GB2430705A - Multi-configuration lockerbank construction - Google Patents

Abstract

An automated lockerbank comprises one or more columnar housings, each divided into a plurality of lockers by means of adjustable internal dividing walls and interchangeable doorframe units comprising a door pre-assembled on a doorframe and preferably including a lock, which are releasably mounted on the front of the housing. By providing interchangeable doorframe units in a variety of door heights the standardised housing may be adapted to local demand. The doorframe units are less susceptible to structural deformation than the larger housing and therefore maintain each door in more rigid relationship to its frame. A plurality of doorframe units may be integrated into a complete housing fascia assembly, or alternatively each doorframe unit may be integrated with the internal walls of its respective locker so as to form a rigid box shaped insert. Alternatively or additionally, each locker comprises at least one internal side wall which is spaced apart from the corresponding side wall of the housing so as to define a vertical structural cavity in the housing. The cavity may accommodate a vertical rigidifying element forming part of the housing or part of the doorframe units, as well as accommodating the locks of the interchangeable locker doors. Each door may be extended across the vertical cavity for additional security.

Description

Lockerbank construction This invention relates to automated lockerbanks

for the deposit and collection of goods, and in particular to the constructional and structural details thereof.

Lockerbanks are automated facilities, usually networked and often sited in public places, which enable goods (which may for example have been ordered by a consumer from a retailer or online "etailer", or by a service engineer from a central warehouse) to be deposited by a first person and then securely stored for later collection by another person. A lockerbank typically comprises an electronic controller which is in communication with a remote, central network computer, a user interface including a screen, a keypad and a card or tag reader, and an assembly of one or more locker units or housings, usually of columnar form, each unit comprising one or more secure lockers, each locker having an individual door with one or more locks operated by the controller. The controller responds to stored instructions from the central computer to lock or unlock each locker door in accordance with the data received via the interface. S... * * es..

*:::: It is important for the lockerbank to be robust, and in particular for each of its * 20 component lockers to be adequately secure against attempts to deform or prise open its door. At the same time, the construction of the lockerbank should preferably be simple and inexpensive, and the overall shape and dimensions of each locker unit should preferably be standardised so as to faäilitate manufacture and installation as well as ensuring customer recognition. Each lockerbank may be assembled from a varying number of columnar units, selected to suit the expected volume of business at the site on which it is installed.

Since different sites may be expected to serve different types of customer, the typical size of the packages or letters which are likely to be handled by the lockerbank will also vary from site to site, and it is therefore desirable for different lockcr units to comprise different numbers of lockers of the required size. For example, where a lockerbank is expected to handle a large volume of letters and relatively few parcels, it is desirable for each columnar unit to comprise a large number of very shallow lockers, with perhaps one unit including a small number of larger lockers. Where a larger volume of parcels is expected, larger lockers are preferable. However, the provision of different types of locker units increases manufacturing and assembly costs, and makes it necessary to remove and re-install entire locker units or even an entire lockerbank installation in order to respond to changing customer demand.

It is known, for example from EP 1 415 573 A2, to form conventional sports locker assemblies with a modular construction having a standardised, columnar body which is adapted to receive horizontal dividers or shelves and corresponding locker doors in various alternative positions so as to define alternative configurations of lockers of various different heights, within the standard external dimensions of the body. * **

Although this type of locker construction can reduce manufacturing costs, it is found in practice to be unsuited to use in automated lockerbanks. Conventional, S... . . . *. : modular lockers are typically installed in controlled environments, such as train * . 20 stations or sports facilities, where they can be sited on a level floor and perhaps secured to a wall. Automated lockerbanks in contrast are often sited in outdoor, * * public locations, on uneven ground and without the benefit of any supporting structure. They are also required in use to receive a load which may amount to some hundreds of kilos per unit. This causes the ground to settle beneath the weight of the lockerbank, and it is found in practice that the resulting uneven support at the base of each locker unit can result in twisting or departure from orthogonality ("parallelogramming") of the outer structure of the unit.

