the item supported by the received carrier. The carrier identification code is thus traceably linked to the item data. The item data may comprise a supplier identification code of a supplying party which has provided the item. The sensed item data may be compared to reference data stored in the system, for validating the items, such as the quality thereof.

One or more inspection operations may be carried out in order to assert that the supplied items are what they are claimed to be by the third party. These inspection operations may be carried out by a human operator in addition to the recording means or sensor.

The recording of the item data may thus be performed at the remote location, at the receiving station or at both locations.

Automatic supply of items on carriers to the system by third parties is thus possible, leading to cost advantages.

Alternatively or additionally, the receiving station is configured to provide empty carriers for a third party bringing items which are not pre-loaded on carriers.

The items which are loaded in the system are thus known by the control unit, allowing control of the storage and retrieval process.

In one aspect, the retrieval system comprises at least one buffer for buffering retrieved carriers prior to the delivery of said carriers to a collecting station.

In one aspect, the retrieval system comprises a distributor conveyor assembly configured for distributing retrieved carriers to a plurality of collecting stations.

In one aspect, the retrieval system comprises:

- a plurality of delivery conveyors, each ending at a respective collecting station for delivering a carrier to the collecting station;

- at least one distributor conveyor;

- a plurality of transfer devices configured for controllably transferring those carriers which are retrieved for a particular customer from the distribution conveyor to the delivery conveyor ending at the collecting station which is allocated to the customer. To this end, the transfer devices have a sensor for reading the identification code of the carrier.

Advantageously, the system is thus capable of delivering goods to different customers simultaneously. The allocation of a collecting station to a customer may be based on: the proximity of the collecting station to a pay station where the customer has paid, or on an analysis of the chosen goods and the collecting station at which these goods can be delivered in the shortest possible time, based on the locations of the items in the storage rows.

In one aspect, the retrieval system comprises at least one collecting conveyor being configured for collecting retrieved carriers from different storage rows. A plurality of collecting conveyors may be provided for collecting carriers from different horizontal levels.

In one embodiment, the retrieval device comprises:

- a distributor conveyor assembly configured for distributing retrieved carriers to a number of collecting stations,

- a number of buffer devices for buffering retrieved carriers for a particular customer, the at least one buffer device being configured for controllably discharging the buffered carriers to the distributor conveyor assembly at a selected time, - at least one collecting conveyor being configured for collecting retrieved carriers from different storage rows; and

- at least one transfer device comprising control means for controllably transferring selected carriers from the collecting conveyor to the at least one buffer device on the basis of the identification code.

In this way, products for one customer may be collected in one or more temporary buffers without clogging up a collecting station. The buffer may be controllably emptied in order for the retrieved items to be moved to the collecting station when the customer is ready to receive the items.

Preferably, the supply system comprises:

- a loading station wherein carriers are supplied to the supply system;

- a distribution conveyor assembly comprising control means for controllably distributing carriers to selected storage rows and allowing a choice to be made for each individual carrier of which storage row the carrier is to be added to.

Generally the choice of which storage row the carrier is added to will be made by the control unit for instance upon loading of the carrier into the system.

In one embodiment, the supply system comprises a supply buffer for temporarily storing carriers. This allows a temporary storage of one or more carriers when the storage row to which the carrier is to be supplied is not yet available, for instance because a retrieval operation is currently being carried out for that storage row.

Generally the supply conveyors of the supply system may be halted for a time period in order to buffer carriers which are present in the supply system.

Preferably, the supply system comprises at least one conveyor which moves the carriers subsequently to the different horizontal levels, a transfer device being provided for transferring a carrier from the conveyor to a selected horizontal level. This conveyor may be spirally formed.

Preferably, the supply system comprises at least one closed loop conveyor. A closed loop conveyor allows a flexible operation of the supply system, and for instance allows buffering of carriers .

Preferably, the at least one closed loop conveyor comprises one or more short cut conveyors, the short cut conveyor branching off from the closed loop conveyor at one point and merging with the closed loop conveyor at another point. The short cut conveyor allows certain carriers to follow a selected route, e.g. a short route, to the selected storage row, or to avoid busy portions of the closed loop conveyor.

A same configuration of short cut conveyors may be provided for the collecting conveyor and/or the distributor conveyor in the retrieval system.

The short cuts allow local buffering of carriers, because a smaller loop within a large loop is created.

The invention further relates to a computer program comprising instructions for carrying out the method of claim 1 on a computer.

The invention also relates to a carrier for use in the warehouse system according to claim 22 and for use in the method according to claim 1.

Preferably, the carrier comprises a support surface for supporting the item, and the carrier further comprises an identification means which is associated with an identification code, identifying the carrier. The identification means is readable. Such a carrier may be effectively used in the present invention. Preferably, the identification means comprises an RFID tag. The RFID tag is preferably placed on an outer surface of the carrier. More than one RFID tag may be provided on the carrier, for instance one on each side.

The invention further relates to a shop or supermarket comprising a warehouse system according to claim 22, the store or supermarket comprising:

- a plurality of items or item displays displayed in a customer area,

- at least one means for recording order data relating to an order of a customer for retrieval of an item;

- a transmitting device for transmitting the order data to the control unit for retrieval of the ordered item;

- at least one collecting station at which a retrieved item can be picked up by a customer; wherein the control unit is configured to process the received order data so as to retrieve at least one ordered item from the at least one storage row and to deliver the at least one ordered item at the at least one collecting station.

The order data may be recorded by a scanner used by a customer to scan or read item data associated with a selected item which is on display. For instance, bar codes may be visible together with each item and the scanner may be used to read the bar codes. The scanner may transmit the order data by wireless means to the control unit or alternatively, a docking bay may be provided in which the scanner is connected with the control unit for the transfer of the order data to the control unit.

Possibly, mobile telephones with suitable inbuilt functionality or other devices incorporating sensors and transmission or downloading means may be used as scanners in order to select products on display.

Possibly, a sensor is provided on the product display and the customer carries a transmitter which transmits a signal to the sensor on the display.

It is also possible that at the product, a visual item identification code is provided. The customer simply notes (i.e. records) the item identification code on an order sheet, and at the end of his visit to the shop hands in the order sheet at a counter, i.e. an order receiving station/pay station. An RFID tag on the product in combination with a scanner used by the customer is also possible. In a suitable alarmed environment this substantially reduces the chance of the displayed items being stolen.

The order receiving station and the pay station may be combined into one combined station or may be separated. For instance, the orders may be entered prior to the receiving of the ordered items, while the payment may be performed after the ordered items have been received.

In an internet store, the order receiving station may be fully electronic.

The warehouse system may also be configured with an on-line store in which customers can select the desired products from a terminal, possible at home. Later, the customers can collect the selected items at a collecting station. The present warehouse system may be fast enough to delay the retrieval of the selected items until the customer arrives and checks in. Then, all selected products may be retrieved. A combination of on-line shopping and home delivery is also possible.

