Abstract:
The invention provides a solution for automatically stocking, storing, dispensing, retrieving and sorting individual parts or products of a variety of types and sizes and weights for order fulfillment. The invention includes a series of vertical and horizontal carousels that converge to exchange products gently without dumping. Multiple products and/orders can be dispensed simultaneously and sorted for packing. Products can be stocked and retrieved simultaneously. The invention concentrates personnel to a stocking line and eliminates walk time to each location. Additionally, the invention eliminates the need for personnel to pick and sort orders.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit under 35 USC §119(e) to U.S. Provisional Patent Application Ser. No. 60/805,924 filed on 27 Jun. 2006, hereby incorporated by reference in its entirety. 
     
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to a stocking and retrieval system, and, more specifically, to an automated stocking and retrieval system capable of stocking, storing, dispensing, and sorting of homogenous and/or non-homogenous products for order filling applications. 
         [0004]    2. Description of Related Art 
         [0005]    Receiving, stocking, retrieving, and shipping items is common practice in the consumer products industry. Warehouses or distribution centers are generally used to store a supply of items or products for a predetermined period of time, i.e., until the items are sold, collected, and shipped. The manual process of stocking and retrieving products by hand can be very time consuming and expensive, especially for larger warehouses having a multitude of products. To reduce the time and costs associated with manually stocking, retrieving and sorting products, automated systems have been developed. 
         [0006]    Conventional warehousing automation systems typically include opposing storage frames with storage bins arranged in a vertical and/or horizontal manner. A load carrier generally moves automatically along the aisles of the storage frames and often uses an elevator to transport objects to different shelving levels of the storage frames. To assist in retrieving and storing products, the elevator or load carrier may be equipped with an extractor or load handling mechanism for transferring a product from the carrier to the selected storage bin within the storage frame and, similarly, for picking a product from a selected storage bin to a carrier for delivery to a packing station. This system is typically used for bulk packaged products and is not designed for broken case picking. 
         [0007]    To assist in transferring products to and from the load carriers, the storage frame can also include inbound and outbound conveyors. The inbound carriers can move stock to an associated pickup and discharge station for handling by the load carrier, while the outbound carriers can move particular items from the storage volumes to a packing station. The inbound and outbound conveyors are generally situated lateral to the storage frame and lead to pickup and packing stations located nearby. Such conveyors and shelving units require considerable floor space for installation. 
         [0008]    To expedite the process of stocking and retrieving items from shelving, storage conveyors with multiple levels have been introduced and are widely used for the storing and handling of relatively small articles such as those that can be packed within a box. Unfortunately, as the demand for products has increased in quantity and variety, stocking and retrieving containers by the conveyors has also increased. When time is not of the essence, mechanisms have been used for performing the stocking and retrieval functions in conjunction with the rotary conveyors. These mechanisms, however, are limited in that they cannot be accelerated during operation, which is often necessary based on a growing demand for faster stocking and retrieval systems. 
         [0009]    To accommodate faster stocking and retrieval of products within a warehouse, large amounts of floor space can be utilized for material handling operations, which includes the storage of containers used in storage conveyors. Unfortunately, the increased cost of the space used and the cost of moving the products around the available space are restrictive to efficient operation of the warehouse. 
         [0010]    Moreover, distribution centers are often required to supply less than caseload quantities of a large variety of products to a multitude of different customers. Broken case order picking requires the assembling of orders of less than caseload quantities of particular products ordered. To reduce cost and errors associated with broken case order picking, order dispensing systems have been introduced that automate the process. 
         [0011]    A typical order dispensing system can include a central conveyor and a plurality of product dispensers positioned near the central conveyor. Generally, each product dispenser can be loaded with a particular product. When a particular product is ordered, a central controller (such as a computer) causes the corresponding product dispenser to place the ordered quantity of the product on the central conveyor, wherein the central conveyor transports the product to a packing station for eventual delivery to the customer. 
         [0012]    In such an order dispensing system, the product dispenser controls the dispensing of the products onto the central conveyor, based on an instruction from a central controller. To ensure proper retrieval of the product, the product dispenser must be able to provide a particular and correct quantity of a product to the central conveyor. As configured, each product dispenser, therefore, must be designated to a particular product, such that multiple identical products are stored in the product dispenser assigned to the particular product. 
         [0013]    To address the required designation of a product dispenser to a particular product, vertical conveyor dispensers have been developed including a plurality of compartments for holding a product to be dispensed from the vertical conveyor. Each compartment is not necessarily dedicated to any particular product and, therefore, can be used to dispense multiple products of various types and sizes. Products can be manually or automatically loaded into the compartments of the vertical conveyor, such that during use the compartment located near the bottom of the vertical conveyor dispenses its contents onto a central conveyor. Unfortunately, a container having multiple products cannot easily dispense a singular, desired product. 
         [0014]    Such order fulfillment facilities (e.g., warehouses) that consist of a variety of products that are individually stocked, picked and packed for shipping to a variety of customers typically have a high personnel count and are in need of an affordable automated solution. Present automation solutions are designed to dispense products of the same type. Automation systems that claim to dispense a variety of products are generally limited to the same product throughout the entire conveyor or dispensing unit. 
         [0015]    Vertical carousels have been used for transporting products from one location to another. For example, U.S. Pat. No. 478,263 to Moss discloses an elevator for hoisting building materials from the ground upward to where the building materials can be used for construction of the building. Generally, two sprockets are provided at a lower position and an upper position, such that a chain extends around the lower sprocket and the upper sprocket. Carriers are connected to a chain and receive building materials, such as a brick, near the lower position. As the upper and lower sprockets rotate, a first portion of the chain is moved upward, thereby allowing the carrier to transport the building material towards the upper position. Once the building materials are deposited near the upper position, the chain and carrier begin a descent towards the lower position to acquire additional building materials. The invention, however, is not designed to hold inventory of various types for an extended period of time. Additionally, the carriers are fixed to the chain, such that in a first direction the carriers are capable of holding building materials, but in a second direction (e.g., after wrapping around the upper sprocket) the carriers are not capable of holding the building materials, because the carrier is upside down. 
         [0016]    U.S. Pat. No. 3,626,905 to Giesbert et al. discloses a device for removing eggs from tiered cages. Cup-formed egg receivers are attached to a conveyor for receiving an egg and transporting the egg to a second location. The receivers are permanently attached to the conveyor and do not swivel. They are adapted for a single type of product (i.e., eggs). The invention, however, is not designed to hold non-homogenous materials of various sizes and shapes. Further, the invention is designed for transporting, not for temporarily storing, the particular product. 
         [0017]    U.S. Pat. No. 3,770,107 to Michelbach discloses a device for collecting and transferring eggs from several channels and conveying the eggs to a single channel. The egg transporting device includes a main vertical endless chain conveyor with a number of baskets in the form of multi-tine forks. These baskets can pivot from a collecting position to a delivery position. The baskets can gather eggs from several horizontal carousels via the vertical conveyor and dispense the eggs to a single horizontal carousel. The invention, however, is not designed to hold materials of various types, sizes, and shapes. Moreover, the invention is not designed to temporarily store products, but rather to gather and transport a product from a first location to a second location. 
         [0018]    U.S. Pat. No. 3,776,399 to Atwater discloses an automatic warehousing system including a storage frame area of horizontally and vertically oriented storage volumes with a mechanized load carrier moveable alongside the storage volumes for handling loads at selected storage volumes. The invention is designed for storing bulk products. The device is generally controlled by an operator who selects the box (or volume) to store a product or to a retrieve a product. Products are transported to and from the shelves or boxes, because the shelves or boxes remain stationary. Further, the automation handles one box at a time for stocking and retrieving a product. 
         [0019]    U.S. Pat. No. 3,789,802 to Conley discloses an automatic egg collector for an automated poultry handling system. The invention also includes several feeder conveyors that feed a common transfer conveyor that transfers eggs from the feeder conveyors to an overhead outfeed conveyor. The outfeed conveyor transports the eggs from all of the transfer conveyors to an egg receiver. The invention, however, is designed for transporting eggs from one location to another. Accordingly, the invention is not designed for temporarily storing various types of products for extended periods of time. Moreover, the invention is not designed to transport products of various sizes and shapes. 
         [0020]    U.S. Pat. No. 4,345,682 to White et al. discloses an egg transporting system having a plurality of egg belt conveyors leading from cages of a poultry installation. The egg transporting system includes a transition mechanism for dividing and/orienting the eggs at the output end of each of the egg belt conveyors into a plurality of separate rows and depositing the eggs on an elevator. The elevator includes egg transporting cradles for receiving eggs from the transition mechanism and transporting the eggs to a main conveyor that extends in communication with several egg elevators for accumulating and collecting eggs. The invention, however, is designed specifically for the transporting of a singular product (i.e., eggs) from one location to another and, therefore, is not designed for temporarily storing products of various types, sizes, and shapes. 
         [0021]    U.S. Pat. No. 4,909,697 to Bernard, II et al. discloses an automated work station that may be used in conjunction with two vertical temporary holding conveyors that make use of a tiltable table and associated transition table for each conveyor. During use, the invention brings items in bulk to a worker for picking the required items designated in a purchase order. More particularly, the invention includes a tiltable table that shifts to a first upper horizontal position to receive stored box units that have been supplied with quantities of different materials or items from which the operator selects specified quantities of items and places those items in an empty box until an order is filled. The invention requires, however, operators (personnel) positioned at various locations to retrieve a desired item from a box in order to fulfill an order. 
         [0022]    U.S. Pat. No. 5,141,128 to Pippin discloses a reconfigurable compartmentalized vertical conveyor dispenser for dispensing products in an automated order dispensing system. The dispensing system includes a plurality of shelves attached to a rotating conveyor. The shelves are generally fixed to the vertical conveyor and can generally rotate from a first position to a second position. The rotation of the shelves, however, does not occur gently. Indeed, the products are dumped onto the shelving and then dumped onto a conveyor without care of the fragileness of the product. Further, the invention is directed towards a homogenous product and, therefore, is not designed to handle products of varying shapes, sizes, and types. Moreover, the shelves are not designed for temporary storage of the products, but rather for the transportation of a product from a first position to a second position. 
         [0023]    What is needed is an automated stocking and retrieval system adapted for indefinitely storing various types of products of different size and shape. Moreover, what is needed is an automated stocking and retrieval system that can process multiple orders simultaneously with extreme care, while simultaneously allowing for products to be stocked within the system. Further, what is needed is an automated stocking and retrieval system that can provide products for packing without the need of an operator hand-picking a particular product from storage. It is to such a device that the present invention is primarily directed. 
       BRIEF SUMMARY OF THE INVENTION 
       [0024]    Briefly described, in preferred form, the automated stocking and retrieval system of the present invention provides a solution for automatically stocking, storing and dispensing individual parts or products of a variety of types and sizes and weights for order fulfillment. The invention includes a series of vertical and horizontal carousels that converge to exchange products gently without dumping. Multiple products and/orders can be dispensed simultaneously and sorted for packing. The invention concentrates personnel to a stocking line and eliminates walk time to each location. Additionally, the invention eliminates the need for personnel to pick and sort orders. 
         [0025]    Generally, the automated stocking and retrieval system relates to a series of sectioned storage baskets suspended from a plurality of motor-driven vertical carousel units, which are automatically cued to converge with a series of product carriers connected to a plurality of motor driven horizontal carousel units for a gentle exchange of products for the purpose of stocking, storing or dispensing products. The suspended storage baskets are compartmentalized (divided) and numbered as specific locations to store a product. The compartments or sub-portions permit the storage basket to store a variety of different products and, therefore, a variety of different products are stored on the corresponding vertical carousel unit. 
         [0026]    The present invention is not limited to the concentration of products according to type or kind. Every sub-portion of each storage basket can hold a different product within a reasonable size and weight range. Storage basket and sub-portion sizes are determined by the range of product sizes. The automated stocking and retrieving system is automatically driven by a central controller (such as a computer) and computer software that stocks products, stores product locations, maintains real-time inventory, assembles orders, batches orders, controls the dispenses of products and sorts products for packing. 
         [0027]    In one preferred embodiment, the present invention is an automated stocking and retrieval system capable of stocking, storing, dispensing, and sorting homogenous and/or non-homogenous products for order filling applications comprising a substantially horizontal carousel unit including a plurality of product carriers, a substantially vertical carousel unit including a plurality of storage baskets, and a transfer zone wherein a product is transferred between one of a product carrier and a storage basket, and the other of a storage basket and a product carrier, wherein the substantially vertical carousel unit is movable in a first direction away from the horizontal carousel, and in a second direction toward the horizontal carousel. 
         [0028]    The present invention can include one or more of a stocking phase, wherein products are moved along the horizontal carousel unit toward the vertical carousel unit, the products transferred in the transfer zone from the storage baskets to the product carriers, the vertical carousel unit moving in the first direction; a retrieval phase, wherein products are moved in the second direction along the vertical carousel unit toward the horizontal carousel unit, the products transferred in the transfer zone from the product carriers to the storage baskets; an order fulfillment phase, wherein products are moved along the horizontal carousel unit toward a filtering system, the filtering system moving the products to an appropriate packing level; and a storing phase, wherein products are stored on the vertical carousel unit during the storage phase until the retrieval phase. 
         [0029]    In another preferred embodiment, the present system can be in the stocking phase and the retrieval phase simultaneously. 
         [0030]    The product carriers are preferably cooperatively designed to be able to transport homogenous and/or non-homogenous products. As used herein, non-homogenous products are products that vary among themselves as to at least one of size, shape and weight. While many prior art designs are useful transporting single, conforming products, the present invention is designed to, at any time during the process, transport varying sizes, shapes and weights of products, without the need to change out parts, like the product carriers and/or the storage baskets. Thus, the storage baskets are too preferably cooperatively designed to be able to transport non-homogenous products. Yet, the present invention can work with homogenous product should it be tasked with stocking, storing, dispensing, and sorting of such homogenous product, or portions of a product line that are homogenous as to size, shape, and weight, for example. 
         [0031]    The plurality of product carriers and the plurality of storage baskets are preferably formed of individually spaced members cooperatively spaced so that in the transfer zone, a product carrier and a storage basket can move through one another during product transfer. These and other features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawings. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0032]      FIG. 1  illustrates a front sectional view of an automated stocking and retrieval system in accordance with preferred embodiments of the present invention. 
           [0033]      FIG. 2  illustrates a front sectional view of a plurality of vertical carousel units of an automated stocking and retrieval system in accordance with preferred embodiments of the present invention. 
           [0034]      FIG. 3  illustrates a front sectional view of a horizontal carousel unit of an automated stocking and retrieval system in accordance with preferred embodiments of the present invention. 
           [0035]      FIGS. 4A-4C , collectively referred to as  FIG. 4 , illustrate perspective views of a storage basket without sub-portions in accordance with preferred embodiments of the present invention. 
           [0036]      FIGS. 5A-5C , collectively referred to as  FIG. 5 , illustrate perspective views of a full sized product carrier in accordance with preferred embodiments of the present invention. 
           [0037]      FIG. 6  illustrates a side sectional view of a plurality of vertical carousel units and a plurality of horizontal carousel units having divided storage baskets and multiple product carriers in accordance with preferred embodiments of the present invention. 
           [0038]      FIGS. 7A-7B , collectively referred to as  FIG. 7 , illustrate front and side sectional views, respectively, of the interaction between a storage basket and a product carrier in accordance with a preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0039]    Referring now in detail to the drawing figures, wherein like reference numbers represent like parts throughout the view,  FIG. 1  displays an automated stocking and retrieval system  10  for the automatic stocking, storing, dispensing, and sorting of a multitude of parts or products, such that products can be stocked and retrieved simultaneously. The automated stocking and retrieval system  10  generally eliminates much of the human labor typically associated with the assignment and placement (e.g., stocking) of parts or products into particular locations (such as containers) for storage. Further, the automated stocking and retrieval system  10  eliminates the human labor typically associated with the retrieval (e.g., picking) of stored products from the predetermined locations for order fulfillment. 
         [0040]    The automated stocking and retrieval system  10  includes a plurality of vertical carousel units  100  and at least one horizontal carousel unit  200 , such that the plurality of vertical carousel units  100  are in communication with the products/parts carried by at least one horizontal carousel unit  200 . The vertical carousel units  100  are adapted to receive, provide, and temporarily store a variety of different products or parts until they are ordered. At least one horizontal carousel unit  200  is adapted to transport a product or part away from or towards a vertical carousel unit  100 . During a stocking phase, a product is transported by the horizontal carousel unit  200  towards a vertical carousel unit  100 , where the vertical carousel unit  100  receives the product from the horizontal carousel unit  200 . The vertical carousel unit  100  stores the received product until it is required to fulfill an order. During a retrieval phase, the stored product is provided by the vertical carousel unit  100  to the horizontal carousel unit  200  to be transported to a packing station and then delivered to a customer. In a preferred embodiment of the present invention, the vertical carousel unit  100  and the horizontal carousel unit  200  are adapted to retrieve and store products or parts simultaneously. Accordingly, the automated stocking and retrieval system  10  can be in the stocking phase and the retrieval phase at the same time. 
         [0041]    In an exemplary embodiment of the present invention, the vertical carousel units  100  and the at least one horizontal carousel unit  200  are received within a housing or building  15 , wherein the vertical carousel units  100  and the at least one horizontal carousel unit  200  are supported by conventional rack structures  20 . The rack structures  20  enable the present invention to be constructed to a desired height or width within the housing  15 . Generally, the rack structures  20  maintain the vertical carousel units  100  and the at least one horizontal carousel unit  200  a predetermined distance above the floor  65  of housing  15 . The unit height of the rack structures  20  is generally a function of design and can be changed based on the height of the vertical carousel units  100 . 
         [0042]    To facilitate proper operation of stocking and packing procedures, the housing  15  generally includes a port  25  (such as an airlock) for delivery vehicles to provide products for storing. A storage room  30  can be situated next to the port  25 , so that products can be temporarily stored prior to scanning and stocking the items in a more permanent location. A scanning and stocking station  35  can be positioned between the storage room  30  and a first end of the at least one horizontal carousel unit  200 . Accordingly, each product or part can be scanned and recorded into a computer inventory system, prior to being placed on the horizontal carousel unit  200 . The product is then provided by the horizontal carousel unit  200  to a predetermined vertical carousel unit  100  for storage, until an order requires the particular product. 
         [0043]    Once a product is requested, the vertical carousel unit  200  provides the particular product to the horizontal carousel unit  200 , which then transports the desired product or part to a filtering system  300 . The filtering system  300  generally utilizes a proximate vertical carousel unit  400  (an end unit used for product separation onto coordinated conveyors) for moving products to particular packing levels. For example, the filtering system  300  can include, but is not limited to, a plurality of conveyor ramping devices adapted for moving products to particular packing levels within the housing  15 . Accordingly, the housing  15  can include a designated area  40  located near a second end of the at least one horizontal carousel unit  200  for the purpose of receiving the filtering system  300 . Packing stations  45  can be positioned near the filtering system  300 , such that the packing stations  45  are adapted to receive retrieved products for a particular order. The received products are then packaged and sent to a loading zone  50  where delivery trucks can receive the packaged products via a loading dock  55 . The delivery truck can then transport the packaged products to the customer who provided the order via the internet, phone, fax, or by other forms of ordering. 
         [0044]    Orders can be placed on conveyors one at a time or a filtering system  300  can be used for organizing batches. Typically, the filtering system  300  is another vertical carousel unit  100  that interfaces with a set of stacked conveyors. A sorting hinge (not shown) may be used at each conveyor corresponding with the storage basket  500  location. The sorting hinge is generally a series of straight prongs or teeth welded to a hinge and controlled by a servo. The sorting hinges are attached to a series of stacked conveyors. Each sorting hinge is aligned with the spaces between the prongs  505  on the storage baskets  500  on the last vertical storage unit  300 . The sorting hinges remove the parts or products and dispense them on the conveyor designated to collect a particular batch or order. The conveyors take the batches to designated packing stations  45 . 
         [0045]    As illustrated in  FIG. 2 , vertical carousel units  100  are generally supported by rack structures  20 . To provide added support, each rack structure  20  can be attached (e.g., welded or bolted) to an adjacent rack structure  20 . Each vertical carousel unit  100  is mounted to at least one horizontal support bar  60  of the rack structure  20  through a mounting bracket  105 . For example, a first horizontal support bar  60  can be positioned at the top of the rack structure  20  and a second horizontal support bar  60  can be positioned at the bottom of the rack structure  20 . More specifically, each vertical carousel unit  100  includes at least one upper sprocket  110 , at least one lower sprocket  115 , and at least one belt or chain  120 . Preferably, each vertical carousel unit  100  includes a pair of upper sprockets  100 , a pair of lower sprockets  115 , and a pair of belts or chains  120 . As configured, the upper sprockets  110  are generally permanently attached at their centers to a rotatable horizontal shaft  117 , which is affixed through pillow block bearings (not shown) that are permanently attached to the corresponding pair of horizontal support bars  60  or mounting brackets  105 , thereby allowing the upper sprockets  110  and rotatable horizontal shaft  117  to rotate freely via the corresponding mounted pillow block bearings. The upper sprockets  110  are large enough to allow the baskets  500  to pass freely over the horizontal shaft  117 . 
         [0046]    Similarly, the lower sprockets  115  are generally attached to a pair of lower horizontal support bars  60  of the rack structure  20 . Again, the lower sprockets  115  are typically permanently attached at their centers to a rotatable horizontal shaft  118 , which is attached to a pair of pillow block bearings (not shown) that are attached to the lower pair of horizontal support bars  60 , thereby allowing the lower sprockets  115  to rotate freely via the corresponding mounted pillow block bearings. In a preferred embodiment of the present invention, the pair of upper sprockets  110  and the pair of lower sprockets  115  are linearly aligned vertically, such that the center of the upper sprockets  110  are substantially in line with the centers of the lower sprockets  115 , and the pair of belts or chains  120  run parallel with equidistance between them along the entire length of the vertical carousel unit  100 . 
         [0047]    The belts or chains  120  include a length significant enough to extend from the upper sprockets  110  to the lower sprockets  115 . The belts or chains  120  partially wrap around the upper circumferences of the upper sprockets  110  and partially wrap around the lower circumferences of the lower sprockets  115 . Each belt or chain  120  includes a first end connected to a second opposite end to form an endless (continuous) loop around an upper sprocket  110  and a lower sprocket  115 . 
         [0048]    A plurality of storage baskets  500  can be pivotally attached between the pairs of belts or chains  120  at predetermined locations. A storage basket  500  is adapted to receive and store products for an extended period of time, and then provide a product to the horizontal carousel  200  when the product has been ordered. 
         [0049]    Each lower sprocket  115  can include a smaller cog surrounding the center of the lower sprocket  115 . A sprocket drive unit  125 , such as a motor with a programmable logic controller (PLC) that can be controlled by a computer software application, includes a drive belt  130  that connects to the smaller cog of the lower sprocket  115 , such that, when activated, the sprocket drive unit  125  can automatically rotate the lower sprocket  115  and corresponding horizontal shaft, thereby moving the belts or chains  120 . The sprocket drive unit  125  can include, but is not limited to, an electric gear motor or could comprise a hydraulic or pneumatic mechanism. 
         [0050]    The belts or chains  120  rotate around the free spinning upper sprockets  110  and, therefore, move the plurality of storage baskets  500  upwardly or downwardly, depending on the rotation speed of the lower sprockets  115 . The sprocket drive unit  125  can also reverse the direction of the drive belt  130 , thereby reversing the direction of the lower sprockets  115  and the corresponding belts or chains  120 . The sprocket drive unit  125  can also include a break line  135 , which permits the controlled slowing down of the rotation of the lower sprockets  115 , thereby stopping movement of the storage baskets  500  pivotally attached to the belts or chains  120 . Each storage basket  500  can include an identifier, for example, an identifier tag that can be read by, for example but not limited to, a bar code scanner, photo recognition or radio frequency identification (RFID) receiver. 
         [0051]      FIG. 3  illustrates a horizontal carousel unit  200  of the present invention. As described above, the horizontal carousel unit  200  is positioned just below the plurality of vertical carousel units  100 , such that the storage baskets  500  of the vertical carousel units  100  can be positioned in communication with the products of the horizontal carousel unit  200  for the exchange of such products. The present invention can include a plurality of horizontal carousel units  200 , such that a horizontal carousel unit  200  corresponds to a horizontal plurality of vertical carousel units  100 . Each horizontal carousel unit  200  is generally supported by rack structures  20 . To provide added support to the horizontal carousel unit  200 , a support brace  215  may be introduced between each of the rack structures  20 . 
         [0052]    The horizontal carousel unit  200  can include a first and second sprocket  205 , such that the first sprocket  205  is positioned at a proximate end of the automated stocking and retrieval system  10  and the second sprocket  205  is positioned at a distal end of the automated stocking and retrieval system  10 . The first and second sprocket  205 , for example, can be attached to a lower horizontal support bar  60  of the rack structure  20 . Further, the first and second sprockets  205  are aligned linearly, such that the center of the first sprocket  205  is generally in horizontal alignment with the center of the second sprocket  205 . Generally, the first and second sprockets  205  are attached to the rack structure  20 , such that the first and second sprockets  205  can freely rotate around their centers. 
         [0053]    The horizontal carousel unit  200  can further include a belt or chain  611  having a length significant enough to extend from the first sprocket  205  to the second sprocket  205 . The belt or chain partially wraps around the circumference of one side of the first sprocket  205  and partially wraps around the circumference of an opposite side of the second sprocket  205 . A first end of the belt or chain is connected to a second end of the belt or chain to form an endless (continuous) loop around the first and second sprockets  205 . 
         [0054]    Further, the horizontal carousel unit  200  can include a track  210  that assists in guiding a product carrier  600  to and from the plurality of vertical carousel units  200 . In a preferred embodiment of the present invention, each product carrier  600  includes rollers  620  or wheels that freely roll on or within the track  210 , when the chain or belt is motion, thereby moving the product carrier  600 . 
         [0055]    A plurality of product carriers  600  can be securely attached to the belt or chain at predetermined locations. A product carrier  600  is adapted to temporarily hold and transport a product to and from a vertical carousel unit  100 . More particularly, a product carrier  600  provides a product to a storage basket  500  of the vertical carousel unit  100  for storage. Further a product carrier  600  receives a product from a storage basket  500  of the vertical carousel unit  100  during retrieval of the product in filling an order by a customer. 
         [0056]    The first sprocket  205  of the horizontal carousel unit  200  can include a smaller cog  220  at the center of the first sprocket  205 . Generally, the smaller cog  220  is attached to the first sprocket  205 . Both the small cog  220  and the first sprocket  205  have bearings in their centers, which are attached to a stationary shaft  225  positioned through the center of the smaller cog  220  and the first sprocket  205  and attached to an upright beam  20 . The smaller cog  220  is adapted to interface with a drive belt, chain or direct drive  130  of a sprocket drive unit  125  (e.g., a motor and programmable logic controller), such that the sprocket drive unit  125 , when activated, can automatically control the rotation of the first sprocket  205 , thereby moving the chain or belt (and the product carriers  600  attached thereto). The belt or chain  120  rotates around the free spinning second sprocket on the opposite end of the horizontal carousel unit  200  and, therefore moves the plurality of product carriers  600  to and from the vertical carousel units  100 , depending on the rotation (clockwise or counterclockwise) of the first sprocket  205 . 
         [0057]    The sprocket drive unit  125  can also reverse the direction of the drive belt  130 , thereby reversing the direction of the first sprocket  205  and the belt or chain. The sprocket drive unit  125  can also include a break line  135 , which permits the controlled slowing down of the rotation of the first sprocket  205 , thereby stopping movement of the plurality of product carriers  600  attached to the belt or chain. 
         [0058]      FIGS. 4A-4C  illustrate a storage basket  500  of the present invention utilized for receiving a product, storing a product for a predetermined period of time, and providing a product once the particular product has been ordered. Each storage basket  500  can comprise a plurality of prongs  505  (or teeth  505 ), such that each prong  505  is spaced a predetermined distance apart from adjacent prongs  505 . The plurality of prongs  505  are connected together by one or more horizontal support bars, one of which is generally positioned near the top portion of the storage basket  500 . Another horizontal support bar can also be added for additional support of the plurality of prongs  505 . 
         [0059]    Each prong  505  of the storage basket  500  is cooperatively-shaped for a product, for example, generally J-shaped or C-shape, permitting an object to be placed within the storage basket  500  for storage. The top of each prong  505  can be attached to a bar having swivel fittings on either end that are attached to the chain or belt  120  of the vertical carousel unit  100 . Further, the swivel fittings can allow the storage basket  500  to pivot from the connection point of the storage basket  500  with the belt or chain  120 , which pivot action can be free or controlled. Such pivoting allows the storage basket  500  to gently receive and provide products during stocking and retrieving processes. Each storage basket  500  generally is maintained in a horizontal orientation, generally perpendicular to the connecting belts or chains  120 , so that products can adequately be stored within various sub-portions  530  of the storage basket  500 . 
         [0060]    In an exemplary embodiment of the present invention, a storage basket  500  includes a plurality of prongs  505  spaced apart by distance approximately three (3) times the width of a prong  505 . The prongs  505  can be made of a rigid material such as, but not limited to, cold-rolled steal or plastic. Each storage basket  500  can be divided into a plurality of sub-portions  530  by the use of dividers  520  ( FIGS. 6 ,  7 B). Generally, there are approximately four (4) to twenty-four (24) prongs  505  per sub-portion  530  of the storage basket  500 . Moreover, each storage basket  500  is approximately but not limited to three (3) to four (4) feet wide, and divided into a number of sub-portions  530  depending on the configuration of the dividers  520  and product width. 
         [0061]    As described above, the prongs  505  are suspended and held in position by at least one horizontal support bar  516 , which can be extended on either end and attached to the belt or chain  120  on either end of the storage basket  500 , for example, via swivel fittings (not shown). A second horizontal support bar  515  may be positioned along each of the prongs  505 , thereby connecting each of the prongs  505  together, but the second horizontal support bar  515  is not generally suspended to the belt or chain  120 . Further, the second horizontal support bar  515  allows the prongs  505  of the storage basket  500  to remain a fixed position apart in relation to each other, but the storage basket  500  is able to swing freely from the belt or chain  120  during use. The second horizontal bar  515  can serve as a counter weight to balance the basket  500  to the correct product carrying orientation. The length of the second horizontal bar  515  is measured from the first prong  505  of the basket  500  to the last prong  505  of the basket  500 . 
         [0062]    Each prong  505  can have a partially circular shape (i.e., C-shape) and can vary in diameter from approximately but not limited to four (4) inches to twenty (20) inches, depending on the desired storage basket  500  size. Generally, each prong  505  of the storage basket  500  has the same diameter and, therefore, same physical characteristics regarding product support strength. 
         [0063]    The dividers  520  of the storage basket  500  can be made of a variety of suitable products, including, but not limited to, a solid sheet material that keeps parts or products from intermingling within the storage basket  500 . Such dividers  520  of the storage baskets  500  are governed by the design parameters, and allow for a more efficient use of space. Parts and products can be generally categorized by size to conserve space. The sub-portions  530  of the storage baskets  500  are generally designed to contain a quantity of one individual part or product. The transition mechanism, however, functions the same regardless of the size of the parts or products, as described more fully below. In order for the transition to function properly, the sub-portions  530  of the storage basket  500 , should match at least one product carrier  600  of the horizontal carousel unit  200  in compatible size. 
         [0064]      FIGS. 5A-5C  illustrate a product carrier  600  of the present invention for receiving a product, transporting the product to a storage basket  500  or a sub-portion  530  of a storage basket  500 , providing a product to a storage basket  500 , or a sub-portion  530  of a storage basket  500  receiving a product from a storage basket  500 , or a sub-portion  530  of a storage basket  500  and transporting a received product to the filtering system  300  for delivery to the packing stations  45 . Each product carrier  600  comprises a plurality of prongs  605  (or teeth  605 ), such that each prong  605  is spaced a predetermined distance apart from adjacent prongs  605 . The plurality of prongs  605  are connected together by at least one horizontal support bar  615 , which is generally positioned near the bottom of the product carrier  600 . 
         [0065]    Each prong  605  of the product carrier  600  is generally shaped having a valley at the top, thereby permitting an object to be placed and be relatively securedly maintained on top of the product carrier  600  during transport. The product carrier  600  can also include at least one connection bar  610  adapted to connect the product carrier  600  to the belt or chain of a horizontal carousel unit  200 . To assist in movement of the product carrier  600 , a plurality of wheels or rollers  620  can be utilized. A roller  620  is generally located at a distal end of a first prong  605  and at a proximate end of the first prong  605 , such that the rollers  620  can engage a support track  210  connected to the support brace  215  of the horizontal carousel unit  200 . Further, a prong  605  positioned at the opposite end of the product carrier  600  than the first prong  605  can also include a roller  620  at a distal end and proximate end. As configured, an axle  625  to the rollers  620  can run horizontally across from the first prong  605  to the last prong  605  of the product carrier  600 , thereby connecting the plurality of prongs  605  thereof. The rollers  620  are adapted to freely roll within or on the track  210  of the horizontal carousel unit  200 , thereby assisting in maintaining the product carrier  600  in relationship with the storage baskets  500  of the vertical carousel units  100 . 
         [0066]    In an exemplary embodiment of the present invention, the product carrier  600  includes a series of prongs  605  spaced apart by a distance approximately three (3) times the width of a prong  605 . One skilled in the art will recognize that the prongs  605  of the product carrier  600  can be made of a variety of suitable materials, such as, but not limited to, cold-rolled steal or plastic. Corresponding to the prongs  505  of the storage basket  500 , there are approximately four (4) to twenty-four (24) or more prongs  605  per product carrier  600 . 
         [0067]    The width of the product carrier  600  is generally determined by the width of the corresponding sub-portion  530  of the storage basket  500  to which the product carrier  600  may interface with. The product carrier  600  generally can have four (4) rollers  620  that are guided by track  210  of the horizontal carousel unit  200  to keep the product carrier  600  in line with the vertical carousel units  100  and corresponding storage baskets  500  and the corresponding sub-potions  530  of the storage basket  500 . Each prong  605  has a generally convex circular shape at the top to hold products and parts and to interface with a storage basket  500  of a vertical carousel unit  100 . For proper transition of products to and from the horizontal carousel unit  200  and the vertical carousel unit  100 , the product carrier  600  is generally scaled to a compatible size corresponding to a particular storage basket  500  or sub-portion  530  of the storage basket  500 . 
         [0068]    As discussed above with reference to  FIG. 6 , each storage basket  500  can be divided into a plurality of sub-portions  530  with the use of dividers  520 . The dividers  520  are designed to keep the product or parts within the storage basket  500  from intermingling. Generally, each storage basket  500  is divided into a predetermined number of sub-portions  530  equal to the number of associated product carriers  600 . For exemplary purpose only,  FIG. 6  illustrates a storage basket  500  without any sub-portions  530  (leftmost unit  100 ), and with dividers  520  generating a storage basket  500  with two (2) (middle unit  100 ) and four (4) (rightmost unit  100 ) sub-portions  530 . 
         [0069]      FIG. 6  also illustrates the corresponding product carriers  600  corresponding to the sub-portions  530  of the respective storage baskets  500 . Generally, but not necessarily, all of the storage baskets  500  on a vertical carousel unit  100  are configured with the same number of sub-portions  530 , because a predetermined and corresponding number of product carriers  600  of the horizontal carousel unit  200  are associated with the vertical carousel unit  100 . During use, for example, a product stored in a second sub-portion  530  of the storage basket  500  only requires that one of the product carriers  600  associated with the entire storage basket  500  be used for retrieving the particular product from the second sub-portion  530 . 
         [0070]    Generally, the vertical carousel units  100  are aligned in rows. The horizontal carousel units  200  are aligned to interface with each row of the vertical carousel units  100 . Further, each division or sub-portion  530  of the storage baskets  500  in the vertical carousel units  100  corresponds to a horizontal carousel unit  200 . Horizontal carousel units  200 , therefore, have a plurality of product carriers  600  that interface with the storage baskets  500  or sub-portion  530  of the corresponding vertical carousel units  100 . There are many alternative solutions for gliding the product carriers  600 . The horizontal carousel units  200  are also independently driven by a power device and controlled by a computer or similar device, as described below. 
         [0071]    One skilled in the art will recognize that the storage baskets  500  can be divided into multiple arrangements with varying sub-portions  530  without varying from the scope of the invention. The number of sub-portions  530 , however, is generally directed by size, shape and weight of the parts or products to be stored in the storage basket  500 . The number of product carriers  600  are associated with the particular storage basket  500  or corresponding sub-portion  530  of the storage basket  500 . 
         [0072]      FIGS. 7A-7B  illustrate the interaction between a storage basket  500  of the vertical carousel unit  100  and a product carrier  600  of the horizontal carousel unit  200 , wherein a product  70  is transferred between. As the prongs  505  of the storage basket  500  or sub-portion  530  correspond to the prongs  605  of the product carrier  600 , a smooth and gentle transaction can occur. More particularly, the prongs  505  of the storage basket  500  fit between the prongs  605  of the product carrier  600 , thereby allowing the storage basket  500  to gently pick-up or gently drop off a product  70  (based on the direction of travel of the storage basket  500 ). As the storage basket  500  is pivotally attached to the belts or chains  120  of the vertical carousel unit  100 , a precise and smooth transaction can result from the interaction between the storage basket  500  and the product carrier  600 . This type of exchange allows for parts or products  70  to be diverse in shape, sizes and weight. Further, the transaction is gentle because the storage basket  500  and product carrier  600  do not come in contact with each other during use. 
         [0073]    The automated stocking and retrieval system  10  of the present invention provides movable shelving in the form of storage baskets  500  that can store various products  70  or parts until retrieval is required (e.g., an order for the particular product is processed). The parts or products  70  within the storage baskets  500  can remain in storage indefinitely. 
         [0074]    To control the movement of the storage baskets  500  of the vertical carousel units  100  and the product carriers  600  of the horizontal carousel units  200  for the stocking and retrieval processes, a computer software program can be utilized to activate the sprocket drive units  125  of the present invention. Accordingly, the automated stocking and retrieval system  10 , when initiated by computer command, electro-mechanically retrieves the parts or products  70  from the scanning and stocking station  35 , automatically assigns a location for the parts or products  70  within a particular sub-portion  530  of a storage basket  500 , electro-mechanically provides the parts or products  70  to the sub-portion  530  of the storage basket  500  for storage, and digitally stores the part number and location via computer memory. 
         [0075]    When retrieval is required, the computer software initiates the automated stocking and retrieval system  10  to electro-mechanically retrieve the specified parts or products  70  from the correct sub-portion  530  of the storage basket  500  (via a product carrier  600 ), and provides the product to a packing station  45  for packaging and delivery. Accordingly, the travel time needed for a human to stock and retrieve products  70  and parts is completely eliminated. Further, the present invention requires fewer human members to stock and retrieve products  70  for delivery to a customer. 
         [0076]    The automated stocking and retrieval system  10  is not limited to a single stocking or retrieval process, but can stock and retrieve multiple products at the same time, thereby greatly reducing the time required for stocking and picking products. Further, the automated stocking and retrieval system  10  of the present invention is able to retrieve multiple batches (or orders) simultaneously. 
         [0077]    Advantageously, the automated stocking and retrieval system  10  can automatically sort individual parts or products  70  into batches or orders and dispense the items to individual packing or user locations. The transfer mechanism (e.g., the interaction between the storage baskets  500  and/or sub-portions  530  and the product carriers  600 ) allows for products  70  or parts to consist of a large variety of shapes and sizes. This universal quality allows for great flexibility for a variety of applications and the ability to handle, store, and retrieve parts or products  70  of dissimilar shapes and sizes, simultaneously. The automated stocking and retrieving system  10  adequately handles parts or products  70  gently without damaging them. 
         [0078]    The computer software program allows the automated stocking and retrieval system  10  to reassign storage locations (e.g., sub-portions  530  of a storage basket  500 ) in real-time to any part or product  70  and, therefore, the system is not limited to a specific skew number associated with a product  70 . Such a quality allows for a more efficient use of the storage baskets  500 , as sub-portions  530  are not permanently assigned to a particular product  70 . Accordingly, storage locations do not have to remain empty simply because an item is out of stock. Indeed, the computer software application controls the interaction between the storage baskets  500  and the product carriers  600 , as well as keeping track of the exact locations (all of or sub-portions  530  of the storage baskets  500 ) particular products are stored. 
         [0079]    Although the present invention is adapted to stock, store, retrieve, and sort individual products of various shapes and sizes, one skilled in the art will recognize that the present invention is not limited to single products, but can also be utilized for products or parts that are packaged in bulk. 
         [0080]    One skilled in the art will recognize that the automated stocking and retrieval system  10 , including the vertical carousel units  100  and horizontal carousel units  200 , and all of the components and/or elements thereof can be made of a variety of suitable materials including, but not limited to, plastic, rubber, metal, or other suitable materials or a combination thereof. 
         [0081]    Numerous characteristics and advantages have been set forth in the foregoing description, together with details of structure and function. While the invention has been disclosed in several forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions, especially in matters of shape, size, and arrangement of parts, can be made therein without departing from the spirit and scope of the invention and its equivalents as set forth in the following claims. Therefore, other modifications or embodiments as may be suggested by the teachings herein are particularly reserved as they fall within the breadth and scope of the claims here appended.