AUTOMATED PRODUCT PACKAGING AND DELIVERY SYSTEM WITH ADVANCED BAGGING TECHNOLOGY

Abstract

An automated product packaging and delivery system for use in automated retail environments, comprising a rectangular system frame defining a product delivery chamber, a vertically moveable lift box frame with lift panel, and a mechanized door panel providing secure consumer access. The system includes a bag feeder assembly for dispensing flat-folded bags, right and left bag opening assemblies utilizing rotating scissor lifts with suction cups for precise bag manipulation, and proximity sensors ensuring proper component alignment. The system processes orders through multiple operational states and can accommodate both bagged and unbagged products, making it particularly suitable for applications including food products, prepared meals, and secure package delivery services.

Claims

1. An automated product packaging and delivery system comprising: a system frame defining a product delivery chamber; a lift box frame mounted within the system frame and configured for vertical movement; a lift panel mounted to the lift box frame; a door panel mounted to the system frame and configured to provide access to the product delivery chamber; and at least one bag opening assembly mounted adjacent to the system frame and configured to manipulate a bag into an open configuration.

2. The system of claim 1, wherein the lift box frame comprises: a linear actuator assembly mounted to the system frame and configured to drive vertical movement of the lift box frame; and linear bearing guide rails mounted to the system frame and engaging linear bearings affixed to the lift box frame.

3. The system of claim 1, further comprising a bag feeder assembly mounted adjacent to a rear wall panel of the system frame and configured to feed flat-folded bags through a slot in the rear wall panel onto the lift panel.

4. The system of claim 3, wherein the bag feeder assembly comprises: a bag storage chute; a feed roller assembly comprising feed wheels driven by a feed wheel motor; and separation roller wheels driven in an opposite direction from the feed wheels by a separation roller motor.

5. The system of claim 4, further comprising a spring-loaded plate configured to push bags against a front wall of the bag storage chute.

6. The system of claim 1, wherein the at least one bag opening assembly comprises: a right bag opening assembly mounted adjacent to a right wall panel; and a left bag opening assembly mounted adjacent to a left wall panel.

7. The system of claim 6, wherein each bag opening assembly comprises: a scissor lift; bag engaging devices mounted at an end of the scissor lift; a scissor lift drive mechanism; and a rotating drive mechanism.

8. The system of claim 7, wherein the bag engaging devices comprise suction cups.

9. The system of claim 6, further comprising concealing doors mounted on the right and left wall panels and configured to selectively conceal the right and left bag opening assemblies.

10. The system of claim 1, wherein the door panel comprises: a door panel carrier engaging horizontal slots in the system frame; shaft blocks mounted to the door panel and engaging shaft block slots; and a mechanical driving mechanism configured to move the door panel between open and closed positions.

11. An automated product packaging system comprising: a product delivery chamber; a lift panel configured for vertical movement within the product delivery chamber; a bag feeding mechanism configured to dispense individual bags onto the lift panel; and opposing bag opening mechanisms configured to engage and manipulate a dispensed bag into an open configuration.

12. The system of claim 11, wherein the lift panel comprises: a centrally located opening; and a semi-permeable layer covering the opening configured to apply vacuum to hold a bag in position.

13. The system of claim 11, further comprising proximity sensors configured to monitor movement of system components.

14. The system of claim 11, wherein the opposing bag opening mechanisms are configured to: sequentially engage opposite sides of a dispensed bag; lift the bag to a vertical orientation; and manipulate the bag into an open configuration suitable for receiving products.

15. The system of claim 11, wherein the system is configured to operate in multiple operational states comprising: an initialization state; a bag preparation state; a product placement state; and a delivery state.

16. A method of automated product packaging comprising: dispensing a flat-folded bag onto a lift panel within a product delivery chamber; engaging a first side of the bag with a first bag opening assembly; lifting the bag to a vertical orientation; engaging a second side of the bag with a second bag opening assembly; manipulating the bag into an open configuration; raising the lift panel to a product receiving position; and lowering the lift panel to a delivery position.

17. The method of claim 16, further comprising: applying vacuum through the lift panel to secure the flat-folded bag; and maintaining vacuum during bag manipulation.

18. The method of claim 16, wherein engaging the first and second sides of the bag comprises: deploying scissor lifts through concealing doors in the product delivery chamber; applying suction to the bag with suction cups mounted on the scissor lifts; and retracting the scissor lifts while maintaining suction.