It is also possible that both the entering of the ordered items and the payment are performed prior to receiving the products.

It is also possible that a stack of order sheets or objects is provided near an item, and that he customer simply takes an order sheet or order object for each item he wishes to order. The customer hands in the order sheets or order objects at the end of his visit at a counter or enters the sheets or objects at a order receiving station/pay .station, which may be automated.

Other ways of recording the order data may also be possible, for instance a voice recorder in which the customer simply enters order data by orally naming the type of product and the number of products he wishes to order.

A customer-friendly, high speed shop or supermarket with a ^"limited number of staff is thus achieved.

In one aspect, the shop or supermarket comprises a plurality of collecting stations, wherein the control unit is configured to allocate a specific collecting station to a specific customer, and to deliver the at least one retrieved item to the allocated collecting station. Advantageously, a plurality of customers may shop simultaneously and checkout simultaneously. Preferably the at least one collecting station comprises an area in which the retrieved carriers are collected, which area is closable by means of a door, lid, cover or a similar suitable closing device, and wherein identification means are provided for identifying a customer to which the collecting station is allocated, and wherein the identification means are configured to generate a signal opening the closing device when a customer has been identified.

It can thus be guaranteed that items for a specific customer cannot be taken by a different customer. Preferably, the shop or supermarket comprises a ^Λreal' section wherein products are present which can be selected by a customer, in particular fresh products, and comprising a merging system for merging said products with the items retrieved from the storage rows, in order to deliver both the products from the ^Λreal' section and the products from the storage rows to the same collecting station. These Afresh' products are loaded onto a carrier and the item data is associated with the carrier identification code.

This configuration allows a customer to handpick fresh items in the customer area, and to collect these items at the collecting station.

A coffee shop or small restaurant may be provided in the customer area. Consumed goods may be added to the order data, to be paid at the order receiving station/pay station.

The claims and advantages will be more readily appreciated as the same become better understood by reference to the following detailed description and considered in connection with the accompanying drawings in which like reference symbols designate like parts, or parts with the same or similar function.

Brief Description of the Drawings

Fig. 1 shows perspective view of a carrier according to the invention;

Fig. Ia shows a perspective view of a carrier supporting an item; Fig. 2 shows a perspective view of a storage row according to the invention;

Fig. 2a shows a perspective view of an arrangement of three storage rows according to the invention; Fig. 2b shows a top view of a storage row;

Fig. 3 shows a perspective view of a combination of storage rows and discharge rows;

Fig. 3a shows a perspective view of a scanning and transfer assembly according to the invention;

Fig. 3b shows a side view of a number of storage rows with three retrieval organs;

Figures 3cl, 3c2, 3c3 and 3c4 show perspective views of some embodiments of the retrieval organ; Fig. 3d shows a perspective view of an embodiment of the retrieval organ according to the invention;

Fig. 3e shows a perspective view of an assembly of a number of retrieval organs and a number of storage rows;

Fig. 4 shows a top view of storage rows and discharge rows; Fig 4a shows a diagrammatic perspective view of a storage area; Fig. 4b shows a diagrammatic perspective view of an alternative embodiment of the invention;

Figure 5 shows a schematic top view of a distribution system of the retrieval system; Figure 5a shows a schematic top view of a another distribution system of the retrieval system;

Figure 5b shows a schematic top view of a another distribution system of the retrieval system;

Figure 6 shows a schematic top view of a supermarket or shop according to the invention;

Figure 6a shows a diagrammatic view of a scanner; Figure 7 shows a diagrammatic view of a loading station; Figure 8 shows a schematic top view of a supply system; Figure 9a shows a schematic view of a collecting station; Figure 9b shows a schematic top view of a collecting station; and

Figure 10 shows a plan view of another embodiment of a warehouse.

Detailed Description of the Drawings

Turning to Figs. 1 and Ia, a carrier 10 is shown for supporting an item 12 (also referred to as a product) . The carrier comprises one or more surface (s) 13 which may be inclined to support an item sideways and urge it in a certain orientation and into a certain position, for instance centrally on the carrier. The surface 13 may have a visual pattern 130 or marking to assist in sensing whether the carrier holds an item. The pattern may be a bar code. At least one metal or magnetic strip 14 or disc may be provided, for instance on any side of the carrier, which can assist in handling of the carrier 10 in the system and alignment of the transfer organ. The carrier may also comprise at least one other integral feature which will assist its handling and passage through all parts of the system, which may include indents on its base surface to assist alignment.

The carrier 10 comprises identification means 16 which may be a visual tag, an RFID tag, a barcode, a magnetic device or semiconductor device or any other suitable identification means known in the art. A plurality of tags may be provided, e.g. one on each side, to ensure that the carrier is identifiable from different directions or that the location and orientation of the carrier can be determined, in particular the centre of the carrier. The carrier may have a front face 59.

For some applications, a limited number of carrier sizes may be provided in order to accommodate products of different sizes.

Figures 2 shows a storage row 20. Figure 2a shows three storage rows 2OA, 2OB, 2OC for accommodating carriers 10. The storage rows 20 are formed by conveyors 22, which in this case are formed as belt conveyors. The storage rows 20 support the carriers 10 and are connected to a controllable drive 26 configured to move the carriers in the direction of arrow 24. The shown storage rows 20 are straight, but different forms may be used.

The belt conveyor (or other type of conveyor) may extend from one end of the storage row to the other end of the storage row. Alternatively, a plurality of belt conveyors may be provided in an end-to-end relationship for a storage row. Roller conveyors may also be used, having a plurality of rollers arranged in parallel, on which the carriers may rest. Roller conveyors allow for a controlled driving of a subset of the rollers, enabling the moving of one or several carriers in a storage row while keeping other carriers still.

A plain surface may also be used for the storage row/ in combination with a separate drive mechanism, such as a pusher device or puller device which may be provided overhead the carriers. Each storage row 20 is defined by an elongated support area 21 being configured to support carriers and being configured to allow the moving of the carriers along the storage row 20.

The carriers 10 are shown to have different sizes. The carriers 10 may be in contact with one another or be separated from one another by a gap.

Figure 2b shows a top view of a storage row 20 having a support area 21 with a certain width 51, in which carriers 10 of varying widths 53 and lengths 55 are shown. The carrier length will typically be less than the storage row width 51. The front faces 59 of the carriers are typically aligned. It is also possible that carriers of a fixed width 52 are used and with a variable length 55 or vice versa. Carriers with fixed width and length are also possible.

If the carriers have variable widths 53, the forward movement of the carriers may be non-discrete. The movement may be non-discrete for other reasons. If all carriers have a same width 53, the forward movement may be discrete.

Figure 3 shows the storage rows 20 with a discharge row 28 extending adjacent to each storage row. Carriers on the discharge rows are also driven (not shown) in order to move retrieved products in the direction of arrow 30.

