Stock retrieval system and method

Abstract

A stock retrieval system is provided, comprising: i) a storage container for housing stock; ii) a base plate configured to support stock and be stored within the storage container; the base plate being movable vertically with respect to the bottom of the storage container; and iii) a drive mechanism configured to move the base plate with respect to the bottom of the storage container from a lowered position where the base plate is at a level lower than the top of at least one side wall of the storage container to an raised position where the base plate is at or above substantially the same vertical level as the top of at least one side wall of the storage container, wherein the drive mechanism comprises at least one support rod having an upper end configured to engage with the lower surface of the base plate.

Description

Technical Field

[0001] The present disclosure relates to, for example, a stock picking system for use in an automated warehouse or storage system, and a method of using said stock picking system.

Background Art

[0002] When a customer orders a product for delivery, it is an important part of the customer experience that the product arrives properly packaged without damage. This can be particularly problematic in the case of clothing, which can very easily become wrinkled during transportation if not folded properly and carefully packaged. The object of the present disclosure is to provide a means of removing stock from a storage container in a fast, efficient manner that causes no damage or disruption to the stock.

[0003] The stock picking system described herein can be used as part of a larger storage and retrieval system, such as the cube-shaped automated storage and retrieval system described in WO2015 / 185628A.

Summary of the Invention

[0004] In one aspect, the present disclosure is a stock picking system comprising i) a storage container for containing stock, and ii) a base plate configured to support the stock and be stored within the storage container, the base plate being movable in a direction perpendicular to the lower part of the storage container, iii) a drive mechanism configured to move the base plate relative to the lower part of the storage container from a lowered position where the base plate is at a level lower than the upper part of at least one side wall of the storage container to a raised position where the base plate is at substantially the same vertical level or higher than the upper part of at least one side wall of the storage container and The drive mechanism provides a stock removal system comprising at least one support rod having an upper end configured to engage with the lower surface of a base plate.

[0005] This configuration of the support rod provides a simple and convenient way to move the base plate from a lowered position to an raised position, and does not require the storage container itself to have any complex parts or moving parts.

[0006] The storage container may have a bottom wall with at least one opening, and at least one support rod may be configured to protrude through at least one opening. In other examples, the storage container may open at the bottom, having retaining lips and / or retaining projections that support a base plate inside the storage container. The storage container may have a box-like structure with four side walls and a bottom wall. As a further alternative, the storage container may taper so that the base plate is held in place at the bottom of the container by friction or interference fit.

[0007] The lower wall may have multiple openings, and the drive mechanism may have multiple support rods configured to protrude through the multiple openings, each of which has an upper end configured to engage with the lower surface of the base plate.

[0008] A base plate can be a flat plate in a plane. A base plate can be square or rectangular in shape. A base plate can have at least one side wall that is substantially lower in height than at least one side wall of the storage container. A base plate can be a tray with side walls or lips on all edges of the base plate. An advantage of a base plate that is a flat plate or tray with lips or short side walls is that it is easier to add stock to or remove stock from the base plate than to place stock in or remove stock from a container with higher side walls.

[0009] Advantageously, when the baseplate is in the raised position, the stock supported on the baseplate is above the level of the top of at least one sidewall, and therefore the stock is easily accessible from the side without the sidewall of the storage container obstructing it. This easy accessibility facilitates the quick retrieval of stock from the storage container. The stock can be retrieved manually, for example, by a human worker lifting one or more stock items from a portion of the stock above the top of at least one sidewall, or by an automated retrieval means, as described later. Fast retrieval allows the automated system to operate quickly and efficiently with a high level of throughput. Convenient retrieval also has the advantage that stock items are less likely to be damaged or disturbed during the retrieval process. The raised position can be at the same vertical level as the top of at least one sidewall, or at a higher vertical level, and in either case, the entire stock supported on the baseplate is easily accessible from the side without the sidewall of the storage container obstructing it.

[0010] The stock retrieval system may further comprise a control system configured to control a drive mechanism to move a base plate between an elevated and a lowered position. The control system for the stock retrieval system may be separate or, in the case of a larger storage system, integrated into the control system.

[0011] The control system may be further configured to control the drive mechanism to move the base plate from a lowered position to at least one intermediate position that lies on the vertical level between the lowered and raised positions.

[0012] The advantage of an intermediate position is that the portion of the stock that is vertically above the top of at least one side wall can be changed, and therefore the stock retrieval system can conveniently handle stock of different sizes and quantities. For example, if it is necessary to remove the entire stock from the storage container, the elevated position is more convenient for retrieval because the entire stock is above the level of the top of at least one side wall. Conversely, if only one stock item or a small portion of several stock items is needed, an intermediate position may be more convenient because the base plate is lower than the vertical level of the top of at least one side wall, and therefore only the stock item to be needed is above this level.

[0013] In other words, as well as a single raised position where the base plate is at or above the vertical level of the top of at least one side wall, the base plate can occupy one or more intermediate positions with different spacings of the base plate relative to the lower wall of the storage container, and the control system may be further configured to selectively move the base plate from the lowered position to one of the one or more intermediate positions, and thus change the portion of the stock that is at a higher level vertically above the top of at least one side wall.

[0014] The drive mechanism may be configured to move at least one support rod vertically upward to lift the base plate within the storage container from a lowered position to an elevated position. This configuration has the advantage that the base plate and stock are lifted to a higher vertical level, which can be more convenient for retrieval.

[0015] The drive mechanism may be configured to move the storage container downward in a direction perpendicular to the base plate. This configuration has the advantage that the drive mechanism can be lighter and less expensive, as at least one support rod does not need to lift the entire weight of the stock on the base plate, and therefore the drive mechanism does not need to be capable of providing sufficient force to lift heavy weights.

[0016] The stock retrieval system may further comprise a container transport means configured to transport a storage container to a retrieval position, wherein, when the storage container is in the retrieval position, a plurality of support rods are configured to be located below the retrieval position and protrude through a plurality of openings in the lower wall. The container transport means may be a conveyor, a robotic arm, one or more vehicles, or any other suitable means capable of transporting the storage container. An advantage of this configuration is that the container transport means can transport the storage container from another part of a larger storage system or facility in which the stock retrieval system forms part. Different embodiments of the larger storage system may be linked together to automate the processes of the storage system and increase throughput. Furthermore, the container transport means may also remove the storage container once the required stock has been retrieved to free up space, so that the stock retrieval system is ready for the retrieval of another storage container containing stock.

[0017] In an example where the container transport means is a container conveyor, the container conveyor may be equipped with rollers, and support rods may be configured to protrude between the rollers of the container conveyor. The advantage of this configuration is the efficient use of space, since the drive mechanism can otherwise be located beneath the container conveyor in dead space. The space between the rollers of the container conveyor allows the support rods to perform their function without interfering with the operation of the container conveyor.

[0018] The drive mechanism may be contained within the storage container. This configuration has the advantage that the drive mechanism does not occupy additional space in a larger storage system, and the retrieval process can be performed in any part of the storage system where the storage container is located without the need to install other equipment.

[0019] The drive mechanism may comprise one or more linear actuators. Each of the linear actuators may comprise a hydraulic piston and / or a rack and pinion mechanism and / or one or more electric motors. Any suitable drive mechanism or combination of mechanisms may be used to perform the function of moving the base plate between a lowered position and an raised position.

[0020] The stock retrieval system may further comprise a transfer means configured to remove at least one item of the stock from the base plate when the base plate is in the raised position. The advantage of the transfer means is that it provides a convenient way to retrieve the stock, resulting in a faster and more efficient stock retrieval system.

[0021] The stock retrieval system may further include a stock surface. In an example where the stock retrieval system includes a transfer means, the transfer means can remove at least one stock item and place at least one stock item on the stock surface. In an example where a human worker retrieves the stock, the worker can place at least one stock item on the stock surface.

[0022] The stock surface may be a stock conveying means configured to transport at least one stock item away from the stock retrieval system. The advantage of the stock conveying means is that once stock is removed from a storage container, it may be transported away from the stock retrieval system to another part of a larger storage system, for example, a picking station or a packing station. The stock conveying means keeps the stock moving and therefore has available space for stock items that will be taken from the next storage container and placed on the stock conveying means, without having to wait for the stock taken from the previous container to be processed. The stock conveying means may be a stock conveyor, a robotic arm, or any other suitable means capable of transporting stock.

[0023] The transfer means may comprise a robotic arm having an end effector with one or more horizontal lifting plates, so that in the closed position, one or more horizontal lifting plates are movable between a closed position in which one or more horizontal lifting plates support at least one item of stock from below and an open position in which one or more horizontal lifting plates are separated from at least one item of stock. The robotic arm provides flexibility in terms of movement, i.e., stock can be removed from the storage container within the range of the robotic arm without the storage container having to be precisely in the correct location. Another advantage of this configuration is that the lifting plates can slide beneath the stock item, ensuring support for the stock item and reducing the risk that the stock item would fall and potentially be damaged. Also, since the lifting plates support the stock item from below rather than applying pressure to both sides of the stock item, there is a reduced risk that the stock item would be crushed or damaged during transfer.