19. The method of claim 16, further comprising: opening a door panel to enable access to the product delivery chamber; positioning the door panel to block access to an interior of the system during product retrieval; and returning the system to an initialization state after product retrieval.

20. The method of claim 16, wherein the method is configurable to process orders with or without bags based on consumer preference.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized. The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings, in which like reference numerals refer to similar elements, and in which:

[0012] FIG. 1 is a front view of an automated retail system incorporating multiple automated product packaging and delivery systems according to certain aspects of an embodiment of the invention, showing secure pickup windows behind which the automated product packaging and delivery systems are located.

[0013] FIG. 2 is a front perspective view of an automated product packaging and delivery system for use in the automated retail system of FIG. 1.

[0014] FIG. 3 is rear perspective view of the automated product packaging and delivery system of FIG. 2.

[0015] FIG. 4 is a front view of the automated product packaging and delivery system of FIG. 2.

[0016] FIG. 5 is a rear view of the automated product packaging and delivery system of FIG. 2.

[0017] FIG. 6 is a left side view of the automated product packaging and delivery system of FIG. 2.

[0018] FIG. 7 is a perspective view of a bag feeder assembly for use with the automated product packaging and delivery system of FIG. 2.

[0019] FIG. 8 is a cross-sectional view of the bag feeder assembly of FIG. 7.

[0020] FIG. 9 is a perspective view of the right bag opening assembly for use with the automated product packaging and delivery system of FIG. 2.

[0021] FIG. 10 is a second perspective view of the right bag opening assembly of FIG. 9.

[0022] FIG. 11 is an interior side view of the right bag opening assembly of FIG. 9.

[0023] FIG. 12 is a perspective view of the left bag opening assembly for use with the automated product packaging and delivery system of FIG. 2.

[0024] FIG. 13 is a second perspective view of the left bag opening assembly of FIG. 12.

[0025] FIG. 14 is an interior side view of the left bag opening assembly of FIG. 9.

[0026] FIG. 15 is a detail perspective view of the concealing door for use with the automated product packaging and delivery system of FIG. 2.

[0027] FIG. 16 is a sequence view showing the system in an initial state with a flat-folded bag dispensed onto the lift panel.

[0028] FIG. 17 is a sequence view showing deployment of the left bag opening assembly to engage and lift the bag.

[0029] FIG. 18 is a sequence view showing deployment of the right bag opening assembly to engage the opposite side of the bag.

[0030] FIG. 19 is a sequence view showing the bag in a fully opened configuration.

[0031] FIG. 20 is a sequence view showing the system in a product placement state with the lift panel raised to receive products.

[0032] FIG. 21 is a sequence view showing the system in a delivery state with the door panel opened to allow consumer access.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] The invention may be understood by referring to the following description and accompanying drawings. This description of an embodiment, set out below to enable one to practice an implementation of the invention, is not intended to limit the preferred embodiment, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form.

[0034] Descriptions of well-known functions and structures are omitted to enhance clarity and conciseness. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, the use of the terms a, an, etc. does not denote a limitation of quantity, but rather denotes the presence of at least one of the referenced item.

[0035] The use of the terms first, second, and the like does not imply any particular order, but they are included to identify individual elements. Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. It will be further understood that the terms comprises and/or comprising, or includes and/or including when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

[0036] Although some features may be described with respect to individual exemplary embodiments, aspects need not be limited thereto such that features from one or more exemplary embodiments may be combinable with other features from one or more exemplary embodiments.

[0037] In accordance with certain aspects of an embodiment of the invention, an automated product packaging and delivery system is provided. In an exemplary configuration, the system may be used for automated product packaging and delivery in an automated retail system 10 such as that shown in FIG. 1, which automated retail system 10 may enable the automated retail purchasing, packaging, and secure pickup and distribution of products without requiring human interaction. As shown in FIG. 1, the automated retail system 10 may offer purchases a variety of products available for vending through secure pickup windows 20, behind each of which are located automated product packaging and delivery systems 100 as described in detail below. Each such automated product packaging and delivery system 100 is configured to process a flat package, such as a folded bag for packaging products in the automated retail system 10, into an open configuration to receive such products, and in turn position the filled bag behind a secure pickup window 20 so that an authorized person (e.g., a consumer that has confirmed their identity to automated retail system 10 as the purchaser of a given product or number of products) may retrieve products that they have ordered from automated retail system 10.

