WO2025219510A1

WO2025219510A1 - De-palletiser and palletiser

Info

Publication number: WO2025219510A1
Application number: PCT/EP2025/060633
Authority: WO
Inventors: Leslie Wynn
Original assignee: Ocado Innovation Ltd
Current assignee: Ocado Innovation Ltd
Priority date: 2024-04-17
Filing date: 2025-04-17
Publication date: 2025-10-23
Anticipated expiration: 2026-10-17
Also published as: GB202405397D0; GB2640417A

Abstract

A tool (2) for unloading or loading one or more containers (4) of a plurality of containers stacked vertically in multiple layers on a pallet, each of the plurality of containers (4) comprising a bottom wall and upwardly standing sidewalls arranged in a box-like configuration, each of the upstanding sidewalls having a surface profile, the tool comprising: a) a seat (4) for engaging with the rim (8) of the container (4), the seat (4) having a first seated portion 16 and a second seated portion (18), the first seated portion 16 being substantially perpendicular to the second seated portion (18) such that the seat 14 is configured to rest on a comer of the container; a) a first side engaging portion (24) downwardly extending from the first seated portion (16); b) a second side engaging portion (26) downwardly extending from the second seated portion (18); wherein each of the first and second side engaging portions 16, 18 is configured to engage the container by conforming to the surface profile of at least a portion of the upwardly standing sidewalls 10, 12 of the container such that the container (4) is lifted by the comer of the container when the tool (2) is moved in a vertical direction.

Description

De-palletiser and Palletiser

Field of the Invention

The present invention relates to the field of a material handling system, more specifically to a tool for unloading or loading a pallet (known as de-palletisation or palletisation). The invention may be used to automatically carry out a palletisation and/or de-palletisation process.

Introduction

Most products are delivered to warehouses on pallets, where the products must be unloaded from the pallets so that the products can be processed at the warehouse by a material handling system. The products can be stored in boxes, containers or crates and stacked in multiple layers on the pallet. Whether the products are stored in boxes, containers or crates, for the purpose of definition in the present invention, such products can be termed ‘units’. Once unloaded, the pallets are collected and then returned for reuse. Pallets come in various types and generally comprise a top deck usually formed from a series of planks, otherwise known in the art as runners and a lower deck spaced from the top deck by blocks of wood.

Once at the warehouse, the products need to be removed from pallets (known as de-palletising) and singulated so they can be stored in an automatic storage and retrieval system. PCT Publication No. W02015019055A (Ocado) describes a known storage and fulfilment system in which stacks of storage bins or containers are arranged within a grid framework structure. The bins or containers are accessed by load handling devices remotely operative on tracks located on the top of the grid framework structure. In this system, the products and/or other multi-packs of inbound items removed from the pallet are separated and placed, individually or in groups corresponding to their stock keeping unit (SKU) into separate storage containers for storage in the storage and retrieval system. The bins or containers are accessed by load handling devices remotely operative on tracks located on the top of the grid framework structure.

Some products such as fruit, vegetables and meat are stored in crates, typically plastic crates, to prevent damage to the products in transit on pallets in multiple layers to a warehouse. RPC (reusable packaging containers) are a type of reusable packaging for transporting fresh food produce. IFCO (International Food Container Organization) trays are an example of an RPC used in the industry. The storage containers are generally sized such that crates will fit inside the storage containers which are then placed in storage in the grid framework structure removing the need to unpack the crates.

As the products are stored in multiple layers on a pallet, the products tend to be de-palletized in layers with the uppermost layer of products being the starting point layer and successive layers being removed from the pallet. There are usually two approaches to do this. The first is manual de-palletisation, where operators pick the products individually and forward them on an outfeed conveyor. The other approach is to use an automated de-palletiser comprising a robot arm equipped with a layer de-palletizing tool to remove the products layer by layer and drop them on an outfeed conveyor. Similarly, products destined to leave a warehouse may leave on pallets, which requires similar or different products to be placed on the pallet. This process is known as palletisation, where the items are placed, typically on a one-by-one or layer-by- layer basis, on the pallet. That is, each product is placed to form a current top layer of products on the pallet before proceeding to place products on the next layer (which then becomes the current top layer).

Typically, the crates are positioned in an orderly fashion in layers on a pallet with or without gaps between the products. To help with the removal of the crates from the pallet, the crates are formed with handles in the form of one or more openings in the walls of the crate. The one or more openings in the side walls of the crate function as grip holes. The grip holes enable a person to manually pick up the crates individually by their sidewalls. Typically, the grip holes are formed in opposing side walls of the crates so as to enable an operator to pick a crate from their opposing sidewalls. However, as the crates are stacked in multiple layers in a close packed arrangement on the pallet, only one or two of the sidewalls of a given crate in the uppermost layer are exposed to the operator. Typically, the grip holes at the comers in the uppermost layer are only accessible to the operator. In operation, an operator can use the grip holes in one of the sidewalls of the container to manoeuvre the crates to a position where both grip holes in opposing sidewalls of the container are accessible so as to enable the operator to pick up the crate. The outermost crates are usually first removed exposing the grid holes of the inner crates which are subsequently removed prior to proceeding to the next layer below.

There are various types of automated de-palletisers known in the art. For example, it is known to de-palletize by successively removing layers or parts of layers from the top of a stack of packages with the aid of a suction device. Apart from the relatively high cost of the apparatus required, there is the disadvantage it is limited to lifting closed or substantially closed top containers. Furthermore, if the packages are not completely closed the contents can easily be damaged, for example, with packages containing powders. In the case where the container is a crate such as an IFCO crate, one of the problems encountered when picking up a crate is there is little or no surface to which the suction device can be applied to lift the crate. In addition, when using the grip holes there is the risk of damage or disruption to the content of the crate when a tool or fingers are inserted into the grip holes.

Another de-palletizing method involves gripping the sides of a layer of packages and then lifting it from the stack. As high lateral pressures are generally required for a layer consisting of a number of packages, this leads in practice to a limited lifting capacity, while at the same time the packages can easily be damaged. Another limitation of de-palletising containers stacked in multiple layers on a pallet is the limited options to access neighbouring containers on a pallet.