At the same time, whereas a conventional sports locker must offer sufficient security for relatively short term use in a supervised environment, an automated lockerbank must be sufficiently secure for continuous use, both day and night, in an unsupervised, outdoor environment. It is also important that the doors of the lockerbank remain under the control of the lockerbank controller. It is found that twisting or parallelogramming of the lockerbank frame will cause one corner of each locker door at its opening edge to move away from the frame. The resulting enlarged gap can offer an entry point for a prising tool as well as reducing the depth of engagement of the lock and so compromise the security of the locker. At the same time, the opening edge of the door may contact the frame at its opposite corner, which can cause the door to jam. Although this may be a minor inconvenience in a conventional sports locker assembly, it can prevent the locker door of an automated lockerbank from opening, closing and locking in response to the controller and can therefore effectively remove that locker from service, reducing the capacity of the network.

In order to resist such distortion it has been found necessary to form each columnar unit of the lockerbank as a substantial sheet metal construction with * welded or closely riveted joints, so that each horizontal shelf between adjacent :::: lockers forms a fixed part of the overall structure and helps to rigidify the unit.

* This provides sufficient rigidity to reduce distortion, but makes the unit heavy and *:::: expensive as well as making it difficult to adapt the lockerbank to changing * 20 customer requirements. * S * S S

*. .. It is the object of the present invention to provide a lockerbank which is adaptable to accept different locker configurations while resisting the effects of structural distortion.

According to the present invention there is provided an automated lockerbank as defined in the appended claims.

Various illustrative embodiments will now be described by way of example and without limitation to the scope of the claims, and with reference to the accompanying drawings, in which: Figs. 1A and lB are respectively front and end views of a first lockerbank; Fig. I C shows a fascia assembly of the first lockerbank according to a second embodiment; Fig. 2 is an exploded view of one locker unit of the first lockerbank according to a first embodiment; Figs. 3A and 3B show a locker insert unit of the first lockerbank according to the first embodiment; Figs. 4A and 4B show the rear of the door of the locker insert unit of Figs. 3A and 3B; * Fig. 5 shows the lock controller and user interface insert unit of the first lockerbank according to the first embodiment and I,.. , * S *S.S * : :: : Fig. 6 shows a partial exploded view of one locker unit of the first lockerbank * 20 according to the second embodiment. * S * S S

* * * Referring to Figs. 1 A and 1 B, in a first embodiment an automated lockerbank 1 comprises an assembly of five columnar locker units 2, 3, 4, 5, and 6, covered by a canopy 7. Locker units 2 and 3 each comprise a vertical array of small lockers having small locker doors 8 and medium height lockers with medium locker doors 9. Locker unit 5 has an array of two standard height lockers with doors 10 and one large locker with a corresponding large door 11. Locker unit 4 has a similar array, but in place of the large locker is a lock controller and user interface insert unit 12. Locker unit 6 has a single, full height locker with a door 13. An outer skin 14 is attached to the outer side of each of the end locker units 2 and 6.

Referring also to Fig. 2, each locker unit 3 has an outer housing which supports, protects and retains the locker insert units as explained further below. The housing comprises two sides 30, 30', a back 31, a base 32, a top 33, and a front 34. The back 31 forms part of the rear protective skin of the lockerbank and therefore comprises a solid steel panel, while each side 30, 30' is formed by an open structural framework having vertical corner struts 35, 35' and horizontal struts 36.

The base 32 and top 33 are formed by panels which help to rigidify the housing, while the front 34 is a rectangular opening defined by the front vertical corner struts 35 and the front edges of the base and top panels. The housing is also provided with a locker insert release mechanism, comprising two vertical retaining struts 37 which are rotatably mounted between the top and base panels and rotatable by means of two cranks 38. The cranks are both accessible at a single point via a lockable panel 39 arranged at the top of the housing.

Referring also to Figs. 3A and 3B a locker insert unit 40 comprises a doorframe * unit 41 and a plurality of internal walls which together define an individual locker. **** S... * S

S... . The doorframe unit compnses a doorframe having upper and lower frame bars 42, * : :: : a left hand frame bar 43 and a right hand frame extension plate 44; and a small * 20 locker door 8 which is permanently mounted on hinges 45, 45' between the upper ::; and lower frame bars 42.