[0038] By way of summary and with reference to FIGS. 2-6, each automated product packaging and delivery system 100 includes a generally rectangular system frame 110 formed of, by way of non-limiting example, a rigid metal, such as aluminum or steel, for structural support. A top of each system frame 110 defines a product delivery chamber 125 that, as described in detail below, may receive a completed, fully packaged order securely positioned behind door panel 120 (which may comprise secure pickup window 20 or alternatively may be a separate moveable door panel 120 behind pickup window 20), enabling an authorized consumer to collect their purchased and packaged products. A lift box frame 150 is mounted in the interior volume of system frame 110, and carries a horizontal lift panel 160 on the top of lift box frame 150. Lift box frame 150 (and lift panel 160) is vertically moveable in system frame 110 to enable a bag that is positioned on lift panel 160 to, after being automatically opened as discussed below, be moved to a filling position that is inaccessible through pickup window 20, filled with product via automated robotic arms inside of automated retail system 10, and thereafter moved back down to align with pickup window 20 to enable the authorized consumer to access and retrieve their order from product delivery chamber 125.

[0039] Product delivery chamber 125 is further defined by a right wall panel 126, a left wall panel 127, and a rear wall panel 128. Door panel 120 is mounted to system 100 such that upon opening of door panel 120 to enable a consumer to retrieve their product order, door panel 120 swings upwards to at least partially, or optionally entirely, block or close the top of product delivery chamber 120, such that the interior of automated retail system 10 remains inaccessible from product delivery chamber 125.

[0040] To enable vertical movement of lift box 150 and lift panel 160, a linear actuator assembly 152 is mounted to system frame 110 and to lift box frame 150, and includes an extensible element 153 that may be driven by linear actuator assembly 152 (such as an electric motor, a pneumatically driven piston, or other mechanical actuator as will readily occur to those skilled in the art) to vertically move linear lift box frame 150 in system frame 110. To further facilitate such vertical movement, linear bearing guide rails 154 may be mounted to system frame 110 and may receive linear bearings 156 that, in turn, are affixed to lift box frame 150. Thus, upon activation of linear actuator 152, extensible element 153 will cause lift box frame 150 and lift panel 160 to travel either upwards or downwards inside of system frame 110. At the lowermost position, lift box frame 150 is thus positioned so that lift panel 160 is at the bottom of product delivery chamber 125. Likewise, at the uppermost position, lift box frame 150 is positioned so that lift panel 160 is at the top of product delivery chamber 125. Linear bearing guide rails 154 thus extend from a position inside of system frame 110 upwards to the interior top of product delivery chamber 125 to enable the complete vertical movement of lift box frame 150 and lift panel 160.

[0041] Next and with particular reference to FIGS. 2, 5, and 6, automated product packaging and delivery system 100 further comprises a bag feeder assembly 200 (discussed in further detail below) mounted adjacent to rear wall panel 128 and positioned to feed flat, folded bags from the bottom of bag feeder assembly 200 through a slot 129 in the lower portion of rear wall panel 128, and to position such folded bag flat on lift panel 160. Likewise, automated product packaging and delivery system 100 further comprises a right bag opening assembly 300 mounted adjacent to a first concealing door 130 on right wall panel 126, and a left bag opening assembly 350 mounted adjacent to a second concealing door 130 on left wall panel 127. Each concealing door 130 is configured to open only during a bag opening operation, as described below, in order to allow right bag opening assembly 300 and left bag opening assembly 350 to enter into product delivery chamber 125 and manipulate the bag into the open configuration as discussed below. Thus, when door panel 120 is opened to allow a consumer to access their completed order in product delivery chamber 125, right bag opening assembly 300 and left bag opening assembly 350 are each behind their respective concealing door 130 to prevent access to or visualization of the bag opening assemblies by the consumer.

[0042] As noted above, door panel 120 is configured to open in a manner that moves door panel 120 from a vertical orientation at the front of system 100 to the top of product delivery chamber 125. To enable such lifting and pivoting movement, a mechanical driving mechanism 170 engages a door panel carrier 171 that rides through a horizontal slot 172 at the top of each of right wall panel 126 and left wall panel 127. In an exemplary configuration, a mechanical driving mechanism 170 may comprise a belt and pulley system that engages door panel carrier 171 to move door panel carrier 171 through slot 172. A motor 173, such as a stepper motor, may be mounted to rear wall panel 128 and engage each mechanical driving mechanism 170 to drive each mechanical driving mechanism 170 in coordinated movement for smooth opening and closing of door panel 120. To further aid in movement of door panel 120, shaft blocks 174 are mounted to the rear side of door panel 120 and engage an S-shaped shaft block slot 175 on the inside face of each of right wall panel 126 and left wall panel 127. Each shaft block 174 engages its respective shaft block slot 175 such that as door panel carrier moves through horizontal slot 172, shaft blocs 174 guide the lower portion of door panel 120 through an S-curve pattern such that door panel 120 both moves upward and retracts reward to enable a consumer to access product delivery chamber 125. Preferably, a rotary encoder 176 is provided that may count the number of times that door panel 120 is opened and closed for purposes of inventory and order management.