It has also been proposed to de-palletise packages by using an apparatus in a fixed location to which the stacked packages have to be brought. The apparatus comprises an extendable part of a conveyor roller system, with the leading roller contacting the stacked packages in turn and by frictional contact raising the packages to a position where they ride over the leading roller and pass to fixed conveyor rollers for removal elsewhere. This arrangement has the disadvantage that the apparatus cannot readily be used for de-palletising stacks of different sizes of packages. For example, GB1559973 (Unilever Ltd) teaches a de-palletiser comprising a roller that is placed in contact with a box under sufficient pressure, the friction between the roller and the box causes the box to be lifted. Rotation of the roller causes the box to slip under the box and the box passes over the roller until it lands on a conveyor belt, where it is removed for distribution. Similarly, W02009043151 (Axium Inc) teaches a de-palletizing tool for depalletizing a layer of products on a pallet. The tool is mounted to a robot via a frame, the robot allowing for movements of the tool relative to the pallet. The tool includes a platform mounted to the frame and is provided with a motorized conveyor at the distal end thereof for inserting at least partially the platform under the layer of products and for raising the products onto the platform while the tool is moved towards the distal end of the layer by the robot. The tool includes a pusher also mounted to the frame over the platform for selectively applying pressure onto the products while the platform is inserted under the layer of products.

However, in both teachings it is essential that the target product or package needs to be supported to prevent excessive lateral movement on the pallet in order to provide the necessary reaction force for the pushing force of the roller to slip under the product or package. This is usually provided by the target product or package butting up against another product or package adjacent to the target product or package in a layer on the pallet. Without this reaction force from an adjacent product or package in the layer on the pallet, the roller is unable to lift the product or package and slip under the product or package. The pushing force may simply move the package on the pallet without any real lifting of the package and in a worst case scenario, the package may be pushed off the edge of the pallet. An additional problem with inserting a platform under the product is that the platform has the potential to damage or pinch the contents of the packages if the packages in the layer below the package are not completely closed. This is particularly the case where the content of the products can be easily bruised such as soft fruit. Even if more sensitive products such as fruit, vegetables and meat are stored in crates, e.g. IFCO crates, to prevent damage to the products during transit, the risk of damage to the products during de-palletisation can be still present. For example, sensitive items protruding from the crates are susceptible to damage by the lifting platform when attempts are made to remove the crates in the layer above.

A palletiser or de-palletiser is thus required that can unload and/or load one or more products stored in containers of a plurality of containers stacked in multiple layers on a pallet that does not suffer from the problems described.

Summary of the Invention

In contrast to picking up a container by gripping its opposing side walls which are not easily accessible when the containers are closely packed in multiple layers on a pallet, the present invention has mitigated the above problem by providing a tool that is configured to pick up a container by clamping a comer of the container. For the purpose of the present invention, the “comer” of the container is constmed to mean the comer sidewalls of the container making up a comer of the container, e.g., the long side (side wall) and the short side (end wall). Typically, when stacked in a close packed arrangement in multiple layers, the comers of the containers are exposed to an operator. By picking up the container from its comer removes the need to manoeuvre the container to expose the gripping holes in the opposing sidewalls. In the case where the container is a crate, the exterior surface of the sidewalls is usually strengthened by one or more stiffening members. These are usually in the form of ribs on the exterior surface of the crate. By having a tool that conforms to the exterior surface profile of the comer sidewalls of the crate, the level of friction or engagement between the tool and the crate can be sufficient to lift the container when the tool is moved in a vertical direction. More specifically, the present invention provides a tool for unloading or loading one or more containers of a plurality of containers stacked vertically in multiple layers on a pallet, each of the plurality of containers comprising a bottom wall and upwardly standing sidewalls arranged in a box-like configuration, each of the upstanding sidewalls having a surface profile, the tool comprising: a) a seat for engaging with the rim of the container, the seat having a first seated portion and a second seated portion, the first seated portion being substantially perpendicular to the second seated portion such that the seat is configured to rest on a comer of the container; a) a first side engaging portion downwardly extending from the first seated portion; b) a second side engaging portion downwardly extending from the second seated portion; wherein each of the first and second side engaging portions is configured to engage the container by conforming to the surface profile of at least a portion of the upwardly standing sidewalls such that the container is lifted by the comer of the container when the tool is moved in a vertical direction.

The seat of the tool is configured to rest on the rim at the comer of the container such that the first and the second side engaging portions downwardly extending from their respective seated portions are able to engage two adjacent sides of the container, for example, a long side and a short side of the container. Engagement of the adjacent sides of the container include but is not limited to frictionally or mechanically engaging with the sides of the container. Optionally, each of the first and second side engaging portions comprises a panel that is configured to engage the sidewall of the container. The first and second side engaging portions can extend the height of one or more containers. This enables the tool to pick up a stack of containers in a single lift of the tool. In one optional aspect of the present invention, each of the first and second side engaging portions is moveably mounted to their respective first and second seated portions and moveable from a first position to clamp the upwardly standing sidewalls of the container and a second position to release the container, the first and second side engaging portions being spaced apart from the upwardly standing sidewalls in the second position. Optionally, each of the first and second side engaging portions comprises a plurality of pins, said plurality of pins is retractable to conform to surface profile of the at least a portion of the upwardly standing sidewalls of the container. The plurality of pins is able to engage with the ribs or stiffening members on the exterior surface of the sidewalls of the container to the extent that one or more of the plurality of pins are site between the ribs.

To ensure that the plurality of pins sufficiently engage with the upwardly standing sidewalls of the containers, optionally, the plurality of pins is spaced apart in a longitudinal direction along the first and second side engaging portions. To ensure that the plurality of pins conform to the exterior surface of the container, optionally, each of the plurality of pins of the first and second side engaging portions is resiliently biased in an extended position so as to engage with the surface profile of the exterior surface of the container. In an optional aspect of the present invention, each of the first and second side engaging portions comprises a plurality of resilient fingers downwardly extending from their respective first and second seated portions, each of the plurality of pins of the first and second side engaging portions is mounted to a respective resilient finger of the plurality of resilient fingers such that the plurality of pins conform to the surface profile of the exterior surface of the container by virtue of being mounted to resilient fingers.

