A robotic food vending system

Abstract

A food vending system (1) has a hatch (3) as a single point of entry and exit of a product (P). There are two arrays of storage cells (30-32, 40-42) arranged one on each side of a robotic carriage (52) pathway. A robotic system (50) carriage (52) is arranged to move in the pathway, and a carriage drive (81-83, 90-92) moves the carriage in the pathway to be in registry with a particular cell or the hatch. An actuator (59, 60) moves linearly from the carriage into a cell and from the cell back to the carriage, and a flap (61, 63) is pivotable relative to the actuator between an inoperative position and an operative position engaging a product. The controller moves the flap to pull a product from a cell into the carriage when the carriage is in registry with the cell, and moves the flap (61, 63) to push a product into the hatch (3) when the carriage (52) is in registry with the hatch. The carriage actuator (60) is arranged to move linearly into an upper space of a cell and to pivot the flap from an upper inoperative position downwardly to the operative position protruding into the cell. Any desired arrangement of products (P) within each cell may be achieved by applicable operation of the actuator.

Description

[0001] “A Robotic Food Vending System”

[0002] Introduction

[0003] The present invention relates to food vending for locations such as schools and workplaces, or other public areas including train stations, airports, motorway service stations.

[0004] US2017 / 0053099 (Coughlin et al) describes a prescription storage and retrieval system with a storage matrix with an outer housing and containers. An attachment device is pushed and pulled into and out of compartments.

[0005] US2022 / 189235 (Glucksman et al) describe a food station in which food products are each stored in a portion container carrier with a front plate and a handle for coupling to an end effector.

[0006] US2014 / 212250 (Wolter) describes shelves with rollers and manipulators which can grip a product to roll them in and out of the shelves.

[0007] US2016167879 (Masuda) describes a side arm transfer device which extends and retracts on an arm, laser sensors and a turning mechanism to turn the laser sensor.

[0008] US2022 / 0371821 (Cheng eta ) describes a handling robot having a material handling device with a support bracket, a fork to rotate around the vertical direction, in which the form has a temporary storage unit.

[0009] US2015 / 0291356 (Oke et al) describes a bin module automated storage and retrieval system having dollys on wheels.

[0010] The invention is directed towards providing a system for storage and retrieval of products for vending, to achieve versatility in terms of the product shapes and sizes and indeed number of products. For example, it is desired that a system can store and dispense food items and is not limited to dispensing only certain types of drinks and snacks. Examples include:

[0011] - Ready-made meals (in boxes).

[0012] - Sandwiches / baguettes / wraps.

[0013] - Salads (boxed).

[0014] - Cold drinks bottles.

[0015] - Yoghurt pots. - Chocolate bars.

[0016] - Snack items in bags, such as crisps.

[0017] The present invention is directed towards providing efficient vending of specific meals to individuals in a manner which is easy to use and reliable. Another object is optimisation of storage space within the system.

[0018] Summary of the Invention

[0019] We describe a product storage and dispensing system comprising: a controller with a digital data processor, a hatch for delivery of a product to a customer, a plurality of storage cells arranged in at least one dimension, a robotic system comprising: a carriage arranged to move in a pathway, a carriage drive to move the carriage in the pathway to be in registry with a particular cell or the hatch, an actuator mounted to the carriage and comprising: an arm (68, 69) arranged to move linearly (X) into an upper space of a cell and within the upper space of the cell back towards the carriage, and a flap (61, 63) which is pivotable on the arm between an upper inoperative position in the upper space of a cell and an operative position extending downwardly into space of the cell for engaging a product, wherein the controller is configured to: control the actuator so that the flap (61, 63) is moved to the operative position to pull a product from a cell or the hatch when the carriage is in registry with the cell or the hatch, and to control the actuator so that the flap is moved to the operative position to push a product into a cell or the hatch when the carriage is in registry with the cell or the hatch.

[0020] In some preferred examples, the actuator comprises a plurality of flaps arranged side-by-side apart in a dimension transversely across a cell, and the flap drive is configured to operate one or more selected flap according to transverse position of a product within the cell. In some preferred examples, the controller is configured to control the actuator to retrieve a desired product which is on an opposed side of a product in a cell by: initially retrieving the nearer product into the carriage, placing said nearer product in a different cell, and retrieving the desired product by pulling said desired product because a path in the cell between the desired product and the carriage is clear.

[0021] In some preferred examples, the carriage comprises an internal flap arranged to move products within the carriage to be in a position for placement in a cell by an actuator.