The doorframe unit 41 is permanently mounted on a box shaped assembly of upper and lower horizontal internal walls 46, 47, a rear wall, a left internal side wall 48 and a right internal side wall 49 which when the insert unit is installed extends from the doorframe 42, 43, 44 towards the back 31 of the housing. The right and left internal side walls are provided with flanges having retaining notches 50 which are engaged in use by the retaining struts 37 to retain the insert unit 40 in the housing. On the right internal side wall 49 the flanges are extended so as to space the side wall apart from the right hand side 30' of the housing, so that when the insert unit is installed in the housing it defines a vertical structural cavity between the side wall 49 and housing side 30', which extends from the base 32 to the top 33 of the housing and contains the extended flanges and frame extension plates.

Referring also to Figs. 4A and 4B, a lock 51 having an axially moveable bolt 52 and a door position sensor 53 are mounted on the frame extension plate 44 and electrically connected to the lock controller via a releasable multi-pin connector and a wiring harness (not shown). The door 8 is provided on its internal face with an elongate reinforcement 54 having a recess 55 which receives the bolt 52 when the lock is actuated by the lock controller. For larger doors, more than one lock may be provided.

Referring also to Fig. 5, the lock controller insert unit 12 comprises a fascia 60 which supports the lock controller module 61, which includes a transceiver and modem for communicating with a remote computer which forms the network hub, * a receipt printer 62, and a user interface 63 including a screen and a keypad. The :: insert unit 12 is slideably mounted in the locker unit housing in place of a * S. standard locker insert, which removes the need to provide a dedicated housing for : the lock controller and user interface.

* : * :.* In the example shown, each locker unit 2, 3, 4 and 5 has been adapted to the * . required configuration by inserting a different combination of locker insert units of the required dimensions. The width of each insert unit is the same, while the heights of the units are selected so that they may be combined in a variety of alternative combinations within the overall standardised height of the locker unit.

It is found that by mounting each door on a doorframe to form a doorframe unit, and integrating the doorframe unit with the internal walls of the locker so as to form a rigid box of much smaller dimensions than the locker unit in which it is housed, it is possible to substantially isolate the combined door and doorframe from any distortion which occurs in the housing of the locker unit, and so reduce parallelogramming resulting in unwanted displacement of the door relative to the doorframe. Moreover, the upper and lower internal walls 46, 47 of the insert unit are arranged to form sliding surfaces which support each insert unit slidably against the adjacent units. This allows any distortion of the locker unit housing to be compensated by small sliding displacements between adjacent insert units.

If desired, the locks can be arranged elsewhere on the housing so that each locker occupies substantially the entire width of the locker unit housing. Advantageously however, the provision of a vertical structural cavity between the insert unit side walls and the right hand side 30' of the housing allows the locks to be arranged as shown as an integral part of each doorframe unit, since the locks are then received in the cavity as the insert units are slid into place. By mounting the lock on the doorframe unit, the further advantage is realised that any positional error which might occur between the insert unit and the housing is prevented from displacing the lock relative to the door or the doorframe. Thus, even where the weight of the locker contents and the unevenness of the ground results in distortion of the overall lockerbank 1 and parallelogramming of its component locker unit * housings, this distortion does not result in displacement of each individual locker door relative to its frame, or of the lock relative to the door.

The vertical cavity also allows the right hand part of each doorframe unit to be * . ** extended to form a relatively wide panel 44, which is received in the cavity; this further rigidifies the doorframe unit and, if desired, the panels 44 of each insert unit may be connected together to impart additional rigidity to the housing. A vertical flat, angled or hollow box section strut may also be incorporated in the housing, which is arranged in the vertical structural cavity so that it lies behind the frame extension plates 44 when the insert units are installed. By fixing this strut rigidly to the base and top panel of the housing, overall distortion of the housing is reduced.

By removing the access panel 39 it is possible to rotate the locking mechanism 37, 38 and so release all of the insert units 40 together from the housing. The units 40 may then be slid out of the housing and exchanged, replaced or reconfigured as required. In the first embodiment illustrated, each insert unit is simply supported vertically by the unit below, which provides a simple and economical construction which is highly adaptable. Alternatively however the housing may be equipped with suitable slides for individually supporting each insert unit in a variety of configurations.