Alternatively, or in addition to having a plurality of pins that conform to the surface profile of the exterior surface of the container, in an optional aspect of the present invention, each of the first and second side engaging portions comprises a deformable member that is configured to conform to the surface profile of at least a portion of the upwardly standing sidewalls. Optionally, the deformable member comprises a foam and/or an elastomeric material. The advantage of having a deformable member as opposed to a plurality of retractable pins is that the deformable member is more compliant to different surface profiles of the container than separate pins. The friction between the deformable member and the exterior surface of the container increases as the surface area contact between the deformable member and the exterior surface of the container increases to the extent that the friction is sufficient to pick up the container when the tool is moved in a vertical direction.

Containers such as crates or cases have collapsible sidewalls that are able to rotate about the bottom wall when not in use such that the sidewalls rest against the bottom wall. To collapse the sidewalls, an operator applies a force to the sidewalls sufficient to overcome the connection or joint with an adjacent sidewall or end wall. Such a connection can be a snap fit connection that connects the sidewalls together when erect. However, applying a clamping force to the sidewalls of the containers may inadvertently collapse the sidewalls removing the ability of the tool for grasping the containers. To prevent the sidewalls from inadvertently collapsing when a clamping force is applied to the sidewalls, optionally, each of the first and second seated portions comprises a stop, said stop cooperates with their respective first and second seated portions to define a channel for accommodating at least a portion of the rim of the container. The stop prevents the sidewalls from collapsing when a clamping force is applied against the exterior surface of the sidewalls such that each of the first and second side engaging portions can conform to the exterior surface of the container.

The tool according the present invention is versatile in the sense that it can be retrofitted or mounted on any moving or lifting device. To mount the tool to a lifting device, optionally, the tool further comprises a bracing member connecting the free ends of the first and second seated portions such that the tool adopts a substantially triangular shape, said bracing member comprising a mounting portion for mounting the tool to a lifting mechanism.

In another aspect of the present invention, a robotized de-palletiser for unloading or loading one or more containers of a plurality of containers stacked up in multiple layers on a pallet is provided, said robotized de-palletiser comprising a gantry comprising the tool according to the present invention for moving the apparatus axially in multiple X and Y orthogonal directions.

In yet a further aspect of the present invention, a robotized de-palletiser robot for unloading or loading one or more containers of a plurality of containers stacked up in multiple layers on a pallet, said robotized de-palletiser comprising a robot comprising a robot arm, wherein an end effector is coupled to the robot arm for controlling the movement of the end effector to unload or load one or more containers of a plurality of containers stacked up in multiple layers on a pallet, said end effector comprising a tool according to the present invention. Optionally, the robot may comprise a Selective Compliance Assembly Robot Arm (SCARA) robot.

There is also provided a system for unloading one or more containers of a plurality of containers stacked vertically in multiple layers on a pallet; comprising: a) a vision system comprising a camera for generating an image of a top portion of a pallet positioned under the camera and a controller coupled to the camera for processing the image from the camera; b) a pallet unloading or loading station for receiving one or more pallets of containers, said pallet unloading or loading station comprising a robotized de-palletiser as previously described, said robotized de-palletiser being coupled to the controller of the vision system for receiving image data from the camera; c) a transfer system for receiving one or more containers from the robotized de-palletiser and transferring the one or more containers to a storage and retrieval system.

Optionally, the system further comprises a storage and retrieval system, said storage and retrieval system comprising: a) a grid framework structure comprising a plurality of storage columns for the storage of a plurality of storage containers in multiple stacks of storage bins and a plurality of tracks arranged in a grid pattern on top of the plurality of storage columns, the plurality of tracks for guiding the movement of one or more load handling devices above the grid framework structure; b) one or more load handling device, each of said load handling devices comprising: i) a wheel assembly for guiding the load handling device on the track system; ii) a container-receiving space located above the track system; and iii) a container lifting mechanism comprising a grabber device for releasable connection to a storage container, said container lifting mechanism being arranged to lift a single container from a stack into the container-receiving space.

Brief Description of Drawings

Further features and aspects of the present invention will be apparent from the following detailed description of an illustrative embodiment made with reference to the drawings, in which:

Figures 1 (a and b) are illustrations of (a) a tool for picking up a target container from a plurality of containers stacked up in multiple layers on a pallet; and (b) the container engaged with the tool when the tool is moved in a vertical direction according to a first example of the present invention.

Figures 2 (a and b) are illustrations of the arrangement of the containers on a pallet, where (a) is an isometric view of the container on the pallet; and (b) is a top plan view of the container on the pallet.

Figures 3(a to c) show examples of the different stages of removing one or more containers from the pallets using the tool according to the present invention.

Figures 4(a, b and c) are illustrations of the tool shown in Figure 1 showing (a) the tool approaching a target container from above; (b) a side engagement feature for engaging with a container; and (c) the tool engaged with the comer sidewalls of the container according to the present invention.

Figures 5(a and b) are illustrations of (a) a tool for engaging with the comer of the container; and (b) the tool engaged with the comer sidewalls of the container according to a second example of the present invention.

Figures 6(a, b, and c) are illustrations of a tool for engaging with the comer of the container according to a third example of the present invention; showing (a) the tool approaching a comer of a stack of containers from above; (b) the tool approaching a target container from above; and (c) the tool engaged with the comer sidewalls of the container.

Figures 7(a and b) are illustrations of a tool comprising an elastomeric material for engaging with the comer of the container according to a fourth example of the present invention, where (a) shows the tool approaching a target container from above; and (b) the tool engaged with the comer of the target container.

Figure 8 is an illustration of the tool of Figure 7 configured to pick up a stack of containers.

Figure 9 shows a palletizing/depalletizing system for controlling a de-palletisation process using the apparatus according to a first example of the present invention.

Figure 10 shows a palletizing/depalletizing system for controlling a de-palletisation process using the apparatus according to a second example of the present invention.

Figure 11 (a and b) shows a palletizing/depalletizing system comprising a robotised de- palletiser for controlling a de-palletisation process using the apparatus according to a third example of the present invention, and (b) the robotised de-palletiser for picking up containers.