In use, when a carrier 10 is retrieved from the storage row 20, the carrier 10 is moved from the storage row 20 to the discharge row 28. It is possible that at the time of discharging both the storage row and the discharge row stand still, are moving or that the storage row 20 is held still while the discharge row 28 is moving or vice versa. A plurality of discharge conveyors 28A, 28B, 28C are provided, each in a different horizontal level 41.

When the carrier is retrieved, a gap is created on the storage row. This gap may be quickly removed by moving the carriers forward in order to fill the gap.

Alternatively, the gap may remain for a time. In this case, the carriers are only forwarded at a later stage, for instance in a mode of operation wherein retrieval and storage periods are alternated for a storage row.

In both situations, the positions of the carriers may be determined by scanning the positions of the carriers, i.e. the positions of the identification codes thereof. Figure 3a shows an assembly of storage rows 20, discharge rows 28 and a retrieval organ 38. The retrieval organ 38 (or retrieval assembly) comprises transfer organs in the form of pushers 36, which comprise an actuator (not shown) to push a carrier 10 from a storage row 20 to a discharge row 28 in the direction of arrow 42. Three pushers 36 are provided above one another. The pushers 36 are connected to a frame 37, which is movably mounted on a guide 40 and can move in the direction of arrow 32 along the storage rows 20. A sensor 39 is provided to record the position of the frame 37. The retrieval organ can retrieve carriers in a retrieval sector 44, indicated by dashed lines. The frame 37 comprises sensors 47 for reading the identification means on the carriers, in order to assert that the desired carrier is present and that the carrier is retrieved from the storage row. The stroke of all pushers is sufficient to move any stored carrier off a storage row, typically being at least equal to the storage row width 51.

It will be clear to a person skilled in the art that there are others ways of retrieving products from the storage rows, i.e. manually by a worker, or a by a different device.

In use, the frame 37 is moved in order to update the positions of the carriers and these data are stored in the control unit (see further below) . Via the sensor 39 the position of the frame 37 is recorded. Via the sensors 47, the positions of the carriers are recorded. Thus each position of each carrier 10 is regularly updated in the control unit.

Figure 3b shows a total of fifteen storage rows 20. Three frames 37 are provided, defining three retrieval sectors 44A, 44B and 44C. The frames 37 are independently movable. One pusher can be provided at each horizontal level in each retrieval sector 44A, 44B and 44C.

In use, when a specific item 46 is to be retrieved from the storage area 88, it may happen that several, e.g. four items 46A, 46B, 46C and 46D are available. Prior to the retrieval, each combination of frame 37 and item 46 is assessed. The actual location of the frames 37 is known and the actual location of the available carriers are also known. It is determined which combination of carrier and retrieval organ 38 leads to a shortest retrieval time. The travel time of each carrier with respect to a target collecting point may also be taken into account, which is discussed further below. Subsequently, the selected frame 37 is moved to the selected carrier 10 holding the selected item 46. As will be discussed below, other selection strategies are also possible.

If several items 12 are to be retrieved simultaneously, the plurality of retrieval organs can be deployed simultaneously, independently in parallel.

The average response time of the system is dependent on the number of retrieval organs 38. Therefore, by increasing the number of retrieval organs 38, the average response time can be improved.

Figures 3cl, 3c2, 3c3 and 3c4 show different variants of retrieval organ 38 comprising the pusher organs 36. In dependence of the number of horizontal levels 41 of storage rows, a different number of pushers above one another will be provided. It is also possible to provide more than one pusher per frame in a horizontal direction, as is shown in Figure 3c2. In this way, the retrieval organ will have to travel less, potentially leading to further improvements in response time. In Figure 3c4, an embodiment is shown in which the retrieval organ comprises only a single pusher.

Figure 3d shows a retrieval organ 38 having a pusher 36 which is movable in a vertical direction 48 and a horizontal direction 49. In this way, a single pusher 36 can cover a retrieval sector comprising different storage rows.

It is also conceivable that a conventional robot arm is provided as a retrieval organ.

It is also possible to provide a pusher 36 (or other type of actuator) for each possible carrier position 54 as is shown in Figure 3e. A fast response time is thus possible. In this configuration, the positions of the pushers may be fixed.

Figure 4 shows a possible configuration of four storage rows 20 in plan view. Each storage row 20 has an entry position 50, at which products are added to the storage row 20. Two storage rows 20 are positioned adjacent a discharge row 28. The discharge rows 28 move the retrieved carriers in the direction of arrow 54 to an end 56 of the discharge row, from which location the carrier is further conveyed to the collecting station. Each storage conveyor comprises three retrieval organs 38.

Figure 4a shows how the different storage rows may fill a volume of a warehouse. A total of 40 storage racks are shown, wherein each storage rack comprises for instance 8 different storage rows arranged in different horizontal levels 41. If three retrieval organs are provided per storage row, a total of 960 storage sectors are provided.

In use, for a short response time, it is advantageous if the items are scattered over the different storage rows, for instance randomly. Other ways of scattering are also possible. For instance the storage row to which an item is added may be selected on the positions of the same items which are already present in the system. If several storage rows already contain the item, but other storage rows do not, then one of these storage rows may be selected for adding the item.

Products which are frequently selected may be present in the storage area in greater numbers than products which are rarely selected. Consequently, the frequently selected products have a shorter average retrieval time, because there are more combinations of retrieval organ and product to choose from than for the rarely selected product. Therefore, the average distance between the products to be selected and the retrieval organ will be shorter, and hence, the response time will also be shorter. It is possible that a number of storage rows are provided an a storage area having a lower temperature than other storage rows. A chilled area is possible (e.g. for fresh milk) and also a frozen storage area for frozen products.

It is also possible that the positions of the different collecting points are taken into account when determining a carrier which is to be retrieved. The arrangement of the entire system may be such that the distance between one carrier on a storage row and a selected collection point is substantially greater than the distance between another carrier on a storage row and the same collecting point. Selecting the carrier which is closest to the collecting point may lead to further improvements in the response time.

Turning to Figure 3a, if a carrier 200 and a carrier 202 carry a same item, the response time for carrier 200 may be shorter than ^

the response time for carrier 202, because carrier 200 is located closer to the downstream end 62 of the discharge conveyor 28 and thus needs less travel time on the discharge conveyor 28.

Also, if different retrieval sectors are provided, a carrier in one retrieval sector may be closer to a retrieval organ of that sector than a carrier in another retrieval sector is from a retrieval organ of that other sector. The carrier may be then selected which can be delivered at the collecting station in the shortest response time. In use, it is possible to alternate the adding of carriers to the storage rows and the retrieving of products. For instance during a first time period, carriers can be added, while during a second time period, carriers may be retrieved. It is also possible to add and retrieve carriers at the same time. It is also possible variously for different carrier retrieval, carrier adding, carrier moving and carrier position validation activities to occur simultaneously within different sectors.