[0024] The transfer means may comprise a robotic arm terminating in a grabber device configured to move between a closed position and an open position, so that in the closed position the grabber device is configured to engage with at least one stock item, and in the open position the grabber device is configured to release at least one stock item. The grabber device provides a convenient means for transferring stock.

[0025] The transfer means may comprise an inclination mechanism configured to tilt the base plate to an inclined position in the raised position in order to enable removal of at least one item of the stock by sliding it off the base plate. The advantage of this configuration is that one part (the base plate) is used to perform two different functions, namely not only to move the base plate to the raised position so that the stock becomes accessible, but also to tilt the base plate to remove the stock. Advantageously, the dual function of the base plate means that the stock removal system is simpler, has fewer parts, and thus is less expensive to manufacture, construct and assemble.

[0026] The at least one support bar may comprise a plurality of support bars, and the inclination mechanism may be configured to move the first set of support bars relative to the second set of support bars such that the upper ends of the second set of support bars are at a higher vertical level than the upper ends of the first set of support bars. The sets of support bars may comprise one support bar or a plurality of support bars. This configuration also provides a simple means of moving the base plate between the raised position (which can be a horizontal position) and the inclined position without the need for any additional parts. The support bars provide two functions: lifting the base plate to the raised position and tilting the base plate to the inclined position.

[0027] The transfer means may comprise an extrusion device configured to move in a direction parallel to the base plate in order to remove at least one stock item from the storage container by extruding at least one item of the stock from the base plate. This configuration is a simple and effective way of facilitating the transfer of the stock.

[0028] The transfer means may comprise any combination of the examples described above. For example, the transfer means may comprise a robotic arm and / or an extrusion device and / or an inclination mechanism.

[0029] At least one of the upper ends of the support rods may be equipped with wheels to facilitate the movement of the baseplate to insert / remove it from a container when the baseplate is in the raised position. Advantageously, this configuration provides an easy way to separate the baseplate from the storage container or combine the container with the baseplate. The baseplate may be stocked in different parts of a larger storage and retrieval system, then combined with a storage container, and then stored or shipped in different parts of the system.

[0030] The stock retrieval system may further comprise a container transport means configured to move a container in a first direction to a retrieval position from which a baseplate can be inserted into or removed from a storage container, and a baseplate transport means configured to transport the baseplate to and from the retrieval position in a second direction, the second direction being perpendicular to the first direction. The container transport means may be a container conveyor. The baseplate transport means may be a baseplate conveyor. Advantageously, this configuration makes efficient use of space and allows for loading / removing baseplates (with or without stock) into / from storage containers at the point where the two conveyor lines intersect.

[0031] The upper ends of at least one support rod and / or the lower surface of the base plate may be provided with engaging features configured to engage the upper ends of the support rods with the lower surface of the base plate. This helps ensure that the base plate is moved precisely to the raised or lowered position. For example, in the lowered position, the base plate lies flat on the lower wall of the storage container, and in the raised position, the base plate is horizontal and at the correct height to allow stock to be placed on or removed from the base plate, or to allow the base plate to be removed from the storage container.

[0032] The engagement feature may include one of the following: a high-friction surface, an electronically adhesive surface, an electromagnetic pad, and a permanent magnet pad.

[0033] In cases where the storage container has a bottom wall, the stock retrieval system may further include a seal surrounding the opening in the bottom wall of the storage container and / or a seal surrounding the edge of the base plate and / or a space between the base plate and the bottom wall, optionally comprising a moisture sensor. These features help contain any liquid spills within the storage container and, in some cases, also detect the presence of liquid within the container.

[0034] The interior of at least one side wall of the storage container may be provided with vertical ribs and the base plate may be provided with recesses, so that vertical ribs and corresponding recesses cooperate to guide the vertical movement of the base plate between a lowered position and an raised position. The interior of at least one side wall of the storage container may be provided with vertical grooves and the base plate may be provided with projections, so that vertical grooves and corresponding projections cooperate to guide the vertical movement of the base plate between a lowered position and an raised position. Advantageously, these configurations help to keep the base plate aligned within the storage container and ensure smooth movement of the base plate between the raised and lowered positions.

[0035] In another aspect, the present disclosure is a method for retrieving stock using a stock retrieval system as described above, wherein the storage container comprises one or more items of stock on a base plate, and the method is i) Using a drive mechanism, move the base plate from a lowered position to an elevated position or an intermediate position between the lowered and elevated positions such that at least one item of stock on the base plate is at a level vertically above the top of at least one side wall of the storage container. ii) Remove at least one item from the stock from the base plate. The method provides the steps involved.

[0036] In an example where the stock retrieval system further includes stock transporting means, the method is: iii) Transferring at least one item of the stock onto the stock transport means, iv) Transporting at least one stock item away from the stock retrieval system using stock transport means. Further steps can be added.

[0037] For example, in some cases where the transfer mechanism is a tilting mechanism or an extrusion mechanism, the steps of removing at least one stock item from the base plate and transferring at least one item of the stock onto the stock transport means may be the same action.

[0038] In an example where the stock retrieval system includes container transport means configured to move the storage container to the retrieval position, the method is: Before step i), move the storage container to the retrieval position using container transport means. After step ii), move the base plate to the lowered position using the drive mechanism, move the storage container away from the retrieval position using the container transport means, and move another storage container to the retrieval position using the container transport means. Further steps can be added.

[0039] In some cases, the above method steps can be carried out in reverse order to place the stock in the storage container.

[0040] In another aspect, the present disclosure provides a method for combining a storage container and a base plate using a stock retrieval system as described above, the method being: i) Moving the storage container to the retrieval position using container transport means, ii) Raise at least one support rod, iii) Moving the base plate from the base plate transport means to an elevated position on at least one support rod, iv) Lowering the base plate from the raised position to the lowered position within the storage container. v) Using container transport means to remove the storage container and base plate from the retrieval position. The method provides the steps involved.

[0041] This method can also be applied in reverse to separate the base plate from the storage container. This disclosure is a method for separating the base plate from the storage container using a stock removal system as defined above, the method is: i) Moving the storage container and base plate to the retrieval position using container transport means, ii) Raise the base plate to the raised position. iii) Moving the base plate from the raised position to the base plate transport means, iv) Lower at least one support rod, v) Removing the storage container from the retrieval position using container transport means. The method provides the steps involved.

[0042] Further features and aspects of this disclosure will become apparent from the following detailed description of exemplary embodiments with reference to the drawings. [Brief explanation of the drawing]

[0043] [Figure 1] A schematic diagram showing storage containers and stock for use in a stock retrieval system. [Figure 2a] A schematic diagram illustrating a stock retrieval system in which a support rod lifts the base plate, with the base plate in the lowered position (left) and the raised position (right). [Figure 2b] A schematic diagram illustrating a stock retrieval system in which a storage container is lowered relative to a base plate, with the base plate in both a lowered (left) and raised (right) position. [Figure 3a]A schematic diagram showing a stock retrieval system with the base plate in the lowered position. [Figure 3b] A schematic diagram showing a stock retrieval system with the base plate in an intermediate position. [Figure 3c] A schematic diagram showing a stock retrieval system with the base plate in the raised position. [Figure 4] A schematic diagram showing a first embodiment of a stock retrieval system having a transfer means equipped with a robotic arm having a grabber device. [Figure 5] Figure 3 schematically shows the stock retrieval system with the grabber device in the closed position. [Figure 6] Figures 4 and 5 show schematic cross-sectional views of the stock retrieval system. [Figure 7] Figures 4, 5, and 6 show schematic cross-sectional views of the same stock retrieval system. [Figure 8] This figure shows a second embodiment of a stock retrieval system in which the transfer means is a tilting mechanism. [Figure 9a] A schematic diagram showing a transport mechanism provided by a tilting mechanism in which the base plate is in a lowered position. [Figure 9b] A schematic diagram showing a transport mechanism provided by a tilting mechanism in which the base plate is in an elevated position. [Figure 9c] A schematic diagram showing a transfer mechanism provided by a tilting mechanism in which the base plate is in an inclined position. [Figure 9d] A schematic diagram illustrating a transfer mechanism provided by an inclined mechanism in which the base plate is in an inclined position and the stock is transferred to the stock surface. [Figure 10] Figure 7 shows another view of the stock retrieval system. [Figure 11] Figure 7 shows further details of the stock removal system, where the roller is located between the base plate and the stock surface. [Figure 12] Figure 7 shows further details of the stock removal system with guide wheels. [Figure 13]Figure 7 shows further details of the stock removal system, which has guide channels for guiding the guide wheel. [Figure 14] Figure 7 shows a cross-sectional view of the stock retrieval system. [Figure 15] This figure shows a third embodiment of a stock retrieval system in which the extrusion device is in the retracted position and the transfer means is the extrusion device. [Figure 16] Figure 15 shows the stock removal system with the extrusion device in the deployed position. [Figure 17] Figure 15 shows the stock removal system, which is part of the drive mechanism. [Figure 18] A flowchart illustrating the stock retrieval method using the stock retrieval system as described above. [Figure 19] A diagram showing another example of a stock retrieval machine where the wheel is located on a support rod. [Figure 20a] Figure 19 schematically shows the stock retrieval machine in operation as the base plate is transported to the retrieval position. [Figure 20b] A schematic diagram of the stock retrieval machine in operation with the base plate in the retrieval position (Figure 19). [Figure 20c] A schematic diagram of the stock retrieval machine in Figure 19, showing the base plate being lowered into the storage container. [Figure 20d] A schematic diagram showing the stock retrieval machine in operation with the base plate in the lowered position (Figure 19). [Figure 21a] A diagram showing different examples of engagement features, where a pad is located at the upper end of the support rod. [Figure 21b] A diagram showing different examples of engagement features where the upper end of the support rod tapers. [Figure 22a] A schematic diagram showing an example of a storage container, base plate, and support rod for containing liquid spills in a lowered position. [Figure 22b] A schematic diagram showing an example of a storage container, base plate, and support rod for containing liquid spills in an elevated position. [Figure 23a]A diagram showing examples of alignment features on a base plate and storage container, with vertical ribs and corresponding recesses. [Figure 23b] A diagram showing examples of alignment features on a base plate and storage container, with vertical grooves and corresponding protrusions. [Modes for carrying out the invention]