Figure 12 is an example of a storage and retrieval system for the storage and retrieval of storage bin in a grid framework structure.

Figure 13(a, b, and c) are illustrations of a load handling device operable on the grid framework structure shown in Figure 12. Detailed Description

The following description describes an apparatus or tool for removing one or more containers, typically layer by layer, from a pallet, otherwise known as a ‘de-palletiser’. That is, each container from atop layer of containers on the pallet is removed before proceeding to removing containers from the next layer (which then becomes the current top layer). As the containers are removed, they may be placed in a given location, such as a conveyor belt, to transfer the containers for storage in a warehouse. The container has a bottom wall and upwardly standing sidewalls extending from the bottom wall to form a box like structure. The container can have an open end for receiving the one or more items within the box-like structure or a closed top wall. The containers can come in a variety of sizes and shapes. Examples of containers include various crates or trays such as IFCO (International Food Container Organization) containers that are used to transport fresh fruit and vegetables, meat, fish and seafood, eggs, baked goods, deli and convenience products.

Figures l(a and b) are illustrations of a first example of a tool 2 for de-palletising containers 4 stacked in multiple layers on a pallet 6 and Figures 2(a and b) are examples of an arrangement of the containers 4 stacked on the pallet 6. In Figures 1 (a and b), the containers 4 are closely packed together in three layers on the pallet 6 with or without gaps between adjacent containers. To engage with the container, the tool 2 according to the present invention is configured to approach a target container on the container from above and sit on or engage with the rim 8 of the target container 4. As a result, only the containers in the uppermost layer are accessible to the tool. In operation, the tool removes one or more containers in the uppermost layers before proceeding with the layers below.

In comparison to engaging with opposing sidewalls of the container, the tool 2 according to the present invention shown in Figure l(a and b) is configured to engage with two sidewalls 10, 12 at the comer of the container 2, namely the long side 10 (e.g., sidewall) and the short side 12 (e.g., end wall) of the container. For the purpose of explanation of the present invention, the two sidewalls (e.g. a sidewall and an end wall) is construed to be the ‘comer’ of the container. More specifically, the tool is configured to engage with the exterior surface of the sidewalls at the comer of the container. The engagement between the tool and the exterior surface at the comer of the container can be by friction or by physical engagement with the comer or a combination of both engagement mechanisms sufficient to pick up the container when the tool is moved in a vertical direction. Typically, when containers are layered on a pallet, the containers at the comers of the pallet are easily accessible to the tool since two of their sidewalls are exposed. The arrangement of the containers in the uppermost layer can be explained by the schematic drawings shown in Figures 2(a and b). The containers labelled a, b, c and e are accessible in-situ to the tool from above since a comer of each of these containers is exposed, i.e. on the periphery of the layer of containers whereas the container labelled ‘d’ is not accessible in-situ to the tool since its sidewalls at the comers are sandwiched between the containers labelled d and e. To de-palletise a stack of containers on a pallet, the tool 2 of the present invention can be instructed to remove any one of the comer containers labelled a, b, c or e in the uppermost layer. Removing any one of the comer containers, a, b, c or e exposes the comers of adjacent containers in the uppermost layer and the container in the layer immediately below the uppermost layer. For example, and as shown in Figures 3(ato c), removing container labelled ‘c’ exposes the comer of the adjacent container ‘d’ and ‘a’ and the container in the layer immediately below container ‘c’ . Likewise, removing the comer container ‘d’ exposes the comer of the adjacent container ‘e’ and so on. As a result, there are different options by which the tool 2 of the present invention can be used to remove containers from a pallet. In one optional aspect of the present invention, the tool 2 can be instructed to de-palletise the pallet by removing all of the containers having an exposed comer first before proceeding with the remainder of the containers once their comers are accessible to the tool. Alternatively, the tool can be instmcted to remove any one of the comer containers exposing the comers of adjacent containers to the tool. In all cases, the tool is instmcted to successively expose the comer of adjacent containers to the tool before proceeding to remove the container from the pallet.

There are various ways in which that tool can engage with the comer of the container to pick the container when the tool is moved in a vertical direction. In all of the different examples of the tool, the tool comprises a seat 14 that is configured to sit on at least a portion of the rim 8 of the container 4. The seat enables the tool 2 to rest on the rim of the container when the tool engages with the sidewalls 10, 12 at the comer of the container and comprises a first seated portion 16 and a second seated portion 18. The first seated portion 16 is configured to sit on the rim on the long side of the container and the second seated portion 18 is configured to sit on the rim on the short side of the container. As the tool engages with the comer of the container, the first seated portion 16 is substantially perpendicular to the second seated portion 18. The tool is configured to engage with the container at the comer by applying a clamping force to the comer sidewalls of the container sufficient for the tool to grasp or clamp the container. The comer sidewalls of the container shown in figures to 1 to 3 comprise a long side of the container (also known as the side wall 10) and the short side of the container (also known as the end wall 12). However, it is also possible to use the tool 2 on containers comprising sidewalls of equal length.

In the case where the container is a crate (see Figures 4(a, b and c)), the sidewalls of the crate are generally collapsible relative to its bottom wall to enable the crates to be conveniently stored when not in use. As a result, the sidewalls and end walls are held in the erect or upwardly extending position by a snap-fit joint (not shown) or other physical joint known in the art. To collapse the crate, the sidewalls 10 and end walls 12 are rotated inwardly about the bottom wall 20 such that the sidewalls and end walls rest or he on or are adjacent to the bottom wall. However, applying a clamping force inwardly towards the opening of the crate when grasping the comer of the container may inadvertently cause the sidewalls to collapse and thereby prevent the tool from adequately engaging with the exterior surface of the container sufficient to cause the container to be picked up when the tool is moved in a vertical direction. Optionally, the seat 14 additionally comprises a stop 22 that cooperates with the first and second seated portions 16, 18 to define a channel for accommodating at least a portion of the rim of the container. Thus, when a force is applied to the exterior surface of the sidewalls of the container, the stop 22 prevents the sidewalls from collapsing inwardly by applying an opposing reaction force.