[0022] In some preferred examples, the internal flap has a drive for pivotal movement between an upper inoperative position in an upper space in the carriage and an operative position extending downwardly into space of the carriage for product engagement.

[0023] In some preferred examples, the carriage comprises an actuator on each opposed side of the carriage, and wherein there are cells arranged on either side of the pathway of the carriage.

[0024] In some preferred examples, the carriage comprises an internal flap arranged to move products within the carriage to be in a position for placement in a cell by an actuator, and wherein the controller is configured to: cause a first actuator to retrieve a product from the hatch or a cell on a first side of the carriage and place it in the carriage, internally, within the carriage, cause the internal flap to move the product towards an opposed, second side of the carriage, cause a second actuator to push the product into a cell on said opposed side of the carriage.

[0025] In some preferred examples, the controller is configured to move the carriage in the pathway before causing said second actuator to push the product.

[0026] In some preferred examples, the carriage actuator drive comprises at least one ball screw mechanism for the linear actuator motion.

[0027] In some preferred examples, the carriage actuator drive comprises pneumatic pistons for pivoting the flap between the operative and inoperative positions. In some preferred examples, the controller is configured to move the carriage for both retrieval of delivered product from the hatch and to deliver vended products to the hatch, whereby the hatch is a single point of entry and exit.

[0028] In some preferred examples, there are cells arranged in three dimensions, a lateral (X) dimension, a depth (Y) dimension, and a vertical (Z) dimension.

[0029] In some preferred examples, the system comprises a vertical pathway for the carriage and the cells are arranged to a lateral horizontal side, in use.

[0030] We also describe a product storage and dispensing system comprising: a digital data processor, a hatch for delivery of a product to a customer, a plurality of storage cells arranged in at least one dimension, a robotic system comprising: a carriage arranged to move in a pathway, a carriage drive to move the carriage in the pathway to be in registry with a particular cell or the hatch, an actuator mounted to the carriage and arranged to move linearly from the carriage into a cell and from the cell back to the carriage, and a flap which is movable on the actuator between an inoperative position and an operative position engaging a product, the controller being configured to: move the actuator flap to pull a product from a cell and to push a product into a cell when the carriage is in registry with the cell, and to move the flap to pull a product from the hatch and to push a product into the hatch when the carriage is in registry with the hatch.

[0031] In some preferred examples, the carriage actuator is arranged to move linearly into an upper space of a cell and to pivot the flap from an upper inoperative position downwardly to the operative position protruding into the cell.

[0032] In some preferred examples, the actuator comprises a plurality of flaps arranged side-by-side apart in a dimension Y across a cell, and the flap drive is configured to operate a selected flap according to position of a product within the cell. In some preferred examples, the controller is configured to retrieve a desired product which is on the opposed side of a nearer product in a cell by: initially retrieving the nearer product into the carriage, placing said nearer product in a different cell, and retrieving the desired product by pulling because a path in the cell between the desired product and the carriage is clear.

[0033] In some preferred examples, the carriage actuator drive comprises at least one ball screw mechanism for the linear actuator motion.

[0034] In some preferred examples, the carriage actuator drive comprises pneumatic pistons for pivoting the flap between the operative and inoperative positions.

[0035] In some preferred examples, the carriage comprises an actuator on each opposed side of the carriage.

[0036] In some preferred examples, the carriage comprises an internal flap arranged to move products within the carriage to be in a position for placement in a cell by an actuator.

[0037] In some preferred examples, the internal flap has a drive for movement to upper horizontal positions on both sides and downwardly for product engagement.

[0038] In some preferred examples, the controller is configured to move the carriage for both retrieval of delivered product from the hatch and to deliver vended products to the hatch, whereby the hatch is a single point of entry and exit.

[0039] In some preferred examples, there are cells arranged in three dimensions, a lateral X dimension, a depth Y dimension, and a vertical Z dimension.

[0040] In some preferred examples, there are cells arranged on either side of a path of the carriage.

[0041] In some preferred examples, the system comprises a vertical pathway for the carriage and the cells are arranged to a lateral horizontal side, in use. In some preferred examples, there are cells arranged on both laterals sides of the carriage pathway in a vertical direction and in a depth direction.

[0042] In some preferred examples, the hatch has a front shutter for external access, and a separate internal shutter for internal access by the carriage actuator.

[0043] In some preferred examples, the carriage drive comprises a drive for one dimension (Z) and a separate independent drive for an orthogonal dimension (Y) within the pathway.