[0044] Figure 1 schematically shows a storage container 3. The storage container 3 is an open box with four side walls 7 and a bottom wall 9. The upper edges of the side walls 7 define a rim 11. In the illustrated example, all four side walls 7 have a rim 11 at the same vertical height, and the rim 11 extends around the outer circumference of the storage container 3.

[0045] Storage container 3 contains stock 5. In the illustrated example, stock 5 is a pile of folded clothing, but in other examples, stock 5 could be different kinds of goods. Stock 5 could be one item or several items, for example, a pile of folded clothing stacked on top of each other. Stock 5 is contained within storage container 3 and does not protrude above the level of the rim 11.

[0046] To facilitate the convenient and rapid retrieval of stock 5 from storage container 3, the stock needs to be raised to a level where at least a portion of the stock is above the level of the rim 11. This is achieved by the base plate inside storage container 3 in which stock 5 is placed.

[0047] Figures 2(a and b) schematically illustrate how the stock in the stock retrieval system may be raised relative to the container such that at least a portion of the stock is above the level of the rim 11. In the following description, the terms “raised position” and “lowered position” should be interpreted as describing the relative position of the base plate 13 and the storage container 3, regardless of whether the base plate 13 or the storage container 3 has moved. In other words, the “lowered position” refers to the position where the base plate 13 rests on the lower wall 9 of the storage container 3, and all of the stock 5 in the storage container 3 is at a vertical level lower than the rim 11 of the storage container 3. The “raised position” refers to the position where the base plate 13 is at the same vertical level as the rim 11 of the storage container or at a higher vertical level. In the raised position, all of the stock 5 is above the level of the rim 11. In the illustrated example, in the raised position, the base plate 13 is at the same vertical level as the rim 11. In other examples, the base plate in the raised position may be at a vertical level higher than the rim of the storage container.

[0048] Figure 2(a) shows the stock retrieval system in the lowered position (left) and the raised position (right). As in Figure 1, the storage container 3 is an open box-shaped structure with a bottom wall 9 and side walls 7. In the lowered position, the base plate 13 is located inside the storage container 3 and rests directly on the bottom wall 9. The base plate 13 is a planar plate with free edges 15. The free edges 15 of the base plate 13 are adjacent to the side walls 7 of the storage container 3. In the illustrated example (viewed from the side), the storage container 3 has four side walls 7, and the base plate 13 is a rectangular plate with four free edges 15. Each of the four free edges 15 is located adjacent to each of the four side walls 7. The base plate 13 is supported by the upper end 25 of a support rod 23, which protrudes through an opening 21 in the bottom wall 9 of the storage container 3. The opening 21 has holes positioned to ensure that the support rod 23 moves in the correct direction, for example, vertically.

[0049] Although shown in Figure 2 as a flat plate with free edges, in other examples, the base plate 13 may be a tray with lips on one or more of its edges.

[0050] In the raised position (right), the support rod 23 is raised upward by a drive mechanism (not shown). The base plate 13 is raised from its original position and separated from the lower wall 9 of the storage container. The base plate 13 is lifted vertically upward to the same vertical level as the rim 11 of the storage container. All of the stock 5 is above the level of the rim.

[0051] The arrows in Figure 2(a) (right) indicate the direction of movement. In this example, the base plate 13 and stock 5 are lifted upward (see vertical arrow) relative to the storage container 3, which remains in its original position. With the base plate 13 in the raised position, the side wall 7 of the storage container 3 is no longer an obstruction, so the stock 5, which is now above the level of the rim 11, can be removed more easily horizontally (see horizontal arrow).

[0052] Figure 2(b) shows an example in which the storage container is moved vertically downward relative to the base plate 13 and stock 5, which remain in their original positions. In the raised position (left), the example in Figure 2(b) looks the same as the example in Figure 2(a), but in the lowered position (right), it is the storage container 3 that has moved, not the base plate 13 and stock 5. The arrows in Figure 2(b) indicate the direction of movement. In this example, the storage container 3 moves downward (vertical arrow) relative to the base plate 13 and stock 5. Again, when the base plate 13 is in the raised position, the stock 5 is above the level of the rim 11 of the side wall 7 of the storage container 3, which facilitates the removal of stock items from the top of the pile in the horizontal direction (see horizontal arrow).

[0053] In some cases, the storage container 3 may be lowered or the base plate 13 may be raised in order to move from a lowered position to an elevated position.

[0054] When the base plate 13 is in the raised position, the stock 5 is above the level of the rim 11 and therefore can be more easily accessed. In some examples, one or more stock items (e.g., clothing lifted from the top of a stack of clothing) can be accessed by a human worker. In other examples, a transfer means is provided to transfer one or more stock items from the base plate 13 to a stock surface located adjacent to or near a storage container.

[0055] The stock retrieval system may be provided with a control system for controlling the drive mechanism. The control system can control the movement of the base plate and / or storage container to move between an elevated position and a lowered position.

[0056] The number of support rods can be changed. For example, a single support rod, a pair of support rods, or four support rods positioned to engage with or near the four corners of a square or rectangular base plate may be used.

[0057] Figures 3(a to c) schematically illustrate a stock retrieval system with the base plate in (a) the lowered position, (b) the intermediate position, and (c) the raised position. The lowered position shown in Figure 3(a) is described above with respect to Figure 2(a)(left), and the raised position shown in Figure 3(c) is described above with respect to Figure 2(a)(right). When in the intermediate position, as shown in Figure 3(b), the base plate 13 is at a vertical level between the vertical level of the base plate 13 in the lowered position and the vertical level of the base plate 13 in the raised position. In the intermediate position, a portion 19 of the stock 5 on the base plate protrudes above the vertical level of the rim 11, and a portion of the stock 5 is below the vertical level of the rim. The portion 19 of the stock above the vertical level of the rim is accessible from the side for retrieval. The intermediate position may be more convenient when retrieving a single stock item or a small portion of a stock item from a storage container, rather than the entire stock.

[0058] The intermediate position is also applicable to examples such as the one described with respect to Figure 2(b), where the storage container is lowered by the drive mechanism rather than the base plate being raised. In this case, when in the intermediate position, the base plate remains at the same vertical level, but the vertical level of the storage container in the intermediate position is between the vertical level of the storage container in the lowered position and the vertical level of the storage container in the raised position.

[0059] Although only a single intermediate position is shown in the illustrated example, in other examples, the base plate may have multiple intermediate positions at different vertical positions between the lowered and raised positions.

[0060] Robot arm-transfer mechanism, first embodiment Figure 4 schematically shows an example of a stock retrieval system 1 having a transfer means 31. In this example, the transfer means 31 comprises a robotic arm 51 having a grabber device 64. The distal end of the robotic arm 51 comprises a central hub 63 and a pair of jaws 53 configured to open and close to pick up stock items from a base plate 13 or from a portion 19 of stock 5 above the level of the rim 11 of a storage container 3. Each of the jaws 53 comprises two frame members 61 connected to a horizontal plate 55. The frame members 61 of the jaws 53 are connected to the central hub 63 of the grabber device 64 in a sliding manner. The central hub 63 comprises four horizontally extending members 65. Each of the four frame members 61 is engaged with each of the four horizontally extending members 65 in a sliding manner, so that the frame members 61 can slide inward and outward relative to the central hub 63 to open and close the jaws 53. The movement of the frame members is actuated by actuators 67 located on each of the four horizontally extending members 65.