There are various ways in which the tool applies a clamping force to the exterior surface of the container. In all of the examples, the tool comprises first and second side engaging portions 24, 26 that are configured to engage with the exterior surface at the comer of the container. The first and second side engaging portions 24, 26 extend downwardly from the respective first and second seated portions 16, 18 of the seat 14 and are configured to clamp the exterior surface of the container. The first and second side engaging portions 24, 26 shown in Figures 4(a, b and c) may comprise a plurality of retractable pins 28. The number and the arrangement of the plurality of retractable pins 28 largely depends on the interaction between the first and second side engaging portions 24, 26 and exterior surface profile of the sidewalls 10, 12 of the container. Also shown in Figure 4a, is that the tool 2 comprises a mounting portion 30 for mounting to a lifting device such as a robotic arm or a gantry. In the particular example shown in Figure 4a, the distal ends of the first and second seated portions of the tool are braced by a cross member 32 such that the profile of the tool 2 adopts a triangular shape. The cross-member 32 provides a mounting area for mounting the tool to a lifting device. The tool of the present invention can be mounted to a gantry or a robotic arm to assist with the movement of the depalletizing tool into engagement with the container profile. Various releasable coupling mechanisms known in the art can be used to mount the tool of the present invention to the gantry or the robotic arm. Examples of releasable coupling devices include but not limited to various mechanical coupling device including but not limited to push-fit joints, bayonet joints, electromagnetic coupling or a combination thereof. Further detail of the tool being mounted to a gantry or robotic arm is discussed below.

The first and second side engaging portions 24, 26 are each moveably mounted to their respective first and second seated portions 16, 18 and independently moveable from a first position to clamp the upwardly standing sidewalls of the container and a second position to release the container. In the example shown in Figures 4(a, b and c), the first and second side engaging portions 24, 26 are each rotatably mounted to their respective first and second seated portions and rotatable from the first position to engage with the exterior surface of the sidewalls of the container and the second position to release the container. Another way of describing the first and second side engaging portions 24, 26 is a moveable paddle that is pivotably mounted to the seat. However, the present invention is not limited to the first and second side engaging portions being moveably mounted to their respective first and second seated portions in order to engage with the container and engagement with the container can be achieved by moving the tool relative to the container.

To physically engage with the exterior surface of the container, each of the first and second side engaging portions comprises the plurality of retractable pins 28 that are configured conform to the exterior surface profile of the container. Each of the first and second side engaging portions 24, 26 comprises a panel 34 that is moveably mounted to their respective first and second side engaging portions 16, 18. The retractable pins 32 are shown carried by a respective panel of the first and second side engaging portions and arranged in an array along a longitudinal direction of the panel 34. To engage with the exterior surface of the container, the panels 34 of the first and second side engaging portions are shown rotatably mounted to their respective first and second seated portions and rotate to the first position towards the exterior surface profile of the comer of the container and the second position to space apart from the comer of the container. When moved to the first position, the plurality of pins 28 interact with the exterior surface of the sidewalls of the container. In the example of the container shown in the figures, the exterior surface of the container comprises a plurality of ribs or stiffening members 36. Such ribs 36 are typically found in crates to enable the crates to be stacked one on top of the other. The ribs can be arranged in various patterns and alter the exterior surface profile of the container. The plurality of pins 28 is resiliently biased in an extended position so as to conform to the exterior surface profile of the container when the first and second engaging side portions 24, 26 are brought into engagement with the comer of the container. When the first and second engaging portions are rotated to the first position to engage with the container, one or more pins of the plurality of pins retract to conform to the exterior profile of the container. The extent by which the pins retract will depend on whether the one or more pins (more specifically, the free ends of the pins) butt up against the ribs and those that are inserted between the ribs or remain extended between the ribs. Those one or more pins that remain extended between the ribs have a tendency to be caught between the ribs such that when the tool is moved in a vertical direction, the one or more pins supports the ribs, thereby picking up the container. The greater the number of pins being caught up in or engaged with the exterior surface profile of the container, the greater is the support from the tool and thus, the greater the weight that can be bome by the tool of the present invention.

Instead to having a group of retractable pins arranged in a longitudinal direction along the respective panels 34 of the first and second side engaging portions, in the second example of the tool 102 shown in Figures 5(a and b), the plurality of pins of each of the first and second side engaging portions are divided into a plurality of sub-groups 38, each of the plurality of sub-groups 38 comprises subset of the plurality of pins 28. One or more of the subsets of pins are configured to conform to the exterior surface profile at the comer of the container to the extent that one or more of the pins are inserted between the ribs. In comparison to the first example shown in Figures 4(a, b and c), the first and second side engaging portions 24, 26 are not moveable relative to their respective first and second seated portions 16, 18. In the second example shown in Figures 5(a and b), the first and second side engaging portions are rigidly held to their respective first and second seated portions. Engagement of the first and second side engaging portions, more specifically, the plurality of pins, with the exterior surface profile of the container involves moving the tool relative to the container. However, the present invention is not limited to the first and second side engaging portions being rigidly held to their respective first and second seated portions and the first and second side engaging portions can be moveably mounted to their respective first and second seated portions. In a third example of the depalletizing tool 202 shown in Figures 6(ato c), the plurality of pins 28 of the first and second side engaging portions 24, 26 are mounted to a plurality of fingers 40. The plurality of fingers 40 extends downwardly from the first and second seated portions 16, 18. Instead of the plurality of pins being resiliently retractable within the panel of the first and second side engaging portions as the first and second example of the tool 2, 102, the plurality of pins 28 are mounted to the plurality of fingers 40. Each of the plurality of fingers 40 are resilient deformable to enable the plurality of pins 28 to retract when a force is applied to the plurality of pins. In the particular example shown in Figures 6(a, b and c), the plurality of fingers 40 is supported to a side panel 42 that is moveable between a first position to engage with the comer of the container (see Figure 6c) and a second position to disengage from the container. When in the first position, one or more of the plurality of fingers 40 deform as their respective pins 28 butt up against the ribs of the container sidewalls. The remainder of the pins remain extended between the ribs and therefore, engage with the ribs when the depalletizing tool 202 is moved in a vertical direction. As with the first and second examples of the tool, the plurality of pins is configured to conform to the exterior surface profile of the sidewalls of the container.