[0044] In some preferred examples, the controller is programmed to optimise product placement in the cells according to pattern of usage. In some preferred examples, the hatch has a machine reader to read both a product unique identifier, and to automatically alert need for expelling product which are at or beyond their best-before date. In some preferred examples, the controller is programmed to automatically expel said expired products before entry of fresh product are allowed.

[0045] In some preferred examples, at least one cell comprises a heater, and the controller is configured to activate the heater when a product is present within the cell to prepare it for dispensing. In some preferred examples, said cell includes a door and an actuator to close the door when heating is taking place.

[0046] Detailed Description of the Invention

[0047] The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which:

[0048] Fig. l is a perspective view of a food vending system of the invention,

[0049] Fig. 2(a) is a perspective view of the system with the front cover removed, illustrating the major internal components, and Fig. 2(b) is a diagram illustrating possible food product placement positions in cells of the system,

[0050] Fig. 3 is a perspective view showing a robot of the system in more detail,

[0051] Fig. 4 is a perspective view of a carriage of the robot, Fig. 5 is a plan view and Fig. 6 is a perspective view of the carriage with both cell product manipulation actuators in outer positions,

[0052] Fig. 7 is a perspective view of an actuator in more detail,

[0053] Fig. 8 is a front view of a central product manipulating flap device when folded, and Figs. 9 and 10 show this device with the flap folded in the opposite direction and when extended respectively,

[0054] Fig. 11 is a plan sectional view in the direction of the arrows D-D as graphically shown within Fig. 11,

[0055] Fig. 12 is a side sectional view in the direction of the arrows E-E as graphically shown within Fig. 12,

[0056] Figs. 13(a) and 13(b) are front views of a loading hatch with the shutter closed and open respectively,

[0057] Figs. 14(a) and 7(b) are a perspective view and a front view of the loading hatch receiving a food product and subsequently shutting respectively,

[0058] Figs. 15(a) and 15(b) are a front view and a perspective view of the robot in use moving into registry with the hatch,

[0059] Figs. 16 is a perspective view showing a safety door being opened for access to the hatch by the robot,

[0060] Fig. 17 is a perspective view showing the carriage moving into registry with the hatch,

[0061] Fig. 18 is a top perspective view showing a robot actuator moving into the hatch, and Fig. 19 shows the actuator flap lowering to catch the product,

[0062] Fig. 20 is a top perspective view showing the product being pulled from the hatch by the robot flap, Fig. 21 is a top perspective view showing in further detail how the robot flap is controlled,

[0063] Fig. 22 is a top perspective view showing the product being pulled into the carriage,

[0064] Fig. 23 is a front view showing delivery by the robot of the product into a storage shelf,

[0065] Fig. 24 is a top perspective view showing how the robot pusher retracts and it’s flap lowering when the product is in the target storage shelf,

[0066] Fig. 25 is a front view showing the product being pushed into the storage shelf,

[0067] Fig. 26 is a top perspective view showing the robot returning to a home configuration, and

[0068] Figs. 27 to 35 are a sequence of perspective views showing an actuator in use in a sequence of steps for placing and retrieving products.

[0069] Description of the Embodiments

[0070] Referring to Figs. 1 and 2(a) a food vending system 1 of the invention comprises a rectangular housing 2 with a loading / unloading hatch 3 for food products which forms a single point of entry or exit from the system, and which is closed by a vertical shutter 4 when not in use. There is a viewing window 5 at a central location of the front of the housing 2, and a touch screen human interface 6. The top of the housing 2 has a cooling system with ventilation grilles 7. The housing 2 is mounted on casters 8.

[0071] As shown most clearly in Fig. 2(a) the system 1 has a central robotic system 50 having a carriage 52 which moves vertically (Z-direction), and horizontally between the front and rear (Y-direction). On either side of the robot 50 there is a set of nine rows of storage shelves which are three-deep. As viewed from the front the shelves on the left are indicated by 30, 31, and 32 and those on the right are indicated as 40, 41, and 42 from front to back. Depending on the sizes of the products each shelf can store up to six products. On the right side one of the storage shelf spaces is taken up by the hatch 3, which is transiently used for placing products into the system and taking products out of the system.

[0072] In summary, a product such as a pre-prepared meal in a box is inserted into the hatch 3, the robot 50 picks it from the hatch 3 and places it into a designated storage shelf, and stores in memory a product identifier which is automatically machine read from a bar or other code and also stores an associated shelf identifier. When a customer purchases a product, he or she gives instructions, identification, and payment via the interface 6 and the robot 50 picks the relevant product form the storage shelf 30-32 or 40-42 and delivers it to the hatch 3, from where it is removed after the shutter 4 is opened. In some examples the product is purchased in advance using an app and the controller automatically retrieves the relevant product upon the user providing an instruction to reclaim the product.