[0043] As noted above, lift panel 160 is carried by lift box frame 150 to move a bag that has been opened upward to a filling position (described below) and back down into product delivery chamber 125 for retrieval by an authorized consumer. Lift panel preferably has a centrally located opening, such as a circular opening that may be covered by a thin, semi-permeable layer, that enables a slight vacuum to be applied through lift panel 160 to the bottom of a package, such as a bag for packaging a consumer's order, to hold the bag in position as it proceeds through the opening and filling operations (via right bag opening assembly 300 and left bag opening assembly 350) as discussed below.

[0044] Preferably, system 100 may be equipped with one or more proximity sensors 180 that monitor the movement of the moveable components of system 100 and ensure proper location and alignment of all such elements through the bag deployment, filling, and retrieval processes.

[0045] Next, FIGS. 7 and 8 show detail views of bag feeder assembly 200 that is mounted to real wall panel 128 of system 100 to enable feeding of bags into product delivery chamber 125 (FIG. 8 showing bag feeder assembly 200 in cross-section). Bag feeder assembly 200 includes a bag storage chute 202 comprising an open chamber sized to receive a plurality of flat-folded bags in a generally stacked configuration. A spring-loaded plate 204 pushes the stack of bags against the front wall of bag storage chute 202, but may easily be retracted against springs 205 to enable loading of additional flat-folder bags into chute 202. The bottom of chute 202 houses a feed roller assembly comprising feed wheels 206 driven by a feed wheel motor 207, and separation roller wheels 208 driving in the opposite direction of feed wheels 206 by a separation roller motor 209. Separation roller wheels 208 are positioned with respect to feed wheels 206 to grab the front-or top-most flat-folded bag in the stack of bags inside of chute 202, pushing the bag downward and through a bag dispensing slot 212 that is aligned with slot 129 in rear wall panel 128, thus positioning the bag on lift panel 160 inside of product delivery chamber 125. Preferably, bag feeder assembly 200 is mounted on a mounting arm 210 that is positioned adjacent the exterior of rear wall panel 128.

[0046] Next, FIGS. 9-11 show the details of right bag opening assembly 300 which is mounted adjacent to right wall panel 126 on a frame member 301 of system frame 110 (FIG. 2). Right bag opening assembly 300 includes a scissor lift 302 mounting a pair of bag engaging devices 304, such as for example suction cups, at the end of scissor lift 302. Scissor lift 302 is mounted for deployment from a right bag opening assembly housing 303 so that bag engaging devices 304 may be moved outward and away from housing 303, and back again to a collapsed scissor lift configuration with the bag engaging devices 304 fully retracted. A scissor lift drive mechanism 306 (which may comprise, for example, an electric motor) engages and controls deployment and retraction of scissor life 302 from housing 303. Further, the entire housing 303, with scissor lift 302 and scissor lift drive mechanism 306, may be rotated by right bag assembly rotating drive 308 (which again may comprise an electric motor). As suction cups 304 are mounted vertically on scissor lift 302 (i.e., facing a direction parallel to the deployment direction of scissor lift 302), rotating housing 303 causes suction cups 304 to face the interior of product delivery chamber 125 so that the may engage a sidewall of a bag after it has been lifted by left bag opening assembly 350, as discussed below.