In a fourth example of the tool 302 shown in Figures 7(a and b), the first and second side engaging portions 24, 26 are configured to engage with the container sidewalls largely by friction. To increase the surface area contact and thus, frictional contact between the sidewalls of the container and the tool 302, the first and second side engaging portions 24, 26 comprise a deformable material 44 such as an elastomeric material that is configured to conform to the exterior surface profile of the sidewalls of the container. Examples of an elastomeric material include but are not limited to rubber, foam, etc. The advantage of the use of a deformable material 44 to frictionally engage with the exterior surface profile of the container is that the tool can be used with solid sided containers. As a result, the tool 302 is not just limited to picking up a crate but can be used to pick different types of containers as long as there is frictional contact between the tool 302 and the sidewalls of the container. In the particular example shown in Figures 7(a and b), the elastomeric material is mounted to a backing panel or backing plate 44 and is movable relative to its first and second seated portions 16, 18 between a first position to engage with the sidewalls of the container and a second position to disengage from the sidewalls of the container. As with the other examples discussed above, the first and second side engaging portions can be moveably mounted to their respective first and second seated portions, i.e., the first and second side engaging portions function as paddles. The first and second side engaging portions are not limited to comprising a plurality of pins or an elastomeric material and can be any engagement portion sufficient to resist movement in a substantially vertical direction when a clamping force is applied against the sidewalls of the container.

In a fifth example of the present invention shown in Figure 8, the tool 402 is configured to pick up a stack of containers. To pick up a stack of containers 4, the first and second side engaging portions 24, 26 extend across height of a stack of containers 4, e.g., a plurality of containers. Like the examples discussed above with reference to Figures 1 to 7, the first and second side engaging portions 24, 26 are configured to clamp the comers of the stack of containers by conforming to the exterior surface profile of the containers. Whilst the stop 22 of the tool 402 is configured to engage with the rim of the uppermost container of the stack of containers, the sidewalls of the lower containers are prevented from collapsing by engaging with the uppermost container. The tool of the present invention is not limited to pick up two containers as shown in Figure 8 and can be configured to pick up more than two containers. The number of containers is dependent on the height of the first and second engaging portions and the height of the containers.

The tool 2, 102, 202, 302, 402 of the present invention can be employed in a system 46, 146, 246 comprising a pallet unloading station 48, 148, 248 for receiving one or more pallets of containers 4, a robotized de-palletiser 50, 150, 250 equipped with the tool 2, 102, 202, 302, described above with reference Figures 1 to 7 for picking one or more containers layer by layer on a pallet. The robotized de-palletiser 50, 150, 250 instructs the tool to pick one or more containers from the top layer and transfers the containers to a given location such as a conveyor 52 for transferring to a warehouse or storage and retrieval system as taught in W02015019055 (Ocado) and detailed below. In all examples of the robotized de-palletiser 50, 150, 250 described below, the robotized de-palletiser 50, 150, 250 can be assisted by a vision system for identifying a target container on the pallet 6 and guiding the tool to pick up the target container from the pallet and transfer the target container to a given location. The vision system can be an overhead camera 54 combined with appropriate image processing techniques to take an image of the top layer of the containers on the pallet 6 and a processor or controller in communication with the camera to determine the target container from the top layer to be removed and its current position on the pallet. The vision system can, as an initiation step and as part of a de-palletisation process, identify a top layer of containers on the pallet 6 as well as identify the next container with which the tool interacts, and monitor the movements of the tool as it interacts with the target container. This can be used as a feedback loop to control the movements of the first and second sides engagement portions. For example, the vision system may be used to select the next most accessible container, such as a comer container, in a layer of containers, and control the movement of the tool and thus, engagement portions accordingly. The target container can be any container on the pallet where the comer sidewalls of the container are easily accessible to the tool of the present invention. Due to the versatility of the tool of the present invention to pick up a container from its comer sidewalls, there are a number of options available to the robotized de-palletiser to identify the target container and is not restricted to any particular container on the pallet.

Various robotized devices can be used to robotize the de-palletizing operation. In the first example of the robotized de-palletiser shown in Figure 9, a gantry 56 can be equipped with the tool 2, 102, 202 of the present invention for controlling the movement of the tool to unload one or more containers from the pallet 6 in the pallet unloading station 48. The gantry 56 comprising a frame 58 is configured to move the tool 2, 102, 202, 302, 402 in multiple orthogonal directions, namely X, Y and/or Z Cartesian directions. In addition to moving the tool in multiple orthogonal axes, the tool can optionally be rotated about a vertical axis. The gantry 56 is shown in Figure 9 in the unloading station 48 positioned adjacent to the pallets and a transfer system 51 so that the tool 2, 102, 202, 302, 402 is within easy reach of the containers on the pallet and the transfer system 51. In the particular example of the present invention shown in Figures 9 to 11, the transfer system 51 comprises a conveyor 52. By virtue of the multi-axes robot, the gantry 56 can be instructed to move the tool 2, 102, 202, 302, 402 to remove one or more containers from the pallet and transfer the one or more containers to a given location such as the conveyor 52 for subsequent transfer to a warehouse or a storage and retrieval system. The one or more containers removed from the pallet can either be deposited directly on the conveyor 52 or alternatively, the tool 2, 102, 202, incorporating the side engaging portions 24, 26 can deposit the container into a storage bin for subsequent transfer to the storage and retrieval system. To differentiate between the containers on the pallet and the storage containers in storage in the storage and retrieval system, the storage containers in storage in the storage and retrieval system are defined as storage bins. The ability of the tool to engage with the comer of the container would mean that the number of movements to engage with the container is reduced in comparison to prior art de-palletising systems. For example, prior art de-palletiser systems require the target container to be moved multiple times before the target container can be safely removed from the pallet (see GB1559973 (Unilever Ltd)). A controller can control the gantry, in particular a drive system of the gantry, to move the tool in multiple orthogonal axes to offer up the first and second side engaging portions to the target container identified by the vision system on the pallet for transfer to the given location.