[0061] The robot arm 51 is mounted on a robot base 57, which allows the robot arm 51 to rotate 360°. The robot arm is equipped with joints 59 (in this case, elbow and wrist joints) to allow the jaws to move horizontally and vertically. A container conveyor 27 with a storage container 3 containing stock 5 is located beside the robot arm. The drive mechanism 17 is located beneath the container conveyor 27. The stock surface 29 is positioned beside the robot arm 51.

[0062] While the example in Figure 4 uses a container conveyor 27, in other examples, different container handling means may be used instead of the container conveyor 27. For example, the container handling means could be a conveyor, a robotic arm, one or more vehicles, or any other suitable means capable of transporting storage containers. Any suitable container handling means may be used in combination with any example of the stock retrieval machine described herein.

[0063] During use, the storage container 3 containing the stock 5 is transported along the container conveyor 27. When the target storage container 3 is within range of the robot arm 51, for example, in a predefined retrieval position above the drive mechanism 17, the drive mechanism is activated to lift the base plate (not visible in this figure) and the stock 5 to the raised position. When the base plate is in the raised position, either the entire stock 5 or a portion 19 of the stock 5 protrudes above the vertical level of the rim 11 of the storage container 3, and is therefore accessible from the side. The robot arm 51 moves until the grabber device 64 is positioned over the storage container 3. The jaws 53 move to the open position, which is achieved by a frame member 61 that slides outward relative to a horizontally extending member 65. The robot arm lowers the grabber device 64 until the horizontal plate 55 is positioned beside either the stock 5 or a portion 19 of the stock 5 above the level of the rim 11 of the storage container 3 in the retrieval position. The actuator 67 then retracts the frame member 61 and slides inward relative to the horizontally extending member 65, moving the jaw 53 from the open position to the closed position. As the jaw 53 closes, the horizontal plate 55 slides under the stock items to lift the stock items from the top of the pile of stock items in the storage container 3.

[0064] Figure 5 schematically shows the stock retrieval system of Figure 4 with the jaws 53 in the closed position. Two horizontal plates 55 are brought closer together to close the gap between them and support the stock item 33 on the two horizontal plates 55. The robotic arm 51 can then lift the grabber device 64 and the stock item 33 and place the stock item 33 on the stock surface 29.

[0065] As can be seen in the illustrated example, the robot base 57 can move the grabber device 64 away from the storage container 3 and rotate to place the grabber device 64 and the stock item 33 on the stock surface 29.

[0066] Once positioned on the stock surface 29, the robotic arm lowers the stock item 33 and the grabber device 64 until the horizontal plate 55 rests on or slightly above the stock surface 29. The jaws 53 then move from the closed position to the open position, and the horizontal plate 55 slides out from under the stock item 33, placing the stock item 33 on the stock surface 29.

[0067] The stock surface 29 may be, for example, a table in an order picking station and / or packing station. In another example, the stock surface 29 may be a stock conveying means that transports the stock items 33 away from the stock retrieval machine to, for example, an order picking station and / or packing station in a warehouse or another part of the storage and retrieval system. For example, the stock conveying means may be a conveyor, a robotic arm, one or more vehicles, or any other suitable means capable of transporting the stock. Any suitable stock conveying means may be used in combination with any example of the stock retrieval machine described herein.

[0068] In the illustrated example, the stock surface 29 extends perpendicular to the container conveyor 27. This configuration is an efficient use of space, particularly in the case of a stock conveyor where the stock surface 29 is configured to transport stock away from the stock retrieval system in a direction perpendicular to the direction of the container conveyor. In other examples, other configurations of the container conveyor and the stock surface or stock transport means are possible.

[0069] After the stock item 33 is removed from the storage container 3, the base plate 13 may be moved back to the lowered position, and then the storage container 3 may be transported away from the retrieval position, and another storage container 3 may be transported to a retrieval position where the robotic arm 51 and grabber device 64 are ready to retrieve the stock item from the other container 3.

[0070] In the illustrated example, the grabber device 64 comprises two opposing jaws 53. In other examples, other configurations of the grabber device may be used. For example, the grabber device may comprise claws or other gripping elements instead of jaws, and may be provided with three or more gripping elements instead of a pair. In another example, the jaws or claws or other gripping elements may engage directly with the stock item 33 and hold the stock item by applying pressure to one or more sides of the stock item rather than the horizontal plate sliding beneath the stock item.

[0071] Figure 6 is a cross-sectional view of the stock retrieval system shown in Figures 4 and 5.

[0072] The drive mechanism 17 may be located beneath the storage container 3 in the retrieval position. The drive mechanism 17 comprises four support rods 23, each having its own piston 37 configured to drive the support rod 23 up and down. The upper ends of the support rods 23 engage with the lower surface of the base plate 13, lifting the base plate 13 and the stock 5 resting on it. In the illustrated example, the four support rods are configured such that one support rod is located near each of the four corners of the base plate 13, but in other examples, different numbers and configurations of support rods 23 are possible. The drive mechanism 17 may be a hydraulic mechanism, a linear actuator, a rack and pinion mechanism, or any other preferred mechanism or combination of mechanisms.

[0073] The container conveyor 27 (shown with the front section removed for ease of explanation) is equipped with rollers 35. The rollers rotate to transport the storage containers 3 along the container conveyor 27. The support rods 23 are configured to protrude through the space between the rollers 35. In other examples, different types of conveyors may be used. In some examples, the container conveyor 27 may be provided with stoppers (not shown) to stop the storage containers 3 in the unloading position, i.e., in the correct position aligned with the support rods 23.

[0074] As can be seen in Figure 6, at the intermediate position, the base plate 13 is still below the vertical level of the rim 11 of the storage container 3. A portion 19 of the stock 5 protrudes above the level of the rim 11, but a portion of the stock 5 is still below the level of the rim. The height of the horizontal plate 55 of the grabber device 64 can be changed by the movement of the robotic arm 51. Thus, it is possible to vary how much of the stock 5 is lifted by the grabber device, i.e., how many stock items 33 are picked up and transferred from the storage container to the stock surface. Advantageously, this makes it possible to take out the required number of stock items 33. For example, if a customer order is for one stock item, the grabber device can take out one stock item 33 and leave the rest of the stock 5 in the storage container 3.

[0075] In Figure 6, the base plate 13 is in an intermediate position. The base plate 13 is spaced apart from the bottom wall 9 of the storage container 3. The portion 19 of the stock 5 is raised above the vertical level of the rim 11 of the side wall of the storage container 3 in the retrieval position, and this portion 19 is therefore accessible from the side. From the figure, it can be seen that the jaws 53 (only one is shown) are in the open position and are ready to be closed to lift the stock items from the pile of stock items in the storage container 3.

[0076] In some examples, the drive mechanism and / or robotic arm may be provided with sensors (not shown) to ensure that the horizontal lifting plate engages at the correct vertical level to slide between items in a stock during an item stack, for example. The sensors may be, for example, motion sensors, proximity sensors, or vision sensors. The sensors may be used to determine how high the support rod 23 should lift the base plate 13 and / or the position required for the grabber device before the horizontal lifting plate should move to their closed positions.

[0077] As described above, the stock retrieval system may be provided with a control system configured to control the drive mechanism, for example, by controlling the movement of a base plate to move between a raised position and a lowered position. In some examples, there may be an intermediate position in addition to the raised position, i.e., the control system is configured to selectively raise the base plate to different positions relative to the bottom wall of the storage container, depending on the number of stock items in the storage container and the dimensions of the individual stock items. The different positions will raise different portions of the stock above the level of the rim of the storage container. For example, the raised position may be appropriate if all or most of the stock is to be transferred, while the intermediate position may be more convenient if only one or a small portion of the total number of stock items is to be transferred, leaving some stock items in the container. In some examples, there may be further positions at a vertical level above the raised position.

[0078] Figure 7 is a cross-sectional view of the same stock retrieval system shown in Figures 4, 5, and 6, viewed from below to show the drive mechanism in more detail. In the figure, one of the pair of jaws 53, the container conveyor 27, and the side walls of each of the storage containers 3 have been removed for illustrative purposes. Three storage containers 3a, 3b, and 3c may be seen. An opening 21 in the lower wall 9 of storage container 3 can be easily seen. It can be seen that the support rod 23 passes through the opening 21 in the lower wall 9 of storage container 3b in the retrieval position, with the upper end 25 of the support rod 23 engaged with the lower surface of the base plate 13. The lower surface of the base plate 13 may have engaging features for positioning the support rod 23, such as a recess shaped to receive the upper end 25 of the support rod 23.

[0079] The direction of movement of the storage containers 3 along the container conveyor (not shown) is indicated by the arrows in Figure 7. The storage container labeled 3a has already had some of its stock 5 removed. The storage container labeled 3b is currently in the retrieval position, ready for the grabber device 64 to retrieve some stock items. The storage container labeled 3c has a higher level of stock 5 and is waiting to move to the retrieval position in the line of storage containers 3 once stock items are retrieved from the previous storage container 3b.

