Automated multi-dispenser and multi-replenisher of products, and method for product unloading

Abstract

An automated multi-dispenser and multi-replenisher of products for concurrent loading and unloading of products that simplifies existing systems, consisting of an elongated structure (1) which supports several central shelving units (2) with a set of inclined shelves (3) arranged at different heights one below the other and one next to the other, comprising a plurality of horizontal shelves (5) at each longitudinal side of the elongated structure (1); at least one rear loading subsystem in the form of a cart (6), which travels over these lateral shelving units (4) in order to leave the products on the highest section of the inclined shelves (3); at least one front unloading subsystem in the form of a cart (7), which collects the products from the lowest section of the inclined shelves (3), where the carts (6) and (7) also cover a plurality of inclined channels (8) including a support (9).

Claims

1. An automated multi-dispenser and multi-replenisher of products consisting of an elongated structure (1), which supports several central shelving units (2) with a set of inclined shelves (3) arranged at different heights one below the other and one next to the other, comprising a plurality of horizontal shelves (5) at each longitudinal side of the elongated structure (1), several shelving units (4), at least one rear loading subsystem in the form of a cart (6), which travels over these lateral shelving units (4) in order to leave the products on the highest section of the inclined shelves (3); at least one front unloading subsystem in the form of a cart (7), which collects the products from the lowest section of the inclined shelves (3); where the cart-type rear loading subsystem (6) and the cart-type front unloading subsystem (7) are automated guided vehicles with wireless control that locate products in the inclined channels (8) using an optical linear encoder and also cover a plurality of inclined channels (8) including a support (9) that is able to rotate about an axis (12), comprising a lower section (10), which is placed in a plane perpendicular to the dead stop (11), and a terminal section (13), which is placed in the plane containing the axis (12) wherein a container-shaped platform (16) turns perpendicularly to each horizontal shelf (5) and rises, thus pushing by means of its protrusion (17) the support (9) of the inclined channel (8) in order to pick the product.

2. The automated multi-dispenser and multi-replenisher of products according to claim 1, wherein an optical linear encoder includes a photoswitch (25) with opaque marks (19) in front of each inclined channel (8) under simple PLC technology control, communicating with the system via LED lighting.

3. A method to pick a product (14) while another product (15) is kept in an inclined channel (8) using the automated multi-dispenser and multi-replenisher of products according to claim 1, wherein there is a support (9) situated in the intermediate region between each pair of adjacent inclined channels (8), and each cart (6) pushes a bottom part (10) of the support (9), which rotates about an axis (12) and pushes a second product (15) against a wall opposite of the inclined channel (8) using its terminal section (13), holding all the products in the channel (8) except for the first one (14), which slides down by gravity.

4. The method according to claim 3, comprising the following operating stages: the system instructs the corresponding cart to pick a product (14) the cart advances with the an upper platform (16) in a horizontal position until it is placed in front of the inclined channel (8) that contains the product (14) without stopping, the cart raises the upper platform (16) until it pushes the product channel support (9) using the a protrusion (17) of one of its ends, then the cart momentarily stops and waits for the product to slide down by gravity into the cart's upper platform, while holding the other products of the channel then the cart moves backwards while placing the upper platform (16) in a horizontal 5 position; thus the support (9) of the product channel is released and recovers its rest position, leaving the remaining products in the channel (8) on the dead stop (11) of the channel (8).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of the automated multi-dispenser and multi-replenisher of products, which represents the field of the invention. It includes an elongated structure of modular shelving units supporting a set of inclined shelves where products are stored. Each side of this structure comprises additional shelving units with specific characteristics, horizontal shelves, and rear loading subsystems and front unloading subsystems travelling over every shelf.

(2) FIG. 2 is a view similar to FIG. 1, but showing greater detail and a single shelving module.

(3) FIGS. 3 and 4 are two different views of the product holding part of an inclined channel, which is placed between every pair of adjacent channels.

(4) FIGS. 5 to 15 are perspective views showing the possible states of one of the unloading (cart) subsystems during the unloading process of a particular product, together with the process sequence.

(5) FIGS. 16 to 20 are plan views showing the possible states of one of the unloading (cart) subsystems during the unloading process of a particular product, together with the sequence of this process.

(6) FIG. 21 is a perspective view of an individual inclined shelf with its corresponding horizontal shelves, showing the guiding profiles for carts, the marks used to locate products and the communication system between each shelf and its cart.

(7) FIG. 22 is a plan view of a cart base, showing the guiding profile of the cart, the mark detecting photoswitch and the communication system between the cart and its shelf.