In a second example of the robotized de-palletiser 150 shown in Figure 10, the tool 2, 102, 202, 302 of the present invention can function as an end effector and be mounted to SCARA robot (Selective Compliance Assembly Robot Arm or Selective Compliance Articulated Robot Arm) to provide greater reach between the containers on the pallet and the conveyor 52 via a robotic arm 62. The SCARA robot is shown mounted to a frame 58 and comprises parallel arms connected by an elbow or moveable joint to enable movement of the tool in multiple configurations. More specifically, the base 64 of the robot arm 62 is mounted to a vertical shaft 66. The robotic arm 62 arm is moveable in a vertical direction along the vertical shaft 66 to lift a target container 4 from the pallet.

In another example of the robotized de-palletiser 250 shown in Figures l l(a and b), the robotised de-palletiser 250 is a six-axes robot enabling multiple movements of the end effector in x, y, and z planes. Unlike the example shown in Figure 10, the base 64 of the robotic arm 62 is mounted on a plinth 68. Also shown in Figure I la, are overhead cameras 54 of the vision system used by the controller to control the movement of the robotized de-palletiser. In comparison to the six-axes robot, the SCARA robot illustrated in Figure 10 provides faster speed and greater reach to the containers on the pallet.

In both examples shown in Figures 10 and 11 (a and b), the robotic arm 62 comprising the tool 2, 102, 202, 302 according to the present invention mounted thereto is positioned within easy reach of the pallet 6 and a conveyor 52 for transferring the container picked from the pallet to a warehouse or a storage and retrieval system. As with the first example of the robotized palletiser shown in Figure 10, the movement of the end effector and thus, tool can be controlled by a controller to offer up the tool to a target container on the pallet and subsequently, transferring the target container to a conveyor.

The robotized de-palletizing systems discussed above allow containers to be removed from a pallet for subsequent transfer to the storage and retrieval system. An example of a storage and retrieval is a storage and retrieval system 70 comprising a grid framework structure comprising a plurality of storage columns 72 for the storage of a plurality of storage bins 74 in multiple stacks of storage bins. One or more robotic load handling devices 76 operable on the grid framework structure 74 is able to retrieve a storage bin 72 from a given storage column 72. A typical storage and retrieval system 70 is taught in W02015019055 (Ocado), the detail of which are incorporated herein by reference and shown in Figure 12. In detail, the grid framework structure 78 comprises a plurality of vertical uprights or upright members or upright columns 80 that support horizontal grid members 82a, 82b. A first set of parallel horizontal grid members 82a is arranged perpendicularly to a second set of parallel horizontal grid members 82b to form a grid structure or grid 84 comprising a plurality of grid cells 86. Each grid cell in the grid framework structure has at least one grid column for storage of a stack of storage containers, otherwise known as hive totes. For the avoidance of doubt, the term “grid framework structure” is used to mean a three-dimensional structure within which the storage containers are stored, and the terms “grid structure” and “grid” are used interchangeably to mean the two-dimensional structure in a substantially horizontal plane upon which the load handling devices operate. The grid cell has an opening to allow a load handling device to lift a storage container or hive tote through the grid cell. In the grid structure, the first set of parallel horizontal grid members 82a intersect the second set of parallel horizontal grid members 82b at nodes. The grid structure is supported by the upright members 80 at each of the nodes or at the point where the grid members intersect such that the upright members are interconnected at their tops ends by the intersecting grid members. The grid members 82a, 82b, 80 are typically manufactured from metal and typically welded or bolted together or a combination of both. The storage bins 74 are stacked between the upright members 80 of the grid framework structure 78, so that the upright members 80 guard against horizontal movement of the stacks of bins 74, and guide vertical movement of the storage bins 74. The top level of the grid framework structure 78 includes rails or tracks arranged in a grid pattern across the top of the stacks to define a track system. The rails support a plurality of load handling devices 76. The track system comprises a first set of parallel rails to guide movement of the robotic load handling devices 76 in a first direction (for example, an X-direction) across the top of the grid framework structure 78, and a second set of parallel rails, arranged perpendicular to the first set, to guide movement of the load handling devices 56 in a second direction (for example, a Y-direction), perpendicular to the first direction. In this way, the rails allow movement of the robotic load handling devices 76 laterally in two dimensions in the horizontal X-Y plane, so that a load handling device 76 can be moved into position above any of the stacks of storage bins 74.

A known load handling device otherwise known as a hot 76 shown in Figure 13(a to c) comprising a vehicle body 88 is described in PCT Patent Publication No. W02015/019055 (Ocado), hereby incorporated by reference, where each load handling device 76 only covers a single grid space or grid cell of the grid framework structure 78. Here, the load handling device 76 comprises a wheel assembly comprising a first set of wheels 90 consisting of a pair of wheels on the front of the vehicle body 88 and a pair of wheels 90 on the back of the vehicle 88 for engaging with the first set of rails or tracks to guide movement of the device in a first direction, and a second set of wheels 92 consisting of a pair of wheels on each side of the vehicle 88 for engaging with the second set of rails or tracks to guide movement of the device in a second direction. Each of the sets of wheels are driven to enable movement of the vehicle in X and Y directions respectively along the rails. One or both sets of wheels can be moved vertically to lift each set of wheels clear of the respective rails, thereby allowing the vehicle to move in the desired direction, e.g., X or Y direction on the grid structure.

The load handling device 76 is equipped with a lifting device or crane mechanism to lift a storage container from above. The crane mechanism comprises a winch tether or cable 94 wound on a spool or reel (not shown) and a grabber device 96 in the form of a lifting frame. The lifting device comprises a set of lifting tethers 94 extending in a vertical direction and connected nearby or at the four comers of the lifting frame 96, otherwise known as the grabber device (one tether near each of the four comers of the grabber device) for releasable connection to a storage bin 74. The grabber device 96 is configured to releasably grip the top of a storage bin or container 74 to lift it from a stack of containers in a storage system of the type shown in Figure 12.