[0073] Fig. 2(b) illustrates graphically the versatility of the system 1. Each cell can store any number up to six products P in configurations as illustrated, with product possibly being on the far side of another product or side-by-side with another product. This allows excellent storage capacity and also versatility in use of the device. Moreover, the cells 30-32 and 40-42 are passive shelves in the form of pigeon-holes, all of the product manipulation being performed by the robot 50, as described below. This allows excellent robustness due to presence of minimal moving parts. The only limiting factor on what items can be handled by the machine is the physical size. Once the physical size of the item does not exceed the size of the individual shelves of the machine (referred to as the “cell”), it can be facilitated. The storage cells (individual storage shelves 30-32 or 40-42) are configured so that one cell can store a single large item or multiple smaller items, as needed. In one example, the cells each have the following dimensions:

[0074] Height: 120 mm.

[0075] Width: 200 mm.

[0076] Depth: 400 mm.

[0077] The desired cell is accessed by movement of the carriage 52 both vertically (Z) and between front and back (Y). If an item that is required to be dispensed is situated “behind” a different item type e.g. in arrangement C of Fig. 2(b), the actuator will retrieve the item that is “in the way”, place it in another location temporarily, dispense the desired item, and then put the first item back where it started.

[0078] The system 1 is an integrated food ordering, delivery, and vending system for industrial or office settings. It is an automated, refrigerated, robotically controlled food vending machine. A smartphone or web browser-based application allows the end user to order food items to their local vending machine, manage orders and facilitate on-demand purchases. Back-end infrastructure (both IT and food production) processes the user orders and delivers the desired food items to the relevant system.

[0079] In one typical use the following are the steps.

[0080] - The user accesses the menu of items that can be ordered via the software application (PC or Smartphone)

[0081] - The user chooses the items they would like to purchase, and the day / date they would like the item delivered to their place of work.

[0082] - The day / evening before the item is desired, the item is delivered to the site along with all the other orders required for the next day.

[0083] - The driver loads each item individually into the machine. The machine (using the internal robotic system 50) automatically places the items into free storage spaces in the machine’s shelves 30-32 and 40-42.

[0084] - The following day, when the customer wishes to retrieve their order, they scan the QR code for their order at the user terminal screen 6.

[0085] - The customer’s order is retrieved by the machine’s robotic system 50 and is dispensed at the hatch 3.

[0086] Any applicable cooking instructions are displayed at the user terminal 6 (a microwave cooker may be provided beside the vending machine). Additional items may be available in the vending machine for spontaneous purchases by customers without the need for pre-ordering.

[0087] The internals of the vending machine are kept refrigerated by the refrigeration unit 7 (located on top of the machine). The robotic assembly and inlet / outlet hatch are controlled by a Programmable Logic Controller (PLC) which is also located in the top of the system.

[0088] The machine can store and dispense generic food items and is not limited to dispensing only certain types of drinks and snacks. The items that can be stored and dispensed include (but are not limited to):

[0089] - Ready-made meals (in boxes).

[0090] - Sandwiches / baguettes / wraps.

[0091] - Salads (boxed).

[0092] - Cold drinks bottles.

[0093] - Yoghurt pots.

[0094] - Chocolate bars.

[0095] - Snack items in bags, such as crisps. Other versions may have different cell sizes, depending on the customer requirements.

[0096] Due to the precision offered by the robotic pick-place operations, items can be placed in various arrangements within the cells, and some sample arrangements are shown in Fig. 2(b). The robot has an actuator with an arm which moves in the X direction to a desired extent to push a delivered product into the cell to the desired extent and to pull it out when vended.

[0097] In this specification the direction X is left to right as viewed from the front of the system 1, the direction Y is front to back, and the direction Z is vertical. The X direction may be regarded as a longitudinal direction for movement of the actuators into and out of the cells, and the cells have a transverse (Y) direction across the cell relative to this longitudinal direction.

[0098] This flexibility means that the storage space of every cell can be dynamically allocated by the software when the machine is being loaded with food items. This is very advantageous. In traditional vending machines, each slot is allocated for a certain type of food item, and this allocation is fixed and may only be changed by changing the machine configuration. Here, the combination of the generic cell design and the pick-place robotics ensure that any cell may accommodate any food item that the vending machine carries. Furthermore, because the system 1 dynamically allocates food items to certain cells based on the available cells and what is currently in each cell, the utilisation of storage space within the machine is exceptionally efficient.