In use, it is possible to move the carriers as far away from the entry position as possible, thereby creating a maximum amount of free space near the entry position. This will always ensure easy filling of the storage rows.

It is also possible to keep the carriers close to the entry position, and to move the carriers only one position each time that a new carrier is added to the storage row. This will minimise the time period in which carriers are to be moved. If moving and adding is alternated, this will maximise the time period available for retrieving carriers .

It is also possible to control the amount of free space such that enough free space is always present, but that the carriers are not moved more than necessary.

It is also possible to move the carriers as far to the end of the storage rows as possible, in order to minimise the travel distances of selected carriers from their respective positions to the collecting points and to thus improve the response time. Since carriers having different sizes may be used, the positions of the carriers on the storage rows may be undetermined. To this end, sensors 39 are configured such that the positions of the carrier can be sensed prior to the retrieval thereof. It is also possible that a validation procedure is performed in which the positions of a plurality of carriers, for instance all carriers on a single storage row, are updated in the control unit. Such a validation procedure may be carried out as a separate procedure, in which the storing and retrieval actions are temporarily halted.

Figure 4B shows a variant wherein a plurality of storage rows 20 are provided, defining a storage area. The retrieval organ 38 is movable in two horizontal directions 130, 132 such that it can move to different carriers 10 on the storage rows. The retrieval organ comprises a connector 134 in the form of a hook which can connect with a mating part 135 on the carrier 10, in order to lift the carrier 10 and to move it to a transfer area 136, where the carrier is disconnected from the connector and transferred to the at least one conveyor 68. Other retrieval means may alternatively be provided. The at least one conveyor 68 may be variously sited about the parallel and adjacent storage rows, for example alongside the storage rows and sharing the same axis as the storage rows .

Figure 5 shows a distribution system configured for simultaneously routing carriers 10 to different collecting stations 74. In use, a collecting station 74 is allocated to a specific customer. A retrieval system 99 comprises different components. A plurality of collecting conveyors 60 is provided at the downstream ends 62 of the discharge conveyors 28. A collecting conveyor 60 is provided at each horizontal level 41. In this configuration, the collecting conveyors have the form of a closed loop. This enables the collecting conveyors to act as a temporary buffer.

A transfer conveyor or ramp 65 is provided for each collecting conveyor 60 for vertically moving the carriers 10. At the downstream end of the transfer conveyors 65, a single distributor conveyor 68 is provided, which also has the form of a closed loop. The distributor conveyor can also act as a temporary buffer.

It is also possible that for each collecting conveyor, a plurality of transfer conveyors 65 are provided. In this case, controllable transfer devices are provided to control which carriers on the collecting conveyor 60 are to be transferred to which transfer conveyor 65. This configuration allows for flexible temporary storage of carriers.

A plurality of delivery conveyors 70 are provided which end at the downstream end thereof at respective collecting stations 74. Transfer devices 75 are provided which controllably transfer carriers from the distributing conveyor 68 to the respective delivery conveyors 70 on the basis of the identification means on each carrier. The transfer device 75 comprises a reader which reads the identification means. If the carrier is destined for the allocated collecting station, then the transfer device 75 transfers the carrier from the distributor loop to the delivery conveyor 70.

The distributor conveyor 68 may be configured to accommodate more than one carrier abreast. In this case, the transfer device 75 is configured to transfer one of several carriers positioned alongside one another on the distributor conveyor to the delivery conveyor 70.

A merging point 76 is present at which fresh goods 78 are entered to the distributor loop. The fresh goods 78 arrive in carriers from a fresh goods area 93 in the shop itself. Here, customers may pick fresh goods 78 which are then loaded into carriers. These carriers with fresh goods are then merged with the flow of carriers 10 with pre-packaged goods from the storage rows at the merging point 76.

Also, an exit 80 is provided in case carriers should be returned to the warehouse. The exit 80 may be connected to a feed point in the supply system, at which the carriers are re-routed back into a storage row 10.

In use, the discharge conveyors 28 transfer carriers 10 to the collecting conveyor 60. The collecting conveyor has the form of a closed loop. From the collecting conveyor 60, the carriers are transferred to the delivery conveyor 70, and subsequently to the target collecting station 14 via the associated delivery conveyor 70. Figure 5a shows a variant of the system of figure 5, comprising a number of spiral chutes 66, elevator devices 66 or - generally - level change devices 66 via which the carriers 10 move vertically, to the level 41 of a distributor conveyor 68. The spirals 66 are connected to the collecting loops 60 via first transfer conveyors 64, and are connected to the distributor conveyor via second transfer conveyors 65.

The combination of a first transfer conveyor 64, chute 66 and second transfer conveyor 65 acts as a temporary buffer for retrieved carriers.

This allows for retrieval and temporary storage during the shopping of the customer. If the customer is using an interactive scanner or other interactive device, chosen items can be immediately retrieved and directed into temporary storage whilst shopping is taking place. The customer continues to select items and proceeds to check out. The items in temporary storage are delivered at the collecting station in a short time span. Larger orders which exceed the temporary storage capacity may comprise both items placed in temporary storage and subsequently retrieved items which remain on the storage rows until space becomes available to receive them.

An optional path 80 is provided to return carriers to other parts of the system if necessary, notably to be able to return carriers back onto the storage rows if a customer declines to buy a previously chosen item at the checkout stage. Figure 5B shows another embodiment. A supply system 100 is shown for supplying carriers to the storage rows 20. The supply system 100 comprises loading stations 94 for either feeding loaded carriers to the system or loading carriers with items and subsequently feeding the carriers into the system. Validation stations 95 are further provided for inspection and validation of the entered carriers. The validation process thus can be an independent process, additional to the sensing and recording of the item data during loading of the carrier.

The validation stations may be provided with sensors for sensing the identification code of the carrier and parameters related to the items .

Conveyors 103 connect the validation stations 95 to a feeding spiral 104 which is configured to feed the carriers to one of a plurality of supply conveyors 61 at successive storage levels where more than one storage level exists.

Each supply conveyor 61 extends along the supply ends of the storage rows 20 where the entry positions 50 are located. The supply conveyor 61 has a loop form and an elongated shape to which at least one spiral conveyor 104 can join. The supply conveyor 61 further comprises cross-links or short cuts 105, which include switch devices 107. With the switch devices 107 and the cross-links 105, it is possible to move a carrier either via the ongoing supply conveyor or via the cross-link 105 which branches off at the switch device. In this way, the carrier may be routed to the destined storage row via a short cut, effectively reducing the travel distance and travel time which is needed for the storage of that carrier. The use of switch devices 107 and cross-links 105 also reduces the likelihood of excessive carrier traffic at any given location. It expands the facility for handling a plurality of carriers simultaneously, advantageously raising the throughput volume capability of the system.

A plurality of transfer devices 108 are provided to transfer carriers from one of the supply conveyors to a selected storage row 20.