The wheels 90, 92 are arranged around the periphery of a cavity or recess, known as a container-receiving recess or container receiving space 98, in the lower part. The recess is sized to accommodate the storage bin 74 when it is lifted by the crane mechanism, as shown in Figure 13(a to c). When in the recess, the storage bin is lifted clear of the rails beneath, so that the vehicle can move laterally to a different location. On reaching the target location, for example another stack, an access point in the storage and retrieval system or a conveyor belt, the bin or container can be lowered from the container receiving portion and released from the grabber device. The container receiving space may comprise a cavity or recess arranged within the vehicle body, e.g., as described in W02015/019055 (Ocado Innovation Limited). Alternatively, the vehicle body of the load handling device may comprise a cantilever as taught in WO2019/238702 (Autostore Technology AS) in which case the container receiving space is located below a cantilever of the load handing device. In this case, the grabber device is hoisted by a cantilever such that the grabber device is able to engage and lift a container from a stack into a container receiving space below the cantilever.

It is understood that the tool of the present invention is not limited to using the tool as a de- palletiser and the tool can equally be used in reverse to palletise a pallet, i.e., placing containers, typically one by one on the pallet. For example, the tool can be instructed to remove one or more containers from a given location (e.g., conveyor) for placement on a pallet. The depalletising operation described above can be used to pick-up one or more containers from the given location. Once held by the tool, the container can be transferred to the pallet. Releasing the container onto the pallet involves either moving the first and second side engaging portions away from the sidewalls of the container. This could be either moving the first and second side engaging portions relative to their respective first and second seated portions, e.g., by rotation, or alternatively, moving the tool away from the container.

11

Claims

1. A tool for unloading or loading one or more containers of a plurality of containers stacked vertically in multiple layers on a pallet, each of the plurality of containers comprising a bottom wall and upwardly standing sidewalls arranged in a box-like configuration, each of the upstanding sidewalls having a surface profile, the tool comprising: a) a seat for engaging with the rim of the container, the seat having a first seated portion and a second seated portion, the first seated portion being substantially perpendicular to the second seated portion such that the seat is configured to rest on a comer of the container; a) a first side engaging portion downwardly extending from the first seated portion; b) a second side engaging portion downwardly extending from the second seated portion; wherein each of the first and second side engaging portions is configured to engage the container by conforming to the surface profile of at least a portion of the upwardly standing sidewalls of the container such that the container is lifted by the comer of the container when the tool is moved in a vertical direction.

2. The tool of claim 1, wherein each of the first and second side engaging portions is moveably mounted to their respective first and second seated portions and moveable from a first position to clamp the upwardly standing sidewalls of the container and a second position to release the container, the first and second side engaging portions being spaced apart from the upwardly standing sidewalls in the second position.

3. The tool of claim 1 or 2, wherein each of the first and second side engaging portions comprises a plurality of pins, said plurality of pins being retractable to conform to surface profile of the at least a portion of the upwardly standing sidewalls of the container.

4. The tool of claim 3, wherein the plurality of pins is spaced apart in a longitudinal direction along the first and second side engaging portions.

5. The tool of claim 3 or 4, wherein each of the plurality of pins of the first and second side engaging portions is resiliently biased in an extended position.

6. The tool of any of claims 3 to 5, wherein each of the first and second side engaging portions comprises a plurality of resilient fingers downwardly extending from their respective first and second seated portions, each of the plurality of pins of the first and second side engaging portions being mounted to a respective resilient finger of the plurality of resilient fingers.

7. The tool of claim 2, wherein each of the first and second side engaging portions comprises a deformable member that is configured to conform to the surface profile of at least a portion of the upwardly standing sidewalls.

8. The tool of claim 7, wherein the deformable member comprises a foam and/or an elastomer.

9. The tool of any of the preceding claims, wherein each of the first and second seated portions comprises a stop, said stop cooperates with their respective first and second seated portions to define a channel for accommodating at least a portion of the rim of the container.

10. The tool of any of the preceding claims, further comprising a bracing member connecting the free ends of the first and second seated portions such that the tool adopts a substantially triangular shape, said bracing member comprising a mounting portion for mounting the tool to a lifting mechanism.

11. A robotized de-palletiser for unloading or loading one or more containers of a plurality of containers stacked vertically in multiple layers on a pallet, the robotized de-palletiser comprising a gantry comprising a tool as defined in any of claims 1 to 9 for moving the tool axially in multiple X and Y orthogonal directions.

12. A robotized de-palletiser for unloading or loading one or more containers of a plurality of containers stacked vertically in multiple layers on a pallet, the robotized de-palletiser comprising a robot comprising a robot arm, wherein an end effector is coupled to the robot arm for controlling the movement of the end effector to unload or load one or more containers of a plurality of containers stacked up in multiple layers on a pallet, said end effector comprising a tool as defined in any of claims 1 to 10.

13. The robotized de-palletiser of claim 12, wherein the robot comprises a Selective Compliance Assembly Robot Arm (SCARA).

14. A system for unloading one or more containers of a plurality of containers stacked vertically in multiple layers on a pallet; comprising: a) a vision system comprising a camera for generating an image of a top portion of a pallet positioned under the camera and a controller coupled to the camera for processing the image from the camera; b) a pallet unloading or loading station for receiving one or more pallets of containers, said pallet unloading or loading station comprising a robotized de-palletiser as defined in any of claims 11 to 13, said robotized de-palletiser being coupled to the controller of the vision system for receiving image data from the camera; c) a transfer system for receiving one or more containers from the robotized de-palletiser and transferring the one or more containers to a storage and retrieval system.

15. The system of claim 14, further comprising a storage and retrieval system, said storage and retrieval system comprising: a) a grid framework structure comprising a plurality of storage columns for the storage of a plurality of storage containers in multiple stacks of storage bins and a plurality of tracks arranged in a grid pattern on top of the plurality of storage columns, the plurality of tracks for guiding the movement of one or more load handling devices above the grid framework structure; b) one or more load handling device, each of said load handling devices comprising: i) a wheel assembly for guiding the load handling device on the track system; ii) a container-receiving space located above the track system; and iii) a container lifting mechanism comprising a grabber device for releasable connection to a storage container, said container lifting mechanism being arranged to lift a single container from a stack into the container-receiving space.