[0099] The robot carriage 52 is driven, as described in more detail below, in the Y and Z directions, and a ball screw mechanism within the carriage moves flaps in the X direction and a pivot mechanism rotates each individual flap between an upper inoperative position and a downward operative position for pushing or pulling products. In all cases, the items are either pushed or pulled by the flaps which descend from the actuator of the carriage 52. Once the flap has descended, and is alongside a product, the flap is either pushed or pulled as needed.

[0100] As described in more detail below, the extent of versatility is achieved without need for complex moving parts. A cell is accessed by a single Z movement controlled by a single motor, and depth Y movement also by a single motor. A single motor causes the X direction movement of the actuator into the relevant cell over any products in the cell and rotation about a transverse axis perpendicular to the X direction to that it extends downwardly into the space of the cell In more detail, and referring to Fig. 3, the carriage 52 is in the form of a shelf with a structure 53 and which is open on both lateral (X-direction) sides. For Z movement, the robotic system 50 has four pillars 80 each supporting a belt 81 driven by pulleys 82 linked with a common motor 83. This mechanism moves the whole robotic carriage 52 in the vertical Z direction for registry with one of the rows of cells. Accuracy and simplicity is achieved because there is only a single common motor driving all of the four belts 81.

[0101] For Y movement, there is a pair of belts 90 driven also by a single common motor 91 to move the carriage 52 forwardly and rearwardly relative to a frame 95 which is driven vertically by the mechanism 80-83.

[0102] Referring to Figs. 4 to 10 the carriage 52 is shown in more detail. It has a frame 53 with a shelf which is open on both sides in the X direction. A first actuator 59 moves out into a cell on the right and a second actuator 60 moves out into a cell on the left. The actuator 59 has an arm 69 pivotally supporting a pair of side-by -side flaps 63 driven individually by pneumatic pistons 67. The actuator 60 has an arm 68 and also has a similar arrangement of a pair of flaps 61 and pistons 67. Each actuator 59 and 60 has a drive provided by a ball screw 64 linked with a motor 65 to move a carriage on the inner end of the associated arm 69 / 68. Within the housing of one of the motors 65 a solenoid switch allows it to provide motion to a carriage 70 for movement within the carriage 52 of a middle flap 62, which can be pivoted by a pneumatic piston 72 up to horizontal and inoperative on one side (Fig. 8), to being horizontal and inoperative on the opposite side (Fig. 9), or down to be operative (Fig. 10) for contact with a product within the carriage.

[0103] Each actuator 59, 60 is moved in the X direction by the operation of the associated linear ball screw 64 driven by a stepper motor 65 - which allows very high precision of movement to a resolution in the range of about 2 mm to 5 mm.

[0104] Fig. 11 shows the arrangement of cells 30-32 and 40-42 at one vertical level D-D, three deep and the Y direction scope for movement of the carriage 52. Fig. 12 is a side view E-E showing the full range of rows and columns of cells and the location of the hatch 3 taking the space on one cell.

[0105] Advantageously, all of the actuator flaps 61, 62, and 63 are pivoted between an upper inoperative position in an upper space of the cell or carriage as applicable. Each is pivoted downwardly to an operative position extending downwardly so that it can push or pull a product. The inoperative position allows the actuator to move freely because it is in the upper space over the products. The internal flap 62 allows effective transfer in the X direction from one side to the other within the carriage on the same principles. The X direction into and out of the cells may be regarded as axial / longitudinal and the Y dimension as transverse across a cell, and the flaps have pivot axes which are aligned transversely.

[0106] Figs 13 to 35 show operation of the system 1 as follows:

[0107] Figs. 13(a) and (b). The hatch 3 has a shutter 4 with a shutter plate 11 driven by a pair of pneumatic pistons 12 to allow loading of a product into the hatch 3.

[0108] Figs. 14(a) and (b). A product P is placed in the hatch 3 and the shutter 4 closes with the shutter plate 11 closing off access to the hatch.

[0109] Figs. 15(a) and (b). The carriage 52 moves to the hatch 3.

[0110] Figs. 16. An internal safety door 14 on the left side of the hatch opens to allow access by the robotic system to the product P.

[0111] Fig. 17. The mechanisms 80-83 and 90-91 move the carriage 52 to the vertical level Z of the hatch 3 and to the front position Y so that it is in registry with the hatch safety door 14.

[0112] Fig. 18. The actuator 60 is moved in the X direction from the carriage 52 so that it is in the hatch 3 and over the product P.