In the retrieval system 99, the flows of carriers from different storage rows at a common horizontal level are merged at a conveyor 68 at the downstream ends 62 of the discharge conveyors 28. For each horizontal level, a conveyor 68 is provided. Thus, a plurality of conveyors 68 are provided.

The conveyor 68 has a loop form and comprises cross-links or short cuts 69. The loop form of conveyor 68 is elongated with two long substantially straight sections and two curved sections which connect the two longer sections, in the substantially the same way as conveyor 61. One substantially straight long section extends along the ends 62 of the discharge conveyors 28. Along the other substantially straight section the transfer devices 75 are provided at the branch off points. The short cuts allow carriers to skip a part of the longer sections, moving from one long section to the other long section along a shorter travel path, with the same advantages as are apparent with conveyor 61 in the supply system 100.

In the downstream direction, carriers from different storage rows at a same horizontal level can be merged, permitting any carrier from any storage row 20 at that level to be directed to any potential exit point, defined by transfer devices 75 which redirect carriers via level change devices 66 to a collecting station 74. Preferably, the level change devices 66 will be spiral conveyors. Carriers will be chosen to be directed to a particular collecting station according to customer.

In comparison, in Figure 5 and Figure 5a the horizontal flows are first merged on a loop conveyor at each level, and subsequently merged into a flow at a common horizontal level, also on a loop conveyor. This latter loop conveyor will merge all carrier traffic before the carriers are subsequently branched off via transfer devices 75 to a collecting station. A return route 199 is provided to return empty carriers from the collecting stations 74 to the loading stations 94.

In use, the conveyor 68 acts as both a collecting conveyor which collects carriers from different storage rows as well as a distributor conveyor which distributes carriers to different delivery conveyors 70. Each delivery conveyor connects into a collecting station 74. The conveyors 68 further act as a distribution conveyor via transfer devices 75. Spiral conveyors 66 move the carriers of a plurality of conveyors 68 (which are provided at different levels) to the common level of the delivery conveyors 70. Other types of conveyors than spiral conveyors are also possible.

In use, the selection of which carrier to retrieve can be a multi-criteria selection, for example taking into account the distance between each carrier and a retrieval organ with which to retrieve the carrier, and in addition taking into account the distance between the carrier and the target collecting station. Other criteria may also be used, such as expiration dates of the items on the carriers, the status of the storage row (is it in use or not, i.e. is it being loaded with new carriers) . Many other criteria may be used. Generally, an optimal response time will be the goal. In use, if the retrieval system is either additionally or separately to provide items to a collecting station in a defined sequence, responsiveness may also be enhanced by considered deliberate use of its buffer capability, notably by controlling the cross-links into a plurality of circulatory buffers on conveyors 68, locally adjacent to a target collecting station.

Figure 6 shows a shop or supermarket, comprising a customer area 80. The customer area 80 comprises regular shops 82 for small items such as tobacco, cards, papers, etc.. A bar 84 is also provided. Scanner stations 87 are provided at which a customer may receive a scanner 90, schematically shown in Fig 6b. The customer area comprises racks 86 on which representative items 12 are displayed. Fresh goods counters 93 and similar such counters where staffing may be desirable, for example a pharmaceutical counter 93, can be provided. These counters all operate in a same manner, where fresh and other goods may be selected, e.g. bread, fruit, vegetables, fish, meat etc.. These goods 78 are loaded into carriers upon selection and carrier data established. The carriers are then merged with the main flow via the merging point 76.

Several pay stations 83 are provided at which customers may check out and pay.

The collecting stations 74 are provided, typically being sited near an exit of the supermarket. The storage area 88 and distribution area 92 are provided near the collecting stations. Also, supply area 90 and a number of loading stations 94 is provided for supplying items to the storage area 88. Figure 7 shows a loading station 94 at which goods may arrive from a plurality of different suppliers. Products can arrive in a variety of different packaging. The goods will be unpacked and loaded onto carriers 10, at which stage, if not already done, the items 12 are singularised, i.e. one item 12 is preferably loaded onto each carrier 10. The loading may take place manually or with an automatic loader. A stream of carriers 10 will thus be generated. At least one scanner 96 is provided which can be used in appropriate loading situations to scan the carriers and to scan items being loaded. More automated scanning, if necessary using alternative scanning devices, may also be undertaken. A record is made of the code of the carrier 10 and the item 12 supported by the carrier 10, thereby matching each specific item to a specific carrier in the control unit. Additional data such as the supply date, the supplier, the weight, the best consumed before date and the dimensions of the product may also be scanned or otherwise entered into the control system. A preferred orientation on the carrier (e.g. this side up) and other similar data can be displayed on a screen to assist manual loading activity when it occurs. In case of remote loading of the carriers, the goods are already on the carriers upon delivery and the goods are directly entered into the storage system. In this instance data as to what items are in what carriers will also preferably be supplied, obviating the need for these data to be separately collated at the time of entry.

Identification means 98 are provided for the supplier to identify himself. The identification data are displayed, so that the supplier may also check that he is correctly identified. A smartcard reader may be used for this purpose during loading to identify who is responsible for loading specific items, hence providing to a traceable record. Alternative identification means are possible.

An indicator may be provided to indicate to the supplier that the goods are accepted. It is possible that a plurality of items arrive in one package. This package is then to be emptied, such that each item may be placed on a separate carrier. Occasionally a multi-pack entity may be encountered, for example for promotional purposes, which is still counted as one item in the terms of the current invention, being stored in the system in a single carrier of appropriate size.

Preferably, remote to the loading activity, separate automated and/or manual inspections may be carried out to securely determine correct loading of the system has occurred. Inspections may comprise weight, height, colour and pattern recognition. Scanning of an item's barcode is additionally possible. X-ray scanning or other types of scans may also be applied. Particularly in the case of remote and automatic inspection which the loader cannot in any way influence (occurring in area 95 of Figure 5b) , the inspections can be used to validate that the items which are claimed to be in the carriers by the supplying party are the items which are indeed in the carriers. These inspection data are also recorded and stored, and when coupled with data as to who conducted the loading can provide a traceable record in the case of dispute. Inspections of freshness, odour, general state of the product, presence of flaws, broken parts or incorrectly opened packages can also serve to validate the quality of the stored items .

When a loading operation for a supplier is finished, a report is generated for the supplier, indicating the stored items. Figure 8 shows a possible configuration of a supply system 100. The supply system comprises a supply point 102 where loaded carriers are transferred to a supply conveyor 104. The supply conveyor 104 has the form of a spiral, spiralling to each horizontal level 41 of the storage rows 20. As can be seen in Figure 5b, multiple feeding spirals are also possible.

At each horizontal level 41 (see Figure 3a) , a loop-formed supply conveyor 61 is provided. A transfer device 108 is provided at each horizontal level to transfer carriers 10 which are destined for said horizontal level 41 from the first supply conveyor 104 to the loop-formed supply conveyor 61.