PREFERRED EMBODIMENT OF THE INVENTION

(8) The automated multi-dispenser and multi-replenisher of products of the present embodiment essentially consists of an elongated structure (1) which supports several central shelving units (2) with a set of inclined shelves (3) arranged at different heights one below the other and one next to the other, this automated multi-dispenser and multi-replenisher of products comprising a plurality of horizontal shelves (5) at each longitudinal side of the elongated structure (1); at least one rear loading subsystem in the form of a cart (6), which travels over these lateral shelving units (4) in order to leave the products on the highest section of the inclined shelves (3); at least one front unloading subsystem in the form of a cart (7), which collects the products from the lowest section of the inclined shelves (3), where the carts (6) and (7) also cover a plurality of inclined channels (8) including a support (9).

(9) The carts (6) and (7) feature a horizontal translational motion parallel to the elongated, central shelving structure (1), and they are not required to move vertically since there is a cart for each vertical level of inclined shelves (3) where products are stored.

(10) The carts (6) and (7) are automated guided vehicles with wireless control that locate products in the inclined channels (8) using an optical linear encoder and include a container-shaped platform (16) used for product transfer at the top of the cart.

(11) This platform (16) turns perpendicularly to each horizontal shelf (5) and rises, thus pushing by means of its protrusion (17) the support (9) of the inclined product channel (8) in order to pick the product, or goes down in order to place a product in the inclined channel (8).

(12) The support (9) of the inclined channel (8) is characterized by a specific method for collecting an individual product while the others remain in the channel; for this purpose, the support (9) is located in the intermediate region between every pair of adjacent inclined channels (8) and each cart pushes the bottom part (10) of the support (9), which rotates about the axis (12) and pushes the second product (15) against the opposite wall of the inclined channel (8) using its terminal section (13), holding all the products in the channel except for the first one (14), which is dropped and slides down by gravity. When the cart goes backward, it releases the bottom part (10) and the support (9) recovers its rest position, where it holds all the products of the channel by means of a perpendicular end (11).

(13) As explained above, the carts (6) and (7) are automated guided vehicles, i.e., they may be any vehicle that is able to travel over horizontal shelves: wheeled vehicles, single rail or double rail vehicles, trolleys, single rails with permanent magnets, Scalextric type, etc. According to the preferred embodiment, carts are wheeled, battery-powered vehicles with optional opportunity charging, driven by electric motors, that travel with guided bearings along a profile (18) in a direction perpendicular to the horizontal shelves (5) over which they travel, locating products in the inclined channels (8) through an optical linear encoder (photoswitch) (25) with opaque marks (19) in front of each inclined channel (8) under simple PLC technology control, and communicating with the system via LED lighting.

(14) The benefit of LED lighting communication is that its manufacturing and maintenance costs are very low (each LED costs just a few cents) and it only requires light sensors, which are very cheap too, for managing communications without using controllers. Furthermore it eliminates the potential wave interferences associated with wireless wave systems, and its programming is simple and reliable.

(15) Every horizontal shelf (5) has at least one communication area (20) with the pertinent cart. This communication area (20) includes a light sensor (21) (LDR photoresistor) for identifying when the cart is ready in terms of communication, and N LEDs (22) to communicate (send) using light 2.sup.N different statuses (number of product/inclined product channel).

(16) Each cart features a LED (23), used to signal when it is ready for communication purposes, and N light sensors (24) (LDR photoresistor), used to communicate (receive) using light 2.sup.N different statuses (number of product/inclined product channel).

(17) The system structure is very simple. The POS (point-of-sale) terminals, the central computer (which may be one of the POS terminals), the MTs (mobile terminals) and the CCSI (communication and control system for the invention) are connected to a local network (LAN) through which the POS terminals and MTs instruct the CCSI which product is to be managed; therefore the CCSI only needs to turn the appropriate LEDs on in the specific shelf, while controlling cart availability through the status LED of the carts.

(18) The procedure used for product collection enables the development of a product unloading method by means of the automated multi-dispenser and multi-replenisher of products, comprising the following operational stages:

(19) The system instructs the corresponding cart to pick a product (14).

(20) The cart advances with the upper platform (16) in a horizontal position until it is placed in front of the inclined channel (8) that contains the product (14).

(21) Without stopping, the cart raises the upper platform (16) until it pushes the product channel support (9) using the protrusion (17) of one of its ends.

(22) The cart momentarily stops and waits for the product to slide down by gravity into the cart's upper platform, while holding the other products of the channel.

(23) The cart moves backwards while placing the upper platform (16) in a horizontal position; thus the support (9) of the product channel is released and recovers its rest position, leaving the remaining products in the channel (8) o the dead stop (11) of the channel (8).