[0113] Fig. 19. The flaps 63 are pivoted to the lower position to engage behind the product P. In this case both of the flaps 63 are operated together because the product P has a width which fills a large part of the area of the hatch. If, however, the product were smaller it might be located on one side in the Y dimension and only one of the flaps 61 or 63 as applicable is operated.

[0114] Fig, 20. The product P is pulled into the carriage 52 by retraction of the actuator 60 by the drive screws 64.

[0115] Fig. 21. The middle flap 62 is moved to one side and is then lowered behind the product P now that it s within the carriage 52. Fig. 22. The middle flap 62 is driven to move the product further away from the hatch, and the hatch safety door 14 closes.

[0116] Figs. 23 and 24. The carriage 52 is moved in Z and Y to be in registry with a desired loading cell, and the actuator 60 is moved in X by the ball screw 64 to push the product into the cell.

[0117] Fig. 25. The product P is pushed further into the cell

[0118] Fig. 26. The actuator 60 retracts fully and the left flap 61 rises. The carriage is now ready for picking a product P from another shelf for delivery to the hatch 3 by performing the above in reverse order, or for storing a further delivered product P by re-performing the above steps 1.

[0119] Figs. 27 to 35 show how the system retrieves a product P in a particular cell 30 and delivers it to a different particular cell 40 for further storage. This is performed for optimum use of space in the cells 30, 31, 32, 40, 41, and 42. In these drawings:

[0120] Fig. 27 shows a product P in a cell 30.

[0121] Fig. 28 shows the actuator 60 being employed to move a flap 61 over the product, with the flap in its horizontal inoperative position.

[0122] Fig. 29 shows the flap 61 after being rotated to its operative position on the far side of the product P and starting to pull it towards the carriage 52.

[0123] Fig. 30 shows the setup when the product P has been pulled into the carriage housing 53 and after being pulled further by the internal flap 62.

[0124] Fig. 31 shows flap 61 returning to its inoperative / horizontal position after having pulled the product into the carriage 52 by about 100 mm. This is the transport position whereby the carriage can be moved to a destination cell and the process continues.

[0125] Fig. 32 shows the second step of moving a product from one side of the unit to the other; it utilises the same actuator that drives the flap 61, but to move the flap 62 (middle flap) into position to move the product from one side of carriage to other. This diagram shows the internal flap 62 with its pivot axis at its furthest extremity on the left side of the carriage as viewed in this drawing, the internal flap being pivoted to be horizontal and lie outside the carriage. Fig. 33 shows the product P at the outer limit on the right side after being pushed by the internal flap 62. The flap 62 is lowered behind the product and the product is pushed to a catch zone for the flap 63 to take over. The catch zone encompasses the right-hand end of the carriage and the start (mouth) of the cell on this side.

[0126] Fig. 34 shows the opposed outer actuator 59 being controlled to push the product P by its flap 63 into the destination cell 40.

[0127] Fig. 35 shows the product after having been left in the destination cell 40 at the desired location within this cell. It can subsequently be pulled back in as illustrated above for movement into the carriage from the left-hand cell (Figs. 28 to 30).

[0128] It is very advantageous that each actuator 59 and 60 can move linearly and a flap 61 / 62 move over a product and then pivot down to engage on either side of a product to push or pull it as desired. By having a pair of flaps on each side, and infinite adjustment in the X direction there may be six product positions in each cell, but with more flaps in other embodiments there would be correspondingly more possible positions.

[0129] For example, to place a product in the left-hand side of a cell, the left flap only descends. Therefore, when the ball screw is actuated, only the left-hand flap will be lowered into the cell cavity. Similarly for an item on the right-hand side.

[0130] If a large item is to be placed in (or retrieved from) a cell both flaps 61 or 63 will descend, ensuring the item is pushed (or pulled) evenly.

[0131] The central flap 62 is required when a product needs to be moved in the X direction within the carriage, such as when loading an item at the inlet-outlet hatch 3 and placing it in a cell on the left side. It is not needed when the product is to right side, being the same side as the hatch 3. Internal transfer of an item from a left cell to a right cell can occur when an item at the back of a cell is to be dispensed, and a differing item needs to be moved “out of the way”, or for internal stock rotation. It is also required as illustrated in Figs. 27 to 35 for transfer of a product from one cell to another to optimise storage.

[0132] The carriage 52 ensures that no specific tooling or bespoke grippers are required in order to manipulate the food items. The operating principle is simple: a flap is placed beside the item and the item is pushed or pulled) as necessary. This simple principle ensures that this single robot can manipulate any of the food items that can be carried by the vending machine, for example meal boxes, soft drinks bottles, baguettes, chocolate bars.