The second supply conveyors extend near the entry positions 50. One or more storage row loaders in the form of manipulators 108 are provided to transfer carriers from the second supply conveyors to the entry positions. The manipulators 108 may be movable to different storage rows 20 in a horizontal direction 110 and/or vertical direction. Thus, the storage row loaders can be dedicated to load a single storage row or a plurality of storage rows.

It is possible that sectors are defined which are allocated to a manipulator 108.

The manipulators 108 are configured to position a carrier on the entry position in the correct orientation and position. Preferably, the loaders 108 are configured to align the carriers in a same storage row. The manipulators 108 comprise sensors and actuators in order to achieve this end.

In an alternative embodiment manipulators 108 may also move vertically, hence being able to deliver carriers to storage rows at a plurality of levels.

Figure 9a and 9b show a collecting station 74. A card reader 123 is provided via which a customer may identify himself. The collecting station 74 comprises a screen 122 for presenting information to a customer. Alternatively, other customer identification means are also possible such as entering a unique code which is supplied to the customer on screen 122, in the case of this screen 122 being a touch-screen. A cover 124 is provided which opens upon identification of the customer.

A camera 138 is provided for imaging the arriving carriers and items. Other sensors 128 are provided to monitor the collecting process_/ for instance to record an item which is not collected. Various sensors may be provided, such as cameras, weight sensors, barcode scanners. Use can be made of a visual sign or pattern 129 on the support area of the carriers in order to determine whether an item has been collected from the carrier. The visual pattern may a barcode matching the identification code of the carrier. The RFID tags or other identification means may be triangulated in order to determine the exact position of the carriers in the collecting area 126. In use, items 12 are delivered on carriers 10. The carriers supporting items 12 are positioned in a collecting area 126, which may be underneath the cover.

The customer may proceed with collecting the items from the carriers. The carriers remain in the collecting area 126. The carriers are provided on a conveyor 150, which is driven by the control unit in direction 152. The collecting area 126 may be divided in several areas, e.g. an upstream area 140 and a downstream area 142. The customer has access to both areas.

If all carriers in the downstream area are emptied, the conveyor is moved forward the length of the downstream area 142 and the process is repeated. This can occur irrespective of whether carriers in the upstream area are either full or empty.

If used, the customer card (or transaction card if one has previously been provided) will be returned by the reader 123. In one embodiment of the collecting station, only two types of sensors are provided for controlling the regular collecting process: at least one RFID sensor and at least one barcode reader for reading the visual barcode on the upper side of the carriers. The presence of carriers is determined via the RFID tags on the carriers and their identity is hence known. That carrier is further is shown to be empty if an upper surface barcode corresponding to the carrier's RFID code (which would otherwise be obscured by the item in the carrier) can be read. The signals provided by these sensors are fed to the control unit and allow complete control of the collecting process, automatically incrementing the conveyor forward by an appropriate amount . Advantageously, triangulation is not needed. Further, the carriers do not need to be separated from one another, and carriers do not need to be oriented in a specific way.

An additional camera is provided which registers the process for use in case of a dispute with a customer. This camera can maintain a record of carriers exiting the downstream area 142, beyond the customer's reach.

When all goods have been collected, the cover 124 will be closed. It is possible to construct the collecting station 74 to allow for the rejection of goods, for instance by providing recording means for a customer to enter a carrier identification code relating to an item the customer wishes to reject upon visual inspection. The non- picking up of the rejected item 12 can be monitored via the sensors 128.

A chute 120 is provided for allowing empty carriers 10 to be returned to the system via a return flow route.

Figure 10 shows an embodiment in which the direction of transport of the delivery conveyors 70 may be reversed, in order to use the collecting stations 74 both as collecting stations and as loading stations. Via route 501 the carriers are routed into the supply system 100, in order to be supplied to the storage rows.

The present system has a high failsafe capability, because of the main components, a plurality of instances may be provided. A plurality of retrieval organs, a plurality of storage rows, a plurality of items of one kind, a plurality of routes via which a carrier can be routed to a collecting poi and a plurality of collecting points may be provided. If one components fails, at least one other component will be available to take over the function of the failing component.

The present method and device may have many application, on being a sorting system for postal services or other delivery service for items. In a postal system, every item may be unique. The receiving station may be configured to receive an incoming load of postal items (or mail) . The postal items are then stored in the storage system.

When a delivery man or unit comes to pick up his or her load of mail, the postal items which are destined for his or her delivery section are retrieved from the system and delivered to the allocated collecting station.

The items may be retrieved in a specific sequence, such that the items are in the correct order for further processing, i.e. delivery.

The warehouse may form part of a network of warehouses in which mail is supplied, sorted and subsequently either shipped out to another warehouse or delivered to a (local) neighbourhood.

For convenience, the loading and collecting stations may be provided in close proximity to one another, for allowing a truck or other transport means to first deliver a load of items at a loading station and to subsequently pick up a load of sorted items from a nearby collecting station for further transport to another warehouse.

In a particular embodiment of the invention, the carriers may be left out. This embodiment may apply for postal services, wherein identification codes of the items are associated directly with the postal items, and in which the postal items have physical characteristics which allow them to be stored and retrieved without the use of carriers. It will be obvious to a person skilled in the art that numerous other changes in the details and the arrangement of the parts may be varied over considerable range without departing from the spirit of the invention and the scope of the claims.

Claims

C L A I M S

1. Method for storing and retrieving items in a warehouse which comprises at least one storage row for accommodating carriers, each storage row comprising at least one entry position, the carriers supporting items of different kinds, the method comprising: - each time adding a carrier to the at least one storage row at an entry position, such that a plurality of carriers is added to the row via the same entry position;

- selecting a carrier to be retrieved from the storage row, wherein the selected carrier is not necessarily the last carrier in the storage row, but may also be another carrier in the storage row;

- retrieving the selected carrier from the storage row by moving the carrier away from the storage row.

2. Method of claim 1, wherein the carrier is retrieved from the storage row by moving the carrier away from the storage row in a direction which is substantially different than the main direction of the storage row at the location of the retrieved carrier, in particular perpendicular to the main direction of the storage row.

3. Method of claim 1 or 2, wherein at least one carrier carrying an item of a first kind is positioned between two carriers each carrying an item of a second kind, for spreading the items of the second kind over an available storage area in order to improve a response time of the warehouse system.

4. Method of any of claims 1-3, wherein a retrieval system is provided comprising at least one retrieval organ, and wherein the retrieval organ retrieves a carrier from the storage row, and wherein prior to the retrieval of the selected carrier the retrieval organ is moved to the carrier.

5. Method of any of claims 1-4, wherein the retrieval organ is moved along the storage row to a selected carrier.

6. Method of any of claims 1-5, wherein for the retrieval of an item of a certain type the positions of a number of^' items in the at ^■ least one storage row which are of the selected item type are known or determined, and wherein the item is retrieved which has a preferred position, in particular:

- relative to the retrieval organ or retrieval person and/or

- relative to the position of a collecting station.