[0080] The first embodiment of the transfer means 31 can also operate in reverse. For example, the grabber device can take one or more stock items 5 from the stock surface 29, the robot arm 51 can move the grabber device 64 over the storage container 3, and the grabber device 64 can return the stock items 5 to the storage container 3 (when the base plate is in the raised or intermediate position). This function can be useful, for example, when processing customer returns. Effectively, the stock retrieval system operates in reverse, i.e., returning stock items to the storage system rather than retrieving them from the storage system.

[0081] The drive mechanism shown in the illustration and described above may also be applied to other embodiments of the stock retrieval system, such as the embodiments described below.

[0082] Second embodiment of tilting mechanism-transfer means Figure 8 shows a stock retrieval system 1 with different transfer means 31. In this case, the transfer means 31 is a tilting mechanism that allows the base plate 13 to be tilted to transfer stock 5 from the storage container to the stock surface 29. The support rods 23 comprise two sets of support rods: a first set 23a and a second set 23b. The first set 23a of support rods is positioned lateral to the base plate 13 closest to the stock surface 29, and the second set 23b of support rods is positioned lateral to the base plate 13 furthest from the stock surface 29. In the illustrated example, the first set 23a and the second set 23b each consist of two support rods, making a total of four support rods 23. Four rods are convenient for a square or rectangular storage container 3, as one support rod 23 can engage with each of the four corners of a square or rectangular base plate 13. In other examples, the first and second support rods 23a, 23b may comprise different numbers of rods, and / or the storage container 3 and base plate 13 may have different shapes. For example, the first set of support rods may comprise one support rod, and the second set of support rods may comprise one support rod.

[0083] During use, the container conveyor 27 carries the storage container 3 to the retrieval position. The support rods 23a and 23b move upward and protrude through the opening 21 in the lower wall 9 of the storage container 3, engaging with the base plate 13. The support rods 23a and 23b continue to move upward, lifting the base plate 13 to the raised position. When in the raised position, the base plate 13 is lifted by the support rods 23a and 23b up to the rim 11 of the side wall of the storage container 3, and thus the base plate 13 is flat. The first set of support rods 23a stops lifting when the base plate 13 reaches the same vertical level as the rim 11. The second set of support rods 23b continues to lift the base plate 13 above the level of the rim 11, and thus the base plate 13 is in an inclined position, tilted toward the stock surface 29. The inclination of the base plate 13 causes the stock 5 to slide from the base plate 13 onto the stock surface 29.

[0084] Unlike the robotic arm and grabber device transfer means in the previous example, in this example, all of the stock 5 in a given storage container 3 is transferred by the transfer means. When the base plate 13 is in the raised position, the entire stock 5 is above the vertical level of the rim 11. In the illustrated example, the stock 5 contains one item, but in other examples, the stock 5 may contain several items, for example, a stack of folded clothing or a stack of other products.

[0085] In the example shown in Figure 8, the transport means 31 is integrated with the drive mechanism 17, and the support rod 23 performs two functions by lifting the base plate 13 to the raised position and further moving the base plate 13 to the tilted position, so that the base plate 13 is tilted to transport the stock 5 onto the stock surface 29. This results in a simpler design with fewer parts.

[0086] Figures 9(a to d) schematically show a transport mechanism 31 in which the transport means is an inclined mechanism. Arrows indicate the direction of movement. In Figure 9(a), the base plate 13 is in the lowered position and rests on the lower wall 9 of the storage container 3. In Figure 9(b), the base plate 13 is in the raised position and is at the same vertical level as the rim 11 of the side wall 7 of the storage container 3. The first and second sets of support rods 23a and 23b lift the base plate 13 through the same vertical distance. In Figure 9(c), the base plate 13 is in the inclined position. The first set of support rods 23a remains in the same position as in Figure 9(b), and the second set of support rods 23b moves further up, lifting one end of the base plate 13 so that the base plate 13 is inclined at an angle to the horizontal. In Figure 9(d), the stock 5 slides off the inclined base plate 13 onto the adjacent stock surface 29.

[0087] Figure 10 shows a different view of the stock retrieval system of Figure 8. Stock 5 is being transported from the base plate 13 onto the stock surface 29. An inclined shelf 71 is provided to connect the stock surface 29 and the base plate 13 in the raised position, giving a smoother transition. The slope of the inclined shelf 71 further assists the stock 5 in sliding from the inclined base plate 13 to the stock surface 29. In the illustrated example, the inclined shelf 71 is attached to the edge of the stock surface 29 closest to the retrieval position.

[0088] In some examples, the stock surface 29 may be a stock conveyor. When stock 5 is transferred to the stock conveyor 29, another stock item 5 on the inclined base plate 13 may be ready to be transferred onto the stock conveyor 29. The advantage of the stock surface 29 being a stock conveyor is that the stock 5 transferred from the storage container 3 can be transported away from the stock retrieval system 1. This frees up space on the stock conveyor 29 for further stock 5 to be retrieved from further storage containers 3 and transferred onto the stock conveyor. Thus, the continuous flow of storage containers 3 on the container conveyor 27 and retrieved stock 5 on the stock conveyor 29 allows the system to operate continuously.

[0089] Figure 11 shows further details of the stock retrieval system 1, in which the transport means is an inclined mechanism. A roller 73 is provided between the stock surface 29 and the bottom of the inclined base plate 13 when the associated container 3 is in the retrieval position and the base plate 13 is in the raised position. The roller 73 further assists the transport of stock 5 from the inclined base plate 13 to the stock surface 29 by rotating in a direction away from the base plate to help move the stock from the base plate to the stock surface 29. The roller may be a passive roller or the roller may be actively driven. In some examples, two or more rollers may be provided. The roller 73 may be used as an alternative to or in combination with an inclined shelf 71, as shown in Figure 10.

[0090] Figure 12 shows further details of the stock retrieval system 1, in which the transport means is a tilting mechanism. In this example, the upper end 25b of a second set 23b of support rods is fitted with a guide wheel 75. As the second set 23b of support rods is raised in height, the guide wheel 75 rotates along the base plate 13 toward the edge of the base plate 13. The presence of the guide wheel makes this movement smoother and prevents wear that may occur due to scraping of the upper end 25b of the second set 23b of support rods against the underside of the base plate 13.

[0091] Figure 13 shows further details of the stock retrieval system 1, in which the transport means is a tilting mechanism. In this example, the underside of the base plate 13 is provided with guide channels 77 for guiding guide wheels 75. These guide channels 77 ensure that the guide wheels follow a predetermined path between their positions when the base plate 13 is in the raised position and their positions when the base plate 13 is in the tilted position. Each guide channel 77 is provided with a guide wheel stopper 79, which stops the guide wheels 75 from moving further along the guide channel 77 when the base plate 13 arrives in the tilted position. This then stops a second set 23b of the support rods from rising any higher. In other words, the guide wheel stopper 79 stops the guide wheels 75 on the guide channel 77 when the second set 23b of the lifting rods reach the end of their movement / their maximum height. Each guide channel 77 is also provided with a support rod stopper 81, which stops a first set 23a of the support rods from moving further along the guide channel 77 when the base plate 13 arrives in its tilted position.

[0092] In Figure 13, the base plate 13 is shown having downwardly curved edges or lips on two opposing sides. The purpose of these lips is to ensure that the base plate 13 lies flat and stable when it rests on the lower wall of the storage container 3 in the lowered position. Guide wheel fasteners 79 and / or rod fasteners 81 may protrude below the bottom surface of the base plate 13, which could otherwise mean that the base plate 13 would be unstable and / or not lie flat.

[0093] Figure 14 shows a cross-sectional view of the stock retrieval system 1 from Figures 8 to 13. Three storage containers 3a, 3b, and 3c can be seen. An opening 21 in the lower wall 9 of storage container 3 can be easily seen. It can be seen that the support rods 23a and 23b pass through the opening 21 in the lower wall 9 of storage container 3b at the retrieval position. The upper end of the first set of support rods 23a engages with the lower surface of the base plate 13 next to the base plate 13 closest to the stock surface 29. A guide wheel 75 at the upper end of the second set of support rods 23b engages with the lower surface of the base plate 13 next to the base plate 13 furthest from the stock surface 29. The second set of support rods 23b is lifted higher than the first set of support rods 23a, and therefore the base plate 13 is in an inclined position.

[0094] The direction of movement of the storage containers 3 along the conveyor is indicated by the arrows in Figure 14. The storage container labeled 3a has already had its stock 5 removed. The storage container labeled 3b is currently in an inclined position and is ready to slide its stock 5 from the inclined base plate 13 onto the stock surface 27. The storage container labeled 3c is waiting to move to the removal position in the line of storage containers 3 once its stock 5 is removed from the previous storage container 3b.