[0133] The use of servo motors allows for extremely high accuracy of movement, in addition to speed. The accuracy of the servo motors allow the carriage 52 to be placed exactly in front of the required storage cell. This is very advantageous.

[0134] As the system 1 can handle perishable items, it must be ensured that the system will not vend an item that is past its best-before date. To this end, the software that governs the machine operation shall log the best before date of every item when that item is loaded into the machine.

[0135] If an item is present in the shelves, and has gone past its best-before date, this item must be removed from the machine. This will be done as a part of the operation that takes place when items are being loaded into the machine by the delivery driver. When the driver initiates a load, a message will be shown on the machine’s display 6 indicating that out-of-date items need to be purged from the machine. The machine will then dispense these items. Once all of them have been dispensed, the delivery driver can load the new items, as normal.

[0136] It may occur that an item will exceed its best-before date between delivery days e.g. if there is a delivery on a Monday night and a Thursday night, and an item expires on Tuesday. In this case, the system’s software will allow the item to be sold until midnight on Tuesday. For Wednesday and all-day Thursday, the item will be marked as “out of date” within the software, and the software will not allow the item to be sold. The item will then be ejected on Thursday night, as above.

[0137] Because every cell size is the same, every cell can accommodate any product, as needed, as described above with reference to Fig. 2(b). There is no need to set up predefined locations for each item. Further to this, the system 1 can even store different item types in the same cell. Because the machine 1 dynamically allocates food items to certain cells based on the available cells and what is currently in each cell, the utilisation of storage space within the machine is exceptionally efficient. It will be appreciated that the invention achieves this extent of versatility without need for any moving parts in the cells: they are passive “pigeon holes” which store items with all of the product manipulation being performed by the central robot 50. Moreover, the robot 50 has only one motor for each of the vertical Z motion, depth Y motion, and one for each of the left and rightside X motions. This achieves reliability and easy maintenance. The carriage 52 it uses simple and generic mechanics to manipulate items of varying size and shape. The same arrangement of flaps, ball screws and stepper motors (all widely available and reliable off-the-shelf products) allows the system 1 to manipulate varying items as long, narrow cylindrical baguettes, ready meals in rectangular boxes, small chocolate bars, and everything in between.

[0138] The automatic ejection of out-of-date items avoids human monitoring and intervention in order to remove out of date stock.

[0139] The system 1 software application allows a user to pre order a meal (from a huge menu) to be delivered to their place of work, days in advance. Once the meal has been delivered, the customer may avail of their meal at a time of their choosing. They are not waiting for a delivery driver to deliver the meal. If the meal arrives at a time that is not convenient, they don’t have to worry about keeping the meal cool or hot.

[0140] Alternative Embodiments

[0141] Components of embodiments can be employed in other embodiments in a manner as would be understood by a person of ordinary skill in the art. The invention is not limited to the embodiments described but may be varied in construction and detail. In other examples of the invention the cells are arranged for access in only one dimension of movement of the robot. For example, they may be arranged in one horizontal row in which case the robot only moves in one dimension and on only one side. It is envisaged that this is more likely if the system is for deployment outdoors where there is more space, such as outside a convenience store for access out of hours. The products may be of any desired type other than food, such as a range of household goods sold in a convenience store.

[0142] It is envisaged that there may be more than one actuator arranged to enter a cell, and they may be to one side instead of at a higher level over the products. It is envisaged that one or more flaps may not be pivoting, but may move linearly by for example sliding into the operative and inoperative positions.

[0143] Heating / Cooking Examples

[0144] The arrangement of static cells as described allows for some or all of the cells to also perform the function of heating the product if it is a food product. In this these cells have an electrical heating element and preferably a door to close the cell. The product is placed into the cell and retrieved from the cell in the same manner as described above, but the controller additionally activates the heater at the applicable times to heat the product before vending at the hatch.

[0145] Bulk Heating In another example multiple items are moved into another set of cells, designated as a bulk heating area. The doors on the heating cell then close, and the entire chamber is heated for the appropriate time to heat the food adequately. At the predefined bulk dispense time, the cell doors open and the items can be dispensed in the manner described above.