7. Method of any of claims 1-6, wherein for a selected item kind a plurality of carriers carrying an item of said kind is available, and wherein for each item a retrieval time period for moving a carrier which holds the item away from the storage row is determined, the retrieval time period being influenced by the distance between the item and the retrieval organ or retrieval person, and wherein the retrieval time periods are used for a selection of which carrier of the available carriers is to be retrieved.

8. Method of any of claims 1-7, wherein at least some carriers carrying the same items are supplied to at least two different storage rows, for spreading the items over an available storage area in order to improve a response time of the warehouse system.

9. Method of any of claims 1-8, wherein a retrieval organ is configured to retrieve carriers from only a single storage row.

10. Method of any of claims 1-9, wherein a plurality of retrieval organs is configured to retrieve items from a same storage row.

11. Method of any of claims 1-10, wherein a retrieval organ is configured to retrieve items from a plurality of storage rows, in particular from storage rows extending in a same vertical plane.

12. Method of any. of claims 1-11, wherein the retrieval system comprises a number of retrieval organs, and wherein a number of the same items are stored in the at least one storage row, and wherein it is determined which combination of an item and a retrieval organ is most favourable for retrieval with regard to retrieving a short response time.

13. Method of any of claims 1-12, wherein each carrier is associated with an identification means identifying the carrier, and wherein a control unit controls the storage and retrieval process on the basis of the identification means.

14. Method of any of claims 1-13, comprising:

- recording carrier data relating to the kind of items on each carrier and the actual position of each carrier; - recording retrieval organ position data relating to the position of the at least one retrieval organ;

- selecting a kind of item which is to be retrieved;

- determining a preferred combination of a carrier and a retrieval organ for retrieving the item from the storage row.

15. Method of any of claims 1-14, wherein prior to the retrieval of a carrier the identification means of the carrier is read by a reader in order to assert that the correct carrier is retrieved.

16. Method of any of claims 1-15, wherein the carrier position data are regularly updated by reading the identification means of the carriers in the storage row.

17. Method of any of claims 1-16, wherein the reader for updating the carrier position data is the same reader device as the reader of the retrieval system.

18. Method of any of claims 1-17, wherein empty carriers are returned from the collecting station to a loading station, and wherein the carriers are reloaded with items at the loading station, and wherein the carrier is re-entered into the storage system.

19. Method of any of claims 1-18, wherein the warehouse comprises a plurality of storage rows and wherein the supply system is configured to supply the carriers to a selected storage row.

20. Method of any of claims 1-19, wherein a storage row to which a carrier is to be added is selected in dependence of: the type of item on the carrier and/or the locations of similar items which are already present on the different storage rows and/or the type of carrier by which the item is supported.

21. Method of any of claims 1-20, wherein carriers of different sizes are added to the at least one storage row.

22. Warehouse system for storing and retrieving carriers which are configured to support items of different kinds, the warehouse system comprising:

- a storage assembly defining a storage row;

- a moving device for at times moving at least a portion of the carriers away from said entry position for creating free space at the entry position; - a retrieval system for retrieving a selected carrier from the storage row by moving the carrier away from the storage row, wherein the selected carrier is not necessarily the last carrier in the storage row, but may also be another carrier in the storage row.

23. Warehouse of claim 22, wherein the entry position is located at one end of the storage row.

24. Warehouse system of claim 22 or 23, comprising:

- a loading station for loading at least one item onto a carrier prior to the entry of the carrier onto the storage row; - a validating station at which the item which is supported by the carrier is validated against carrier data stored in the control unit by sensing at least one feature of the item.

25. Warehouse system of any of claims 22-24, comprising a plurality of storage rows, wherein the supply system is configured to supply the carrier to a selected storage row.

26. Warehouse system of any of claims 22-25, wherein the retrieval system comprises at least one retrieval organ which is movable to the position of a carrier which is to be retrieved.

27. Warehouse system of any of claims 22-26, wherein the at least one retrieval organ is movable and comprises a reader for reading the identification means of the carriers.

28. Warehouse system of any of claims 22-27, wherein a plurality of retrieval organs are provided and wherein a control unit is provided, the control unit being configured to select which of the retrieval organs is in the most favourable position to retrieve a carrier carrying the selected item, and to control the selected retrieval organ in order to retrieve the selected carrier.

29. Warehouse system of any of claims 22-28, wherein a plurality of retrieval organs are provided and wherein a control unit is provided, the control unit being configured to:

- select which of the carriers should be retrieved; - control said retrieval organ in order to retrieve the selected carrier.

30. Warehouse system of any of claims 22-29, wherein the supply system is configured to distribute items of a same type in a substantially scattered or substantially random fashion over the available storage space.

31. Warehouse system of any of claims 22-30, wherein the supply system and the retrieval system are separate systems in order to allow the adding of a carrier to a storage row simultaneously with a retrieval of another carrier from the storage row.

32. Warehouse system of any of claims 22-31, wherein the carrier loading device, the supply system and the retrieval system are configured to handle carriers of different sizes.

33. Warehouse system of any of claims 22-32, wherein the storage rows extend substantially horizontal, and wherein a plurality of storage rows extend in different horizontal planes and/or in different vertical planes.

34. Warehouse system of any of claims 22-33, the warehouse system being substantially free of trolleys or carts onto which the carriers are loaded and which are used for transporting the carriers.

35. Warehouse system of any of claims 22-34, wherein the moving device comprises at least one conveyor for moving and supporting the carriers, in particular a belt conveyor or a roller conveyor.

36. Warehouse system of any of claims 22-35, wherein the retrieval system comprises at least one discharge conveyor for transporting a carrier towards a collecting station.

37. Warehouse system of any of claims 22-36, wherein a plurality of collecting stations are provided, and wherein a plurality of routes are provided via which a retrieved carrier may be conveyed to an allocated collecting station, and wherein the control unit is configured to determine the travel time for a plurality of items of a selected kind based on the available routes and consider the travel times when selecting a carrier.

38. Warehouse system of any of claims 22-36, wherein storage rows are arranged at different horizontal levels, and wherein at least one retrieval organ is movable from one horizontal level to another horizontal level.

39. Warehouse system of any of claims 22-38, wherein each retrieval organ is associated with a reader for reading at least one identification means of a carrier, in particular an identification means arranged on a side of the carrier facing the retrieval organ.

40. Warehouse system of any of claims 22-39, wherein the supply system comprises a receiving station configured for allowing a third party to supply pre-loaded carriers to the supply system.

41. Warehouse system of any of claims 22-40, wherein the retrieval system comprises at least one buffer for buffering retrieved carriers prior to the delivery of said carriers to a collecting station.