[0095] Third Embodiment of Extrusion Device-Transfer Means Figure 15 schematically shows another example of a stock retrieval system 1 having a transfer means 31. In this example, the transfer means 31 includes an extrusion device 91 for pushing the stock 5 from the base plate 13 of the storage container 3 onto the stock surface 29. The extrusion device 91 includes a flat surface and an extrusion rod.

[0096] During use, the drive mechanism 17 first lifts the base plate 13 to the raised position. The extrusion device 91 then moves horizontally from the retracted position to the extended position to extrude the stock 5 from the base plate 13 onto the adjacent stock surface 29. The flat surface of the extrusion device pushes the stock 5 along the surface of the base plate 13 and engages with the side of the stock 5 to bring the base plate 13 onto the stock surface. In the illustrated example, as described above, there is an inclined shelf 71 between the base plate 13 and the stock surface 29 to facilitate the smooth movement of the stock 5 onto the stock surface. In other examples, rollers may be provided as an alternative to or in addition to the inclined shelf.

[0097] The extrusion device 91 can be operated manually or powered by a linear actuator, electric motor, hydraulic system, or any other suitable mechanism.

[0098] Figure 15 shows the extrusion device 91 adjacent to the stock 5 in the retracted position, i.e., with the flat surface in the raised position. Figure 16 shows the extrusion device 91 in the deployed position, i.e., the extrusion device has been moved horizontally through the base plate to push the stock 5 away from the base plate 13 onto the stock surface 29.

[0099] Similar to the example of a stock retrieval system where the transfer means is a tilting mechanism, in this illustrated example, the entire stock 5 is transferred from the storage container 3. However, in other examples, either a single stock item or a stack of stock items may be transferred. When a stack of stock items is transferred, the flat surface of the extrusion device 91 may be higher to engage with the entire height of the stack of stock items.

[0100] As shown in Figure 17, in this example, the drive mechanism 17 includes a support rod 23 that protrudes through an opening in the lower wall 9 of the storage container 3 in a manner similar to that in the embodiments described above.

[0101] The extrusion device 91 may be used in conjunction with the inclined base plate 13 of the previously described embodiment. For example, the extrusion device may be angled so that it moves in a direction parallel to the base plate when the base plate is in an inclined position.

[0102] Support rod with wheel Figure 19 schematically shows another example of the stock retrieval machine 1. The storage containers 3 are moved to the retrieval position by the container conveyor 27 in the direction indicated by the arrow in the upper left of the figure and then transported. Containers upstream of the retrieval position (upper left of the figure) do not have base plates, while storage containers downstream of the retrieval position (lower right) have base plates 13. Below the container conveyor 27 is a drive mechanism (not shown) which operates the support rods 23. Each support rod 23 has a wheel 26 connected to its upper end. The wheel 26 is configured to rotate around an axis parallel to the direction of movement of the storage containers 3 along the container conveyor 27.

[0103] In the illustrated example, each support rod 23 is shown with one wheel 26, but in other examples, a support rod may have an array of wheels on the same support rod. In some examples, a subset of support rods may have wheels, while the remaining support rods do not. In some examples, one or more of the support rods may have wheels, while the rest of the rods may have engaging features as described below.

[0104] A second conveyor, called the baseplate conveyor 30, is positioned on either side of the retrieval position and is aligned perpendicular to the direction of the container conveyor 27. The baseplate conveyor 30 moves to the retrieval position in the direction indicated by the arrow and then transports the baseplate 13. Thus, the wheels 26 allow the baseplate 13 to move in the direction of the baseplate conveyor 30, and therefore the support rods either receive the baseplate 13 from the baseplate conveyor 30 or transport the baseplate 13 to the baseplate conveyor 30.

[0105] To place the base plate 13 into the storage container 3, the base plate 13 is transferred from the rollers of the base plate conveyor 30 onto the wheels 26 of the support rod 23, and when the base plate 13 is within the footprint of the storage container 3, the support rod 23 is lowered to position the base plate 13 into the storage container 3. Alternatively, the base plate 13 can pass along the base plate conveyor 30 via the wheels 26 on the support rod 23 onto the base plate conveyor 30 on the opposite side of the retrieval position without being lowered into the storage container 3. This may be useful in cases where the base plate 13 is transporting stock and the correct stock items need to be placed into the storage container. The stock retrieval machine 1 can also operate in the reverse direction, i.e., to remove the base plate 13 from the storage container 3. In this case, the base plate 13 inside the storage container 3 is lifted to the raised position by the support rod 23, the base plate 13 is transferred from the wheel 26 of the support rod 23 onto the rollers of the base plate conveyor 30, and then the base plate 13 is transported away by the base plate conveyor 30.

[0106] Figures 20(a to d) schematically show the stock retrieval machine 1 in operation. In Figure 20(a), a specific base plate 13a is transported to the retrieval position by the base plate conveyor 30. The support rod 23 is fully extended, and therefore the wheel 26 is at the same vertical level as the base plate conveyor 30. The base plate 13a moves smoothly from the rollers of the base plate conveyor 30 to the wheel 26 on the support rod 23. In Figure 20(b), the base plate 13a has moved to the retrieval position and is at the level above the rim of the storage container 3a, i.e., directly above the specific storage container 3a in the raised position. In Figure 20(c), the support rod is retracted by the driving mechanism while supporting the base plate 13a. Thus, the base plate 13a is lowered below the storage container 3a. In Figure 20(d), the support rod is lowered further so that the base plate 13a rests on the lower wall of the storage container 3a, i.e., the base plate 13a is in the lowered position. Since storage container 3a has had its base plate 13a inserted, storage container 3a can be moved away by the container conveyor 27. Another storage container 3 can then be transported to a retrieval position, ready for another base plate 13 to be inserted in the same manner.

[0107] The base plate 13 is shown in Figures 19 and 20 as a tray with lips on all sides. In other examples, a base plate 13 without lips may be used. For ease of explanation, there is no stock shown on the base plate, but in some examples, a stock removal machine may be used to place trays containing stock into storage containers. Figure 20 shows the operation of placing a base plate into a storage container, but the operation can be performed equally well in the reverse direction, i.e., a stock removal machine may be used to remove a base plate from a storage container (with or without stock).

[0108] The wheeled support rod mechanism is a means for inserting a base plate into or removing a base plate from a storage container. It can be used with an empty base plate or a base plate that holds stock (as shown here). It can be used as an alternative to or in addition to the transport means described above, either at the same station or at different stations in a larger system.

[0109] Engagement feature In some examples, one or more of the upper ends of the support rods and / or the underside of the base plate may be provided with engaging features for engaging the upper ends of the support rods with the underside of the base plate. The purpose of the engaging features is to overcome any snagging or catching of the edges of the base plate into the side walls of the storage container and to ensure good alignment of the base plate within the storage container when in the lowered position. The engaging features are particularly useful when the side walls of the storage container are not necessarily parallel due to manufacturing variations. The engaging features may be located on the upper ends of the rods, on the underside of the base plate, or both.

[0110] High friction surfaces, such as rubber pads or O-rings, may be used. Electro-contact surfaces (e.g., pads) may be used, where current is applied to conductive electrodes to generate an electric field. The electric field creates opposing charges on the surface touched by the pad, resulting in electrostatic adhesion between the electrodes and the induced charges on the contact surface. Magnetic pads, either electromagnetic or permanent magnets, may be used. The upper end of the support rod may be tapered and engage with a corresponding recess on the underside of the base plate. Alternatively, a recess in the upper end may engage with a projection on the underside of the base plate. In the examples shown in Figures 19 and 20, where the support rod includes a wheel, grooves or tracks may be provided on the underside of the base plate as engaging features with deeper portions or recesses to position the wheel appropriately along the track. These are merely examples, and any suitable engaging features may be used.

[0111] Figure 21 shows two different examples of engagement features. Figure 21(a) shows a pad on the upper end 25 of the support rod 23. The base plate 13 is shown as transparent for easy visualization so that the upper end of the support rod can be clearly seen. The pad (e.g., friction, adhesive, or magnetic) provides a larger surface area, which can assist engagement. Figure 21(b) shows another example where the upper end 25 of the support rod 23 tapers.

[0112] Ceiling In some cases, the stock handled by the stock retrieval machine may contain liquids. Depending on the product type, e.g., hazardous liquids, fragile products containing liquids, or mixed product types, e.g., groceries where cleaning solutions and food can be packaged in the same container, it becomes particularly important to contain any spills. Figure 22 shows an example of a storage container 3, a base plate 13, and a support rod 23 for use in such cases. An opening 21 in the bottom wall of the storage container 3 is surrounded by a seal 20 to prevent liquid leakage through the opening 21. The edges of the base plate may also be surrounded by seals.