[0047] Further, FIGS. 12-14 show the details of left bag opening assembly 350 which is mounted adjacent to left wall panel 127 on a frame member 351 of system frame 110 (FIG. 3). Lef bag opening assembly 350 includes a scissor lift 352 mounting a pair of bag engaging devices 354, such as for example suction cups, at the end of scissor lift 352. Scissor lift 352 is mounted for deployment from a left bag opening assembly housing 353 so that bag engaging devices 354 may be moved outward and away from housing 353, and back again to a collapsed scissor lift configuration with the bag engaging devices 354 fully retracted. A scissor lift drive mechanism 356 (which may comprise, for example, an electric motor) engages and controls deployment and retraction of scissor lift 352 from housing 353. Further, the entire housing 353, with scissor lift 352 and scissor lift drive mechanism 356, may be rotated by left bag assembly rotating drive 358 (which again may comprise an electric motor). As suction cups 354 are mounted horizontally on scissor lift 352 (i.e., facing a direction perpendicular to the deployment direction of scissor lift 352), rotating housing 353 causes suction cups 354 to face downward towards lift panel 160 inside of product delivery chamber 125 so that they may engage a sidewall of a bag as it is sitting flat-folded on lift panel 160 following deployment from bag feeder assembly 200, as discussed below.

[0048] As mentioned above, each of right bag opening assembly 300 and left bag opening assembly 350 is mounted adjacent to a concealing door 130 in each of right wall panel 126 and left wall panel 127, respectively. As shown in FIG. 15, each concealing door 130 may include a mechanical actuator, such as an electric motor 132 driving a simple rack and pinion drive assembly 134, to open and close concealing door 130 to allow entry and exit of each of right bag opening assembly 300 and left bag opening assembly 350 into and out of product delivery chamber 125.

[0049] Next, FIGS. 16-21 show the steps of processing a bag that has been deployed onto lift panel 160, from the folded-flat orientation immediately after dispensing from bag feeder assembly 200 (FIG. 16), through opening of the bag with left bag opening assembly 350 and right bag opening assembly (FIGS. 17-19), to a product placement position (FIG. 20), configured to receive product from, for example, a robotic product handling arm in automated retail system 10, and bag to a consumer retrieval position (FIG. 21) enabling the consumer to retrieve the product from product delivery chamber 125.

[0050] At initialization following a product order, fulfillment, and retrieval by a consumer, lift panel 160 is preferably raised to its highest position and door panel 120 is closed, such that the product delivery chamber 125 defines an empty space closed on all sides. In this initialization state, concealing doors 130 are closed, and each of right bag opening assembly 300 and left bag opening assembly 350 are retracted with their respective scissor lifts 302 and 352 retracted and vertically oriented.

[0051] Next, during a bag preparation process and as shown in FIG. 16, lift panel 160 is lowered to its bottom position, a flat-folded bag is dispensed onto lift panel 160 through slot 129 in rear wall panel 128, and suction is applied through lift panel 160 to hold the bag in place on lift panel 160. With the flat-folded bag held on lift panel 160, left bag opening assembly 350 is deployed through the concealing door 130 in left wall panel 127 and, as shown in FIG. 17, suction cups 354 engage a left side wall of the bag to lift up both sidewalls of the bag to a vertical orientation. Then, as shown in FIG. 18, right bag opening assembly 300 is deployed through the concealing door 130 in right wall panel 126 and, as shown in FIG. 18, suction cups 304 engage a right side wall of the bag, at which point both scissor lifts 302 and 352 are retracted while maintaining suction to open the bag to the configuration shown in FIG. 19. At this point, each of right bag opening assembly 300 and left bag opening assembly 350 are fully retracted through their respective concealing doors 130, and the concealing doors 130 are closed.

[0052] Next, lift panel 160 is raised to place system 100 in a product placement state as shown in FIG. 20, with lift box frame 150 having been lifted upward through and fully into product delivery chamber 126 such that lift panel 160 is at the top of system 100, holding the bag in its open position to receive product from a robotic product handling arm in automated retail system 10.

[0053] Of course, in those cases where a consumer places an order for only a single product, or for any reason does not desire a bag, the system may proceed through the foregoing steps without deploying a bag.

[0054] Finally, after the consumer's order has been placed in the bag, lift panel 160 is lowered back into product delivery chamber 125 and door panel 120 is opened to allow a consumer to access and retrieve their bagged order from system 100 through one of pick up windows 20 in automated retail system 10. After the consumer has retrieved their bagged order, the system may return to the initialization state.

[0055] Systems configured in accordance with the foregoing description may be configured for automated packaging of a wide variety of products, including wet and dry food products, pickup of freshly prepared food items in cases in which automated retail system 10 comprises an unmanned food processing or preparation facility, as well as secure, remote package delivery and pickup where automated retail system 10 is operated as a secure package pickup service. Of course, other applications will readily occur to those skilled in the art without departing from the spirit and scope of the invention.

[0056] Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. Thus, it should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein.