Bulk item access and storage system

An access and storage system including a generally enclosed storage compartment configured to be positioned on a ground surface such that a wheeled conveyance device carrying an item to be transferred is rollable directly into the storage compartment. The system includes a sensor system configured to track at least one of a placement, removal, presence or absence of the item or the wheeled conveyance relative to the storage compartment, and an access control system configured to control access to the storage compartment.

The present application is directed to an access and storage system and method, and more particularly, to an access and storage system and method for relatively large items.

BACKGROUND

Retailers often provide or utilize websites, mobile applications, and other channels to facilitate ordering and/or purchasing goods from locations remote from a brick-and-mortar retail location. In order to take possession of the remotely ordered or purchased item, the customer generally must either wait for the purchased item to be delivered to the customer, or alternatively travel to the store during the store's business hours to retrieve the item. Some existing systems may allow relatively small packages to be picked up after business hours, but such systems can be difficult to utilize and may not accommodate larger items or larger quantities of items bundled together in a single order.

SUMMARY

In one embodiment, the present invention is an access and storage system which can accommodate larger items and the like. More particularly, in one embodiment the invention is an access and storage system including a generally enclosed storage compartment configured to be positioned on a ground surface such that a wheeled conveyance device carrying an item to be transferred is rollable directly into the storage compartment. The system includes a sensor system configured to track at least one of a placement, removal, presence or absence of the item or the wheeled conveyance relative to the storage compartment, and an access control system configured to control access to the storage compartment.

DETAILED DESCRIPTION

FIGS. 1-7illustrate certain embodiments of an access and storage system10which can be utilized in a variety of transactions for facilitating transfer of items, products or the like. For example in one case the access and storage system10can enable the transfer of any of a variety of items or products between two users or parties, in one case termed a “stocking” party and a “retrieving” party, in a secure manner that requires little or no direct or interpersonal interaction between the parties at the time of purchase and/or transfer. The stocking party may in one case be a seller, retailer, or picker or other employee at a retail or wholesale store preparing an order for pick up. The retrieving party may in one case be the customer who placed the order, purchased the items and/or takes possession of the items. The systems and methods disclosed herein may alternately be used to facilitate transfer of items in contexts other than sales, such as transfer of leased, rented, gifted, or borrowed property, for example to facilitate rental of equipment from a hardware store.

Referring now toFIGS. 1-4, in one embodiment, the access and storage system10includes one or more storage compartments or stalls12positioned at the same physical address at a retail store15. Each storage compartment12can comprise or be defined by a generally enclosed framework13that can store therein one or a more items, products, supplies, tools, components, parts, ingredients, kits, consumables, or the like14(collectively termed “items” herein). The item14can take any of a wide variety of forms, depending upon the business of the stocking party and the setting in which the system10/storage compartment12is utilized.

The storage compartment12may be relatively large, for example between at least about 2 feet and at least about 5 feet wide (but less than about 20 feet wide in one case), between at least about 3 feet and at least about 8 feet high (but less than about 10 feet high in one case), and between at least about 4 feet and at least about 15 feet deep (but less than about 20 feet deep in one case). In one embodiment the compartment12is about 3 feet wide, about 5-6 feet high, and about 9 feet deep, or larger. Accordingly, the storage compartment12can be large enough to receive therein a wheeled conveyance device16, such as a flatbed cart, a grocery cart, a dolly, a lumber cart, a wheeled rack, a wheeled material handling device or the like, along with appropriately-sized items14stored in or on the wheeled conveyance device16. The storage compartment12may also be sized such that a person having a height of at least about six feet in one case, or an otherwise average sized human adult, can entirely enter the compartment12to position the wheeled conveyance16and any items14thereon or therein into the storage compartment12.

FIG. 1shows a single storage compartment, and as shown inFIG. 2in some embodiments the access and storage system10can include or take the form of a plurality of storage compartments12. In this case different ones of the storage compartments12may have different dimensions, for example to accommodate differently-sized items16, or alternatively each storage compartment12in the system10can have the same size and shape. In the depicted embodiments, the storage compartment12is shaped as a rectangular prism, but the storage compartment12may alternatively have any of a variety of other shapes.

The compartment12can have a base/bottom surface18that can be part of or defined by the framework13, or may instead comprise the underlying floor or underlying support/ground surface such that the wheeled conveyance device16is rollable directly through an opening29and into the storage compartment12. The base18may thus be at a same elevation as (e.g. within about one inch in one case, to avoid having to wheel a potentially heavy conveyance device16over relatively high obstructions/ramps) and/or substantially coplanar with the ground or underlying or immediately adjacent support/ground surface, upon which the storage component12is situated. In this case the door20may lack a frame component along its bottom surface, or if the door20does have a frame component along its bottom surface a ramp or the like may be provided on either side thereof, or the frame component may be recessed, to enable the wheeled conveyance16or items with wheels (such as appliances) to roll into the compartment12. Thus the wheeled conveyance16can be positioned at a same elevation immediately before and after being wheeled into the compartment12. On the other hand, if the compartment12/framework13does not rest directly on the ground, the base18of the compartment12may be elevated from the ground or underlying support surface and a ramp, elevator, conveyor, or other device may be used to facilitate rolling the wheeled conveyance device16into the compartment12.

The compartment12may be anchored to the ground or underlying support surface, or an adjacent wall or other structure. Thus the framework13can take the form of a five sided prism with an open bottom or a six sided prism with a bottom. However, the framework13can include less than five (or six) sides when positioned adjacent to fixed walls, structures or the like. Moreover, while the framework13is illustrated in the form of an open mesh framework, which can allow air circulation and visibility, the framework13can take the form of more solid or substantial walls for improved security.

Each compartment12may include or be divided into a main portion20and a sub-compartment22. In some embodiments, the compartment12may include more than one sub-compartment22. The main portion20can be substantially larger than the sub-compartment22, and the sub-compartment22may be positioned above or to one side of the main portion20. For example, in one embodiment the compartment12is about six feet high in total, where the main portion20is about five feet high and the sub-compartment22is about one foot high, positioned above the main portion20and extending the entire width and depth thereof. Accordingly, when the sub-compartment22is positioned at the top of the compartment12, and positioned entirely above the door28, the sub-compartment22reduces interference with access to the main portion20by the wheeled conveyance device16. The sub-compartment22may be a permanent shelf, or, as discussed in more detail below, the sub-compartment22may include or be defined by a storage shelf24that may be collapsed to increase the size of the main portion20to accommodate larger items that would otherwise not fit into the storage compartment12due to interference with the sub-compartment22.

Each compartment12may include a first or main door28corresponding to the main portion20and a second or sub-compartment door30corresponding to the sub-compartment22to control access to the compartment12. The doors28,30may each be pivotally/hingedly mounted to the framework13and movable independently of each other and cover/close associated access openings29,31. The access opening29may be sized and configured to allow an average-sized adult to pass or walk therethrough in a fully or substantially upright manner to access/enter the main portion20/storage compartment12/framework13. In addition the access opening29, or at least a bottom portion thereof, may have a width of at least about two feet in one case, or at least about three feet in another case, to allow a sufficiently-sized wheeled conveyance16to pass therethrough.

The doors28,30, may be physically coupleable to optionally move together as a unit to access the main portion20and the sub-compartment22simultaneously (or to access an enlarged main portion20in an embodiment with a collapsible storage shelf24in the collapsed position). In one embodiment, the compartment12may include further openings and/or doors at a rear location thereof (not shown), opposite the doors28,30, to provide a secondary access route to the interior of the compartment12, for example to provide additional stocking options to the stocking party. Moreover, in some embodiments only a single larger door28may be utilized, which covers both openings29,31and thereby controls access to both the main portion20and the sub-compartment22, as shown for example inFIG. 6A.

The access and storage system10can be configured to selectively control access to the compartment12, though access to the compartment12need not necessarily be so controlled. In one embodiment, access may selectively granted to the main portion20and/or sub-compartment22of a particular compartment12, but access may be denied to the other portion of the compartment12, by selectively locking/unlocking only one of the first door28or the second door30for that compartment12. Access to the compartment12through one or both of the doors28,30may be controlled with a manual lock, or alternately through a controller38as discussed in more detail below.

Referring now toFIGS. 6A-Cand7A-C, the sub-compartment22may include or be defined by a collapsible shelf24movable between an expanded position where the shelf24is deployed for use and a compact or collapsed position where the shelf24is stowed. When the shelf24is in its collapsed position, substantially the entire height of the storage component12is defined by the main compartment20and available to accommodate a single relatively large order.FIGS. 6A-6Cdepict an embodiment where the shelf24, when in its expanded position has a width (in the left-to-right direction) that extends substantially the entirety of the width of the compartment12, and a depth (in the front-to-back direction) that extends the majority of the depth of the compartment12, for example at least about 50%, 75%, 90%, or 95% of the width and/or depth of the compartment12.FIGS. 7A-Cdepict an embodiment where the shelf24is more shallow than that ofFIGS. 6A-C, having a depth that is less than about 50%, 25%, or 10% of the full depth of the compartment12in which it is installed.

In the embodiments ofFIGS. 6A-Cand7A-C, the collapsible shelf24is coupled to the ceiling/upper surface26of the storage compartment12/framework13by a plurality of suspended supports32coupled to the shelf24by a plurality of first or upper hinges34and second or lower hinges36, respectively. The upper hinges34pivotally couple the supports32to the ceiling26of the storage component12and the lower hinges36pivotally couple the supports32to the platform25of the generally flat/planar collapsible shelf24.

The access and storage system10may include a locking mechanism (not shown) to releasably secure the collapsible shelf24in the each of the expanded and collapsed positions. In the expanded position, the shelf24is suspended from the ceiling26with the platform25of the shelf24substantially parallel with the ceiling26and the supports32substantially perpendicular thereto, thereby defining the sub-compartment22. In the collapsed position, the collapsible shelf24is positioned with the platform25thereof immediately adjacent to the ceiling26and parallel thereto. The collapsible shelf24is movable between the expanded position and the collapsed position by pivoting the collapsible shelf24via the network of hinges34,36in accordance with the movements indicated by arrows39inFIG. 6CandFIG. 7Ato substantially flatten the collapsible shelf24against the ceiling26of the storage component12.

In alternative embodiments, the collapsible shelf24may include alternative or additional structures for transitioning between the expanded and collapsed positions. For example, the shelf24may be hingedly coupled to a side wall of the storage compartment12, and the shelf24may be positioned adjacent to and substantially flat against the side wall when in the collapsed position. The shelf24could then be pivoted to such that its platform25is positioned substantially perpendicular to the side wall to which it is attached and secured to the opposite side wall and/or the ceiling26when in the expanded position. Further alternatively, the collapsible shelf24may be entirely removable from the storage component12. The collapsible shelf24may include additional panels along the sides and/or back thereof to fully contain items thereon, and such additional panels may be attached via hinges or other flexible structures to facilitate folding of the shelf24to and from the collapsed position.

As shown inFIGS. 2-4, the access and storage system10can include multiple storage compartments12/framework13arranged side-by-side in a row or even in an array with ramps provided to the upper compartment12. Each storage compartment12can have the same characteristics and qualities of the storage compartment12described above. The access and storage system10can be configured to selectively control access to all or certain compartments12, or certain main portions20and/or sub-compartments22thereof. In particular, the access and storage system10may include or be associated with a controller38(FIG. 2) which a user can interact with to gain access to all or certain portions of the storage compartments12. The controller38may take the form of a processor, CPU, computer or the like, and may include or be operatively coupled to sensors44to detect and/or track the presence and/or absence and/or movement of the wheeled conveyance device16and/or any items14within the main portion20and/or sub-compartment22of each storage compartment12.

Each storage compartment12/framework13may include one or more sensors44therein or associated therewith, and each sensor44can take any of a wide variety of forms. In one case, as shown inFIG. 5, the sensor44is a break beam sensor and/or weight sensor positioned at the base or floor18of the main portion20of the compartment12such that when a wheeled conveyance device16or item14is positioned in or removed from the storage compartment12, the break beam46is broken or completed, triggering the sensor44. In another case, the sensor44is a light/dark switch which detects the sufficient presence and/or absence of light. However, each of the sensors44can take any of a wide variety of forms, including but not limited to pressure or force sensors, weight sensors, optical or line-of-sight sensors, detectors based on mechanical forces, membrane switches/sensors, magnetic switches/sensors, light or electromagnetic radiation (visible, infrared or otherwise) sensors, contact sensors, photoelectric sensors, ultrasonic sensors, piezoelectric sensors, piezoresistive sensors, accelerometers, motion sensors, tilt sensors, proximity sensors, electric field sensors and other sensing devices.

In addition to sensors for confirming presence or absence of items within the compartment12, the system10may further include a sensor45or sensors45to monitor whether the doors28,30are open or closed, and the controller38may track such activity. The sensor(s)44,45may be positioned at any appropriate location within, on, or outside the compartment12, the doors28,30, and the like, as necessary for the particular type of sensor to properly function for its intended purpose. In one embodiment, sensors or tags such as RFID tags are also included on or in the wheeled conveyance device16and/or any items14positioned in the storage compartment12and the sensor44can take the form of a RFID sensor, providing further tracking capability for items14.

The controller38may be operably coupled to the system10, including the various sensors44,45to track ingress or egress of items14to or from the compartment12, and/or to selectively lock or unlock the doors28,30to control access to the interior of the compartment12for stocking or retrieval of items14by authorized individuals. The controller38may include or be operatively coupled to a user interface or identifying device40in the form of a keypad, touch screen, keyboard, mouse, track ball, audio input device, barcode scanner, qr code reader, card reader, biometric identifying device, or the like, to identify and/or authenticate users. The controller38may be operatively connected to a remote system or server42to provide interne connectivity access, for example to enable communication between web-based order management software systems and locally-based software systems for managing operation access and tracking functionality of the storage system10. In one case each compartment12may include its own associated user interface40. Alternatively, a single user interface40may be associated with multiple compartments12, and in one case such compartments12that are nearby and within a line of sight of a user using the user interface.

Accordingly, the controller38may be used as an access control system to control and monitor stocking and retrieval of items14to and from the main portion20and/or sub-compartment22of specific storage compartments12. The controller38may also be configured to interact with remote systems to communicate stocking and retrieval requirements and permissions as defined by incoming customer orders and pre-programmed software control parameters. In some cases, a separate user interface40may not be needed and a user can interact with the controller38remotely such as by using a mobile device, phone, tablet, computer, etc. which can operate as the user interface40.

The various components of the access and storage system10may be pre-fabricated and shipped as a completed unit to a site for use/installation, or, alternatively the system10may be wholly or partially manufactured on site from locally-sourced components. The system10may be installed and used indoors or outdoors. If installed outdoors, the system10may include weather-resistant components, and/or may be installed within a weather-resistant enclosure. The system10may include or be used in conjunction with security devices such as cameras, security systems, monitoring systems, etc. to provide added security or proof of drop off/delivery/pickup, or to track access to the compartment12. Alternatively, the system10may be positioned in an area monitored by a pre-existing security system.

Referring now toFIG. 8, one embodiment of a workflow of a method for use of the access and storage system10will be described in the exemplary context of the sale of a lawnmower from a hardware store that is packaged in a large box. Of course, the system10can be used for delivery/pickup of any of a wide variety of items in a variety of settings. In the illustrative example, the access and storage system10is positioned at the site of the hardware store, or at an alternate pick-up location such as a warehouse or third party site.

As an initial step of this method, the customer places an order for the lawnmower from the hardware store/vendor, for example through an internet e-commerce website, a mobile phone or tablet application, a phone call, a fax order, or any of a variety of other remote or on-site purchasing channels, indicating the customer's intention and desire to pick up the lawnmower at the site where the access and storage system10is installed. Payment for the lawnmower/item14may be made at this time and the customer can request or be informed the order can be picked up via the access and storage system. In some cases the user may be provided with a unique retrieval code at this time. The order can be automatically or manually inputted into an order management system installed in a computer system, or a web-based system, which is operatively connected with compartment management software installed in the controller38of the access and storage system10. The order management system software and the compartment management software can, in one embodiment, be installed or accessed through one or more computers or controllers or one or more networks of computers and/or controllers.

After the order is input in the order management system, the order management system can notify store personnel that the order will be delivered/retrieved via the access and storage system10. The order management system also communicates the order information to the compartment management system. Alternately, store personnel may communicate the order information to the compartment management system as a separate step. The compartment management system creates a stocking code (for use by the store or stocking entity/individual) and a retrieval code (or a supplemental code, for use by the customer/purchaser) for the order, where the stocking code and the retrieval code can be different from each other. The stocking and retrieval codes may each be unique and single use, meaning that subsequent orders will have different codes. For maximum security, the entity/individual who receives the stocking code should not have access to the retrieval code and should not know the identity of the customer. Otherwise, the stocking entity/individual would have means to provide access to the stocked item to an unaffiliated third party, or to include extra items in the compartment12that the customer is not entitled to receive. One or both of the stocking code or the retrieval code may be a bar code, qr code, or other identifier capable of being entered or scanned into the user interface40.

The compartment management system then provides the stocking code to a store picker assigned to stock the compartment12of the access and storage system10with the lawnmower/item14. The compartment management system may at this time also inform the store picker of the identity/location of the specific compartment12to be used. In one embodiment, the compartment management system automatically assigns the compartment12(and/or main portion20and/or sub-compartment22thereof) into which the item14will be stocked, based on the size and/or shape of the item14and the available compartments12, such that items14can be assigned to size-appropriate compartments12and/or sub-compartments22. Alternately, store personnel may manually select the appropriate compartment12or portion thereof.

A store picker then picks the item14from its storage location within the store or warehouse location, and can position the item14on the wheeled conveyance device16. The store picker then transports the wheeled conveyance device16with the item14to the access and storage system10. The store picker accesses the user interface40and enters the stocking code provided by the compartment management system. The controller38then allows or denies access to the applicable compartment12based on whether the store picker has entered the correct stocking code. If the user interface40is associated with multiple compartments12, the identity/location of the specific compartment12may be provided as an output of the user interface40.

Upon confirmation of the stocking code by the controller38, the controller38unlocks, automatically opens, and/or otherwise provides access to the appropriate door28,30(which may be sensed by the door sensor45) to facilitate stocking of the lawnmower/item14in the compartment12. The store picker then wheels the lawnmower/item14into the storage compartment12, which can trigger at least one sensor44to indicate that the item14is properly positioned within the storage compartment12. In one embodiment, the store picker leaves the wheeled conveyance device16in the storage component12along with the item14(e.g., lawnmower) positioned thereon. The store picker then closes the door28,30, which the controller38may sense via a sensor45. In one case the sensor44can be utilized to ensure one or more qualities of the item14(i.e., weight, outer dimensions, etc.) match the qualities expected for the item14, and send a notification if the measured qualities are outside and/or inside range. Once the door28,30is closed and optionally after the item14is confirmed to be within the storage component12(e.g., via the sensor44), the stocking code expires and can no longer be used to access the contents of the storage compartment12. The item14, positioned on the wheeled convenience device16, can thus be left in storage compartment12.

Once the item14is stocked, the compartment management system can notify the customer that the order is ready for retrieval and send the retrieval code to the customer (if not already sent), for example via email, text message, audio or visual signal, through interaction with a vibrating signal device, or any of a variety of other signaling methods. The compartment management system may additionally notify the customer which compartment12contains the customer's purchased item.

Upon arrival at the access and storage system10, the customer inputs the retrieval code (or scans the barcode, etc.) into the user interface40. In some cases, if the customer has not already paid for the item14, the customer can pay via the user interface40such as by credit card, pay pal payment system, or via a user's mobile device, and the retrieval code is then provided. After the customer enters the retrieval code the controller38then allows or denies access to the applicable compartment12based on whether the customer has entered the correct retrieval code. If the retrieval code as verified by the controller38, the controller unlocks and/or automatically opens the appropriate door28,30to facilitate removal of the item14and may identify or provide the location of the appropriate compartment12. The customer may conveniently use the wheeled conveyance device16upon which the lawnmower or item14is already positioned to transport the item14out of the compartment12. Opening/closing of the doors28/30may be sensed by the sensor45and removal of the item14may be sensed by the sensor44.

After removal of the item14, the customer shuts the door28,30which the controller38may sense via sensors45and/or the door28,30can be automatically closed. Once the door28,30is closed and the item14is confirmed to have been removed from the storage component12(e.g., via the sensor44), the retrieval code expires and can no longer be used to access the contents of the storage component12. Accordingly, the component12is again available for use for another order with new stocking and retrieval codes. In some cases the retrieval code can allow the customer access to a limited area (i.e., behind a typically locked door) in which the system10is located. If the order is not retrieved by the customer within a predetermined period of time (for example within an hour, or within a day or within three days) the compartment management system/controller30may send a reminder to the customer,

Referring now toFIG. 9, another embodiment of a workflow method for use of the access and storage system10will be described, again in the exemplary context of the sale of a lawnmower from a hardware store that is packaged in a relatively large box. In this case, a customer can place a purchase order for the lawnmower/item14, for example through an order management system, as before. The order is communicated to a known store personnel such as a store picker, along with the customer's order number.

The store picker picks the item14from its storage location within the store, and can position the item14on the wheeled conveyance device16. The store picker can then transport the item14with the wheeled conveyance device16to the access and storage system10. The store picker accesses the user interface40and enters the order number via keypad, bar code, qr code, or other suitable entry method. The store picker can also select a suitable compartment size (e.g., full storage compartment12, main part20, or sub-compartment22). The compartment management system can then assign the order to a specific compartment12(or portion thereof). The controller38unlocks, automatically opens, and/or otherwise provides access via the appropriate door28,30to the assigned compartment12to facilitate stocking of the item14. The store picker then transports the item14into the storage compartment12, which can trigger at least one sensor44to indicate that the item14is positioned within the storage compartment12. The store picker then closes the door28,30, which the controller38may sense via sensors45.

Once the lawnmower or other item14is stocked, or at the same time that access is granted to the picker, the compartment management system generates a retrieval code and provides it to the order management system that the customer used to place the order, matched with the order number. The order management system then communicates the retrieval code to the customer to indicate that the item14is ready for pick up, in essentially the same manner earlier discussed with respect to the embodiment ofFIG. 8.

The access and storage system10thus facilitates efficient self-service customer retrieval of items, such as remotely-sold items, including relatively large items and groups of products that require wheeled transports to effectively or efficiently transport the items. A seller can remotely accept a plurality of orders and/or payment for such orders from a plurality of customers, and then prepare each order for customer pickup in a secure manner without the need for interpersonal interaction with the customer to locate and retrieve each customer's particular order upon the customer's arrival at a store location. The system10thus both organizes and segregates each order into a storage compartment12, and also provides security to ensure that customers only retrieve the order(s) for which they have paid, because each storage compartment12requires a different and unique retrieval code for access. This system and method saves time and improves efficiency for the remote customer, who can, in some embodiments, self-retrieve purchased products upon arrival at the sale site, as well as for store personnel who can pick products into a wheeled device14and directly position the wheeled device into the compartment12without the need to unload the product.

The disclosed system10allows customer orders to be picked by the seller, positioned on a cart or other wheeled device14containing the entire order, and then rolled directly into a secure compartment12for retrieval by the customer. The seller does not need to remove the items from the cart14prior to retrieval by the customer and the customer can directly roll the cart to their vehicle for loading, which improves efficiency. A seller can also pick up an order outside of the store's normal business hours.

The disclosed system10also provides a method of tracking the status of items in a compartment12with sensors44that monitor contents of the compartment12. The system10may not rely entirely on monitoring whether a compartment door28,30has been opened or closed to infer contents of the compartment12and can track storage and removal accordingly. Thus, the disclosed system10provides enhanced confirmation capabilities to confirm actual placement and/or retrieval of items from the compartment12.

It should be appreciated that the principles of the access and storage system10and use thereof may be implemented in a variety of manners that depart in certain ways from the embodiments expressly depicted herein, without departing from the scope of the invention. Although the invention is shown and described with respect to certain embodiments, it should be clear that modifications will occur to those skilled in the art upon reading and understanding the specification, and the present invention includes all such modifications.