[0113] Figure 22(a) shows the base plate 13 in the lowered position. It can be seen that there is a space 24 between the base plate and the bottom wall 9. This space can be used as a small reservoir to collect and contain any spilled liquid. In some cases, a moisture sensor may be provided in the space 24 to detect when a spill occurred. Figure 22(b) shows the base plate 13 in the raised position. The lower surface of the base plate has an engaging feature 22, in this example, a self-locating tapered foot. The tapered foot has a dual purpose: to sit in the seal 20 when the base plate 13 is in the lowered position, thus sealing the opening 21 (thus allowing the support rod 23 to be fully retracted and removed), and to act as a spacer that provides the space 24 between the base plate 13 and the bottom wall 9 of the storage container 3.

[0114] Alignment feature section Figure 23 shows an example of alignment features to ensure smooth movement of the base plate 13 as it moves vertically between the raised and lowered positions within the storage container 3. The edges of the base plate 13 slide along the inside of the side wall 7.

[0115] In Figure 23(a), the inside of the two shorter side walls 7 of the storage container is provided with vertical ribs 93 extending from the bottom wall of the storage container 3 to the rim. The base plate 13 has corresponding recesses 95 on the two shorter sides of the base plate 13. The vertical ribs 93 and the recesses 95 cooperate to guide the vertical movement of the base plate between the lowered and raised positions.

[0116] In Figure 23(b), the insides of the two shorter side walls 7 of the storage container 3 are provided with vertical grooves 97 extending from the bottom wall of the storage container 3 to the rim. The base plate 13 is provided with corresponding projections 99 on the two shorter sides of the base plate 13. The vertical grooves 97 and projections 99 cooperate to guide the vertical movement of the base plate between the lowered and raised positions.

[0117] In both of these examples, ribs / recesses or grooves / projections are provided on two opposing sides of the storage container. Other configurations are possible, and alignment features may be provided on one, multiple, or all sides of the storage container, and / or alignment features may be provided on one, multiple, or all corners of the storage container. Different combinations of alignment features may be used.

[0118] Other transformation forms The specific embodiments described herein are non-limiting examples of how a stock retrieval system may be implemented, and it will be apparent to those skilled in the art that variations are possible. For example, the transfer means may be provided by a human worker or by any other suitable mechanism or combination of mechanisms capable of fulfilling the function of retrieving one or more stock items from a storage container when the base plate of the storage container is raised to a raised position so that at least a portion of the stock is accessible from the side. In examples where the transfer means is a robotic arm, other types of end effectors, such as suction cups or magnets, may be used instead of a grabber device.

[0119] In some examples, two or more different types of transfer devices may be provided to the same stock retrieval system. For example, a stock retrieval system may comprise a robotic arm, an inclined base plate, and / or an extrusion device. Different transfer devices may be appropriate in different situations; for example, a robotic arm with a grabber device may allow the transfer of a portion of the stock while leaving some of the stock in the storage container, while an inclined base plate and / or an extrusion device may be suitable for transferring the entire stock on the base plate. Providing various types of transfer devices offers further flexibility and allows the same stock retrieval system to handle different numbers and types of stock items.

[0120] Similarly, alternative drive mechanisms may be used. In other examples, the drive mechanism may be contained within the storage container, for example, a hydraulic or scissor lift or rack and pinion mechanism located within the storage container in the space between the base plate and the lower wall of the storage container and used to raise the level of the base plate from a lowered position to an elevated position.

[0121] In some examples, the distance between the lowered and raised positions of the base plate may be a single fixed distance, while in others, this distance may be variable. A variable distance allows for variations in the portion of the stock that protrudes above the rim of the storage container, thereby allowing different amounts of stock to be dispensed.

[0122] If the drive mechanism is located outside the storage container, the base plate can be lifted relative to the storage container, and / or the storage container can be lowered relative to the base plate, as schematically shown in Figure 2. This principle can also be applied to other types of drive mechanisms.

[0123] The configuration of container handling means and stock handling means in a stock retrieval system can also vary. While the specific example described uses a container conveyor and stock surface or stock conveyor, in other examples, different container handling means may be used instead of a container conveyor, and different stock handling means may be used instead of a stock surface or stock conveyor. For example, the container handling means and / or stock handling means may be a conveyor, a robotic arm, one or more vehicles, or any other suitable means capable of transporting storage containers or stock. For example, a stock retrieval system may be given zero, one, or two or more container handling means of the same or different types, and zero, one, or two or more stock surfaces or stock handling means of the same or different types. A configuration using multiple container handling means has the advantage that storage containers can be moved between the stock retrieval system and other parts of a larger storage system. Similarly, a configuration using multiple stock handling means has the advantage that stock can be moved between other parts of a larger storage system. In some examples, a stock retrieval system may have one or more stock surfaces and one or more stock handling means.

[0124] In some examples, two or more transfer devices may be used within the same stock retrieval system. For example, different types of transfer devices may be suitable for different types or sizes of stock or different types or sizes of storage containers. In other examples, one transfer device may be shared among multiple adjacent stock retrieval systems. For example, if the transfer device is a robotic arm, the robotic arm may be positioned between two stock retrieval systems such that both stock retrieval systems are within the robotic arm's range.

[0125] How to take out the stock Figure 18 is a schematic flowchart illustrating the method of stock retrieval using the stock retrieval system as described above. In step 101, the container transport means carries the storage container containing the stock to the retrieval position, ready for stock retrieval. In step 102, the drive mechanism moves the base plate of the storage container from the lowered position to the raised position. In the raised position, at least a portion of the stock in the storage container protrudes above the rim of the storage container and is therefore accessible from the side. In step 103, the transport means retrieves at least one stock item from the portion of the stock above the rim level and places at least one stock item on the stock transport means. As described above, the transport means can take many different forms. In step 104, the stock transport means moves the at least one stock item just retrieved from the storage container away from the stock retrieval system, for example, to a picking or packing station in another part of the storage facility. In step 105, the drive mechanism moves the base plate back to the lowered position. In step 106, the container transport means moves the storage container away from the retrieval position to make space for another storage container. If the storage container still contains stock (i.e., not all of the stock was retrieved by the transport means in step 103), the storage container may be transported back into the storage system. If the storage container is empty, the storage container may be transported to a different part of the storage system for inspection / cleaning or for reuse for new stock coming into the storage system. In step 107, the container transport means carries another storage container containing the stock items to be retrieved to the retrieval position and is ready to restart the process with the new storage container. The arrow in Figure 18 returning from step 107 to step 102 indicates that the stock retrieval method is repeated for the new storage container.The removal of stock from storage containers can be a continuous process, where new storage containers are transported to the stock removal system by container transport means, and the storage containers are removed from the stock removal system by stock transport means after the required stock has been removed.

[0126] The described method is merely suggestive, and not all steps may apply to all stock retrieval systems. For example, some stock retrieval systems may not be provided with container and / or stock handling means. This method can also be applied using the steps in reverse order to place stock into storage and retrieval systems.

[0127] Further features This disclosure may also be defined by the following numbered clauses.

[0128] 1. A stock retrieval system, i) Storage containers for housing stock, ii) A base plate configured to support the stock and be stored inside the storage container, the base plate being movable vertically relative to the bottom of the storage container, iii) A drive mechanism configured to move the base plate relative to the bottom of the storage container from a lowered position where the base plate is at a lower level than the top of at least one side wall of the storage container to an elevated position where the base plate is at or above substantially the same vertical level as the top of at least one side wall of the storage container. A stock retrieval system equipped with [a specific feature].

[0129] 2. The stock retrieval system according to Clause 1, wherein the storage container comprises at least one side wall having a rim on the upper edge of at least one side wall, which is optional.

[0130] 3. The storage container is equipped with a bottom wall, and is part of the stock retrieval system as described in Clause 1 or Clause 2.

[0131] 4. The stock retrieval system as described in Clause 3, wherein the base plate is movable perpendicular to the lower wall of the storage container.

[0132] 5. A stock retrieval system according to Clause 3 or Clause 4, which is subordinate to Clause 2, wherein at least one side wall and a bottom wall define a box-shaped structure.

[0133] 6. A stock removal system according to any one of clauses 1 to 5, wherein the base plate comprises at least one free edge.

[0134] 7. A stock retrieval system according to Clause 6, which is dependent on Clause 2, wherein when the base plate is stored in the storage container, at least one free edge is adjacent to at least one side wall.

[0135] 8. The stock retrieval system according to any one of clauses 1 to 7, further comprising a control system configured to control a drive mechanism to move a base plate between an elevated position and a lowered position.

[0136] 9. The stock removal system according to Clause 8, further configured to control the drive mechanism to move the base plate from a lowered position to at least one intermediate position on the vertical level between the lowered position and the raised position.

[0137] 10. The stock retrieval system according to any one of the clauses 1 to 9, comprising a drive mechanism, at least one support rod having an upper end configured to engage with the lower surface of a base plate, and optionally, when subject to clause 3, the lower wall having at least one opening, and at least one support rod configured to protrude through at least one opening.

[0138] 11. The stock retrieval system according to Clause 10, wherein the drive mechanism is configured to move at least one support rod vertically upward to lift the base plate in the storage container from a lowered position to an elevated position.