Claims

Claims1. A product storage and dispensing system (1) comprising: a controller with a digital data processor, a hatch (3) for delivery of a product (P) to a customer, a plurality of storage cells (30-32, 40-42) arranged in at least one dimension, a robotic system (50) comprising: a carriage (52) arranged to move in a pathway, a carriage drive (81-83, 90-92) to move the carriage in the pathway to be in registry with a particular cell or the hatch, an actuator (59, 60) mounted to the carriage and comprising: an arm (68, 69) arranged to move linearly (X) into an upper space of a cell and within the upper space of the cell back towards the carriage, and a flap (61, 63) which is pivotable on the arm between an upper inoperative position in the upper space of a cell and an operative position extending downwardly into space of the cell for engaging a product, wherein the controller is configured to: control the actuator so that the flap (61 , 63) is moved to the operative position to pull a product from a cell or the hatch when the carriage is in registry with the cell or the hatch, and to control the actuator so that the flap is moved to the operative position to push a product into a cell or the hatch when the carriage is in registry with the cell or the hatch.

2. A system as claimed in claim 1, wherein the actuator comprises a plurality of flaps (61,63) arranged side-by-side apart in a dimension (Y) transversely across a cell, and the flap drive is configured to operate one or more selected flap according to transverse (Y) position of a product within the cell.

3. A system as claimed in claim 1 or claim 2, wherein the controller is configured to control the actuator to retrieve a desired product which is on an opposed side of a product in a cell by: initially retrieving the nearer product into the carriage,placing said nearer product in a different cell, and retrieving the desired product by pulling said desired product because a path in the cell between the desired product and the carriage is clear.

4. A system as claimed in any preceding claim, wherein the carriage comprises an internal flap (62) arranged to move products within the carriage to be in a position for placement in a cell by an actuator.

5. A system as claimed in claim 4, wherein the internal flap has a drive (71) for pivotal movement between an upper inoperative position in an upper space in the carriage and an operative position extending downwardly into space of the carriage for product engagement.

6. A system as claimed in any of claims 1 to 5, wherein the carriage comprises an actuator (59, 60) on each opposed side of the carriage, and wherein there are cells arranged on either side of the pathway of the carriage.

7. A system as claimed in claim 6, wherein the carriage comprises an internal flap (62) arranged to move products within the carriage to be in a position for placement in a cell by an actuator, and wherein the controller is configured to: cause a first actuator (59) to retrieve a product from the hatch or a cell on a first side of the carriage and place it in the carriage (52), internally, within the carriage, cause the internal flap to move the product towards an opposed, second side of the carriage, cause a second actuator (60) to push the product into a cell on said opposed side of the carriage.

8. A system as claimed in claim 7, wherein the controller is configured to move the carriage in the pathway before causing said second actuator to push the product.

9. A system as claimed in any preceding claim, wherein the carriage actuator drive comprises at least one ball screw mechanism (64, 65) for the linear actuator (60) motion.

10. A system as claimed in any preceding claim, wherein the carriage actuator drive comprises pneumatic pistons (67) for pivoting the flap (61, 63) between the operative and inoperative positions.

11. A system as claimed in any preceding claim, wherein the controller is configured to move the carriage (52) for both retrieval of delivered product from the hatch (3) and to deliver vended products to the hatch, whereby the hatch is a single point of entry and exit.

12. A system as claimed in any preceding claim, wherein there are cells arranged in three dimensions, a lateral (X) dimension, a depth (Y) dimension, and a vertical (Z) dimension.

13. A system as claimed in claim 12, wherein the system comprises a vertical pathway for the carriage and the cells are arranged to a lateral horizontal side, in use.

14. A system as claimed in any of claims 6 to 13, wherein there are cells arranged on both laterals sides of the carriage pathway in a vertical direction and in a depth direction.

15. A system as claimed in any preceding claim, wherein the hatch has a front shutter (4) for external access, and a separate internal shutter (14) for internal access by the carriage actuator.

16. A system as claimed in any preceding claim, wherein the carriage drive comprises a drive (81-82) for one dimension (Z) and a separate independent drive (90-92) for an orthogonal dimension (Y) within the pathway.

17. A system as claimed in any preceding claim, wherein the controller is programmed to optimise product placement in the cells according to pattern of usage.

18. A system as claimed in any preceding claim, wherein the hatch has a machine reader to read both a product unique identifier, and to automatically alert need for expelling product which are at or beyond their best-before date.

19. A system as claimed in claim 18, wherein the controller is programmed to automatically expel said expired products before entry of fresh product are allowed.

20. A system as claimed in any preceding claim, wherein at least one cell comprises a heater, and the controller is configured to activate the heater when a product is present within the cell to prepare it for dispensing.

21. A system as claimed in claim 20, wherein said cell includes a door and an actuator to close the door when heating is taking place.

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