42. Warehouse system of any of claims 22-41, wherein the retrieval system comprises: - a plurality of delivery conveyors, each ending at a respective collecting station for delivering a carrier to the collecting station;

- at least one distribution conveyor;

- a plurality of transfer devices configured for controllably transferring those carriers which are retrieved for a particular customer from the at least one distribution conveyor to the delivery conveyor ending at the collecting station which is allocated to the customer.

43. Warehouse system of any of claims 22-42, wherein the distribution conveyor has the form of a closed loop.

44. Warehouse system of claim 43, wherein the loop-formed distribution conveyor comprises at least one short-cut which allows a carrier to short cut a part of the distribution loop, thereby reducing its travel time to the allocated collecting station.

45. Warehouse system of any of claims 22-44, wherein the supply system comprises:

- a loading station wherein carriers are entered into the supply system of the warehouse;

- a distribution conveyor assembly comprising control means for controllably distributing carriers to selected storage rows and allowing a control unit to make a choice for each individual carrier of which storage row the carrier is added to.

46. Warehouse system of any of claims 22-46, wherein storage rows are provided at different horizontal levels, and wherein the supply system comprises at least one level change device configured to move carriers in a vertical direction to the horizontal level of the target storage row to which the carrier is to be added.

47. Warehouse system of any of claims 22-46, wherein at least one of the supply conveyors comprises a drive, and wherein the control unit is configured to stop said supply conveyor or elements thereof in order to form a supply buffer for temporarily storing carriers .

48. Warehouse system of any of claims 22-47, comprising at least one supply conveyor in the form of a closed loop, the loop extending near the entry positions of the respective storage rows.

49. Warehouse system of any of claims 22-48, comprising a discharge row extending adjacent a storage row, wherein the retrieval organ is configured to transfer a carrier from the storage row to the discharge row, and wherein the discharge row is configured to move the carrier toward a collecting station.

50. Warehouse system of any of claims 22-49, wherein the supply system comprises at least one spiral conveyor configured to move carriers to storage rows at different horizontal levels.

51. Warehouse system of any of claims 22-5O₇ wherein the retrieval system comprises a number of vertical moving devices for moving carriers from storage rows at different horizontal levels to a common horizontal level, and wherein the retrieval system comprises transfer devices for routing carriers to different collecting points, and wherein the transfer devices are provided upstream of the vertical moving devices.

52. Warehouse system of any of claims 22-51, wherein the retrieval system comprises a number of vertical moving devices for moving carriers from storage rows at different horizontal levels to a common horizontal level, and wherein the retrieval system comprises transfer devices for routing carriers to different collecting points, and wherein the transfer devices are provided downstream of the vertical moving devices.

53. Warehouse system of any of claims 22-52, wherein the retrieval system comprises a plurality of collector conveyors arranged at different horizontal levels, and wherein a plurality of vertical moving devices are provided for moving the carriers from the collector conveyors to a common level, and wherein preferably each vertical moving device is associated with a respective collecting station.

54. Warehouse system of claim 53, wherein the vertical moving device comprises a chute having multiple entry points, for allowing carriers from different horizontal levels to enter the vertical moving device.

55. Warehouse system of any of claims 22-54, wherein the retrieval system comprises a collecting conveyor for collecting carriers from different storage rows, and wherein the collection conveyor has the form of a closed loop and further comprises shortcuts for allowing a carrier to short cut a part of the loop.

56. Warehouse system of claim 48, wherein the supply conveyor comprises at least one short-cut, allowing a carrier to short cut at least a part of said loop.

57. Warehouse of claim 44 or 56 comprising control means configured to control the short-cut in order to buffer carriers.

58. Warehouse of any of claims 22-57, wherein the control unit is configured to control a route from the carrier location on the storage row to the collecting station on the basis of an actual or future condition of the system, in particular in relation to the work load at various location and/or routes in the system.

59. Warehouse of any of claims 22-58, wherein a reverse route is provided for routing carriers from the retrieval system back to the supply system, and wherein the control unit is configured to analyse the item distribution in the storage area and to retrieve one or more carriers followed by a routing thereof via the reverse route back into a different location in the storage area for providing said carrier with a more suitable position in the storage area in order to improve the response time of the system.

60. Computer program comprising instructions for carrying out the method of claim 1 on a computer.

61. Carrier for use in the warehouse system according to claim 22 and for use in the method according to claim 1.

62. Carrier according to claim 60, the carrier comprising a support surface for supporting the item, the carrier further comprising an identification means.

63. Carrier according to claim 60, 61 or 62, wherein the identification means comprises at least one RFID tag.

64. Carrier according to claims 61-63, comprising at least one barcode provided on a surface which may be covered by an item when loaded on the carrier.

65. Shop or supermarket comprising a warehouse system according to claim 22, the store or supermarket comprising:

- a plurality of items or item displays displayed in a customer area,

- at least one means for recording order data relating to an order of a customer for retrieval of an item; - a transmitting device for transmitting the order data to the control unit for retrieval of the ordered item;

- at least one collecting station at which a retrieved item can be picked up by a customer; wherein the control unit is configured to process the received order data in order to retrieve at least one ordered item from the at least one storage row and to deliver the at least one ordered item at the at least one collecting station.

66. Shop or supermarket of claim 65, comprising a plurality of collecting stations, wherein the control unit is configured to allocate a specific collecting station to a specific customer, and to deliver the at least one retrieved item to the allocated collecting station.

67. Shop or supermarket of claim 65 or 66, wherein the at least one collecting station comprises an area in which the retrieved carriers are collected, which area is closed by means of a door, lid, cover or a similar suitable closing device, and wherein identification means are provided for identifying a customer to which the collecting station is allocated, and wherein the identification means are configured to generate a signal opening the door or lid when a customer has been identified.

68. Shop or supermarket of any of claims 65-68, wherein the at least one collecting station comprises at least one sensor for sensing whether carriers at the collecting station are empty or not.

69. Shop or supermarket of any of claims 65-60, wherein the at least one collecting station comprises a rejection device allowing a customer to reject a retrieved item.

70. Shop or supermarket of any of claims 65-69, comprising a ^Λreal' section wherein products are present which can be selected by a customer, in particular fresh products, and comprising a merging system for merging said products with the items retrieved from the storage row, in order to deliver both the products from the ''real' section as the products from the storage row to the same collecting station.

71. Shop or supermarket of any of claims 65-70, configured to allow customers to use their mobile phones to photograph or scan a selected item for instance via a barcode, the shop or supermarket comprising receiving means for receiving the photographs or scan data and determining the selected item on the basis of the received photograph or scan data.

72. Method of sorting items, characterized in that the method of claim 1 is used and/or the device of claim 22 is used.

73. Method of claim 72, wherein empty carriers are stored in the storage area for supplying empty carriers to a collecting station for loading carriers with items at the collecting station, and wherein a reverse route 501 from the retrieval system to the supply- system is provided via which carriers are returned to the supply- system for storage in the storage area.

74. Network of warehouses according to claim 22, wherein transport means are provided via which loads of items are transported between the warehouses .