[0139] 12. The stock retrieval system according to Clause 10, wherein the drive mechanism is configured to move the storage container downward in a direction perpendicular to the base plate.

[0140] 13. The drive mechanism is a stock retrieval system as described in any one of clauses 1 to 9, which is contained within the storage container.

[0141] 14. A stock removal system according to any one of clauses 1 to 13, further comprising a transfer means configured to remove at least one item of stock from the base plate when the base plate is in the raised position.

[0142] 15. The stock retrieval system according to Clause 14, comprising a robotic arm having an end effector with one or more horizontal lifting plates that are movable between a closed position in which one or more horizontal lifting plates support at least one item of stock from below and an open position in which one or more horizontal lifting plates are separated from at least one item of stock.

[0143] 16. The stock removal system according to Clause 14, wherein the transfer means comprises a tilting mechanism configured to tilt the base plate to an inclined position in an elevated position to allow removal of at least one item of the stock by sliding it off the base plate.

[0144] 17. A stock retrieval system according to Clause 16, which is dependent on Clause 14, wherein the drive mechanism comprises a plurality of support rods, and the tilting mechanism is configured to move the first set of support rods relative to the second set of support rods such that the upper ends of the second set of support rods are at a higher vertical level than the upper ends of the first set of support rods.

[0145] 18. The stock removal system according to Clause 14, comprising an extrusion device configured to move in a direction parallel to a base plate to remove at least one item of stock from a storage container by pushing at least one item of stock from a base plate.

[0146] 19. A method for removing stock using a stock removal system described in any one of Clauses 1 to 18, wherein the storage container comprises one or more items of stock on a base plate, and the method is i) Using a drive mechanism, move the base plate from a lowered position to an elevated position or an intermediate position between the lowered and elevated positions such that at least one item of stock on the base plate is at a level vertically above the top of at least one side wall of the storage container. ii) Remove at least one item from the stock from the base plate. A method that includes the following steps.

[0147] 20. The stock retrieval system is further equipped with an output conveyor, and this method is iii) Transferring at least one item from the stock on the output conveyor, iv) Transport at least one stock item away from the stock retrieval system using an output conveyor. The method described in Clause 19, further comprising the steps of the preceding paragraph.

[0148] 21. The stock retrieval system comprises an input conveyor configured to move the storage container to the retrieval position, and this method is Before step i), move the storage container to the retrieval position using the input conveyor. After step ii), move the base plate to the lowered position using the drive mechanism, move the storage container away from the retrieval position using the input conveyor, and move another storage container to the retrieval position using the input conveyor. The method described in clause 20 or 21, further comprising the steps of the same.

Claims

1. It is a stock retrieval system, i) Storage containers for holding stock, ii) A base plate configured to support the stock and be stored within the storage container, wherein the base plate is movable perpendicular to the bottom of the storage container, iii) A drive mechanism configured to move the base plate relative to the bottom of the storage container from a lowered position where the base plate is at a lower level than the top of at least one side wall of the storage container to a raised position where the base plate is at or above substantially the same vertical level as the top of the top of at least one side wall of the storage container. Equipped with, The drive mechanism includes at least one support rod having an upper end configured to engage with the lower surface of the base plate. Stock retrieval system.

2. The stock retrieval system according to claim 1, wherein the storage container has a bottom wall having at least one opening, and the at least one support rod is configured to protrude through the at least one opening.

3. The stock retrieval system according to claim 1 or 2, wherein the base plate comprises at least one side wall that is substantially lower in height than the at least one side wall of the storage container.

4. The stock retrieval system according to any one of claims 1 to 3, further comprising a control system configured to control the drive mechanism so that the base plate moves between the raised position and the lowered position.

5. The stock retrieval system according to claim 4, wherein the control system is further configured to control the drive mechanism to move the base plate from the lowered position to at least one intermediate position on the vertical level between the lowered position and the raised position.

6. The stock retrieval system according to any one of claims 1 to 5, wherein the drive mechanism is configured to move the at least one support rod vertically upward to lift the base plate in the storage container from the lowered position to the raised position.

7. The stock retrieval system according to any one of claims 1 to 5, wherein the drive mechanism is configured to move the storage container downward in a direction perpendicular to the base plate.

8. The stock retrieval system according to any one of claims 1 to 7, further comprising a transfer means configured to remove at least one item of stock from the base plate when the base plate is in the raised position.

9. The stock retrieval system according to claim 8, wherein the transport means comprises a robotic arm having an end effector comprising one or more horizontal lifting plates, the one or more horizontal lifting plates being movable between a closed position supporting the at least one item of the stock from below and an open position separating the one or more horizontal lifting plates from the at least one item of the stock.

10. The stock removal system according to claim 8, wherein the transport means comprises a tilting mechanism configured to tilt the base plate to an inclined position in the raised position so as to enable removal of at least one item of the stock by sliding it off the base plate.

11. The stock retrieval system according to claim 10, wherein the at least one support rod comprises a plurality of support rods, and the tilting mechanism is configured to move the first set of support rods relative to the second set of support rods such that the upper ends of the second set of support rods are at a higher vertical level than the upper ends of the first set of support rods.

12. The stock retrieval system according to claim 8, wherein the transfer means comprises an extrusion device configured to move in a direction parallel to the base plate in order to remove at least one item of the stock from the storage container by pushing the at least one item of the stock out from the base plate.

13. The stock retrieval system according to any one of claims 1 to 12, wherein one or more upper ends of the at least one support rod and / or the lower surface of the base plate are provided with engaging features configured to engage the upper ends with the lower surface of the base plate.

14. The stock retrieval system according to claim 13, wherein the engagement feature portion comprises one of a high-friction surface, an electronically adhesive surface, an electromagnetic pad, and a permanent magnet pad.

15. A stock retrieval system according to any one of claims 1 to 14, dependent on claim 2, further comprising a seal surrounding an opening in the front wall of the storage container and / or a seal surrounding the edge of the base plate and / or a space between the base plate and the lower wall, wherein optionally the space comprises a moisture sensor.

16. A stock retrieval system according to any one of claims 1 to 15, wherein the inner side of the at least one side wall of the storage container is provided with the vertical ribs and the base plate is provided with the recesses, such that the vertical ribs and corresponding recesses cooperate to guide the vertical movement of the base plate between the lowered position and the raised position.

17. The stock retrieval system according to any one of claims 1 to 16, wherein the inner side of at least one side wall of the storage container is provided with the vertical groove and the base plate is provided with the projection, such that the vertical groove and the corresponding projection cooperate to guide the vertical movement of the base plate between the lowered position and the raised position.

18. The stock retrieval system according to any one of claims 1 to 17, wherein one or more of the upper ends of the at least one support rod are provided with wheels for facilitating the movement of the base plate to insert the base plate into or out of the container when the base plate is in the raised position, or to remove the base plate.

19. The stock retrieval system according to claim 18, further comprising: a container transport means configured to move the container in a first direction to a retrieval position in which the base plate can be inserted into or removed from the storage container; and a base plate transport means configured to transport the base plate to the retrieval position or from the retrieval position in a second direction, wherein the second direction is perpendicular to the first direction.

20. A method for retrieving stock using the stock retrieval system according to any one of claims 1 to 19, wherein the storage container comprises one or more items of stock on the base plate, and the method is i) Using the drive mechanism to move the base plate from the lowered position to the raised position or an intermediate position between the lowered position and the raised position such that at least one item of stock on the base plate is at a level vertically above the upper part of the at least one side wall of the storage container, ii) A method comprising the step of removing the at least one item from the stock from the base plate.

21. The stock retrieval system further comprises stock transport means, and the method is iii) Transferring at least one item of the stock onto the stock transport means, and iv) Transporting the at least one stock item away from the stock retrieval system using the stock transport means. The method according to claim 20, further comprising the step of:

22. The stock retrieval system includes container transport means configured to move the storage container to the retrieval position, and the method is The method according to claim 20 or 21, further comprising the steps of: before step i), moving the storage container to the retrieval position using the container transport means; after step ii), moving the base plate to the lowered position using the drive mechanism; moving the storage container away from the retrieval position using the container transport means; and moving another storage container to the retrieval position using the container transport means.

23. A method for combining a storage container and a base plate using the stock retrieval system described in claim 19, wherein the method is: i) Moving the storage container to the retrieval position using the container transport means, ii) Raising the support rod, iii) Moving the base plate from the base plate transport means to the raised position on the at least one support rod, iv) Lowering the base plate from the raised position to the lowered position within the storage container, v) A method comprising the step of removing the storage container and the base plate from the removal position using the container transport means.

24. A method for separating a base plate from a storage container using the stock retrieval system described in claim 19, wherein the method is: i) Moving the storage container and the base plate to the removal position using the container transport means, ii) Raising the base plate to the raised position, iii) Moving the base plate from the raised position to the base plate transport means, iv) Lowering the at least one support rod, v) A method comprising the step of removing the storage container from the removal position using the container transport means.

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