Referring to Fig. 6, in an alternative embodiment each door is mounted in a doorframe to form a separate, individual doorframe unit, which however is not integrated with the internal walls of the locker. In this embodiment the doorframe is formed as a robust construction, for example from welded struts, so that its rigidity and relatively small size prevents it from distorting, and for some applications this is found to provide adequate rigidity. The doorframe units are * releasably mounted on the housing in the required configuration, and the internal :::: walls of the locker are independently adjusted to correspond to the configuration S...

selected. I.e. * I S S. S

* 20 In the example shown the locker unit housing 70 incorporates a rigidifying * * :.* vertical strut 71 which is arranged within the vertical cavity 72, indicated by : * dotted lines and formed between the right hand internal side wall 73 of each locker and the right hand outer side wall 74 of the housing. The front wall 71' of the strut occupies the whole width of the cavity and is united with the base and top of the housing so as to provide maximum resistance to parallelogramming. In this embodiment the right hand internal side wall 73 and internal top and base wall 75 of each locker are mounted in slots 76 in the housing so as to conform to the doorframe units installed. The left hand wall and rear wall of each locker are formed respectively by the left hand (not shown) and rear 77 wall panels of the housing, so that in this embodiment each housing has two solid side walls 74 which are shared between adjacent locker unit housings. A releasable locking mechanism comprising a vertical rod 78 and a plurality of cams 79 is arranged to retain the doorframe units to the housing.

Referring also to Fig. I C, in a development a plurality of doorframe units are integrated to form an integral fascia assembly 80, formed as a unitary framework which defines a complete vertical array of doorframes carrying doors 8', 9'. This is found to provide a very rigid construction which helps rigidify the housing as well as preventing parallelogramming of the individual doorframes. The fascia assembly is releasably mounted on the housing so that if it is desired to alter the locker unit configuration, a replacement doorframe having a different array of doors is substituted, and the internal base, top and side walls 75, 73 are adjusted to conform to the new configuration. The locks and sensors of each doorframe unit are pre-wired and the complete wiring harness (not shown) is connected to the lock controller by means of a single, multiple pole connector, which simplifies assembly. * S.

:::: Desirably, a continuous vertical plate or box section is riveted or welded to the * rear face of the fascia assembly in a position corresponding to the frame ::: : extensions 44 of the previously described embodiment, as illustrated by the dotted * 20 line 81, which carries the lock of each doorframe and which is received in the vertical structural cavity 72 of the housing. The plate or box section is fastened * . rigidly to corresponding horizontal plates arranged in the top and bottom of the housing so as to further reduce distortion of the housing; alternatively, horizontal stiffening plates may be included at the top and bottom of the fascia assembly.

In a further alternative embodiment, by arranging the housing to include a vertical structural cavity as shown, the additional rigidity provided by the housing structure may be found sufficient to allow each locker door to be releasably and interchangeably mounted directly on the front of the housing rather than integrated into a doorframe unit as described above. The doorframe is then formed in the conventional way by the housing and the front edges of the internal locker walls, which are positioned to conform to the selected configuration of locker doors, while at least one internal locker wall of each locker defines the rigidifying cavity. Preferably, the locks are mounted within the cavity, for example by attaching them to the internal side walls, or to the rear face of a stiffening plate which defines the front face of the cavity.

It will be noted that in each of the illustrated embodiments, the door is arranged to extend across substantially the whole width of the locker unit housing, so that it lies in front of the frame extension plate 44 and the vertical structural cavity. This advantageously allows the locking point, represented by the bolt receiving recess 55, to be hidden behind the door as shown in Fig. 4B so that the door extends for a considerable distance past the locking point, making it extremely difficult to gain access to the lock when the door is secured in the closed position. This feature gives additional security and is preferably included, even where each door is releasably mounted directly on the housing rather than on a releasable frame to : form a doorframe unit as illustrated. S... S...

* S.. In summary, embodiments provide an automated lockerbank comprising one or *. : more columnar housings, each divided into a plurality of lockers by means of * 20 adjustable internal dividing walls and interchangeable doorframe units comprising * a door pre-assembled on a doorframe and preferably including a lock, which are *: ,* releasably mounted on the front of the housing. By providing interchangeable doorframe units in a variety of door heights the standardised housing may be adapted to local demand. The doorframe units are less susceptible to structural deformation than the larger housing and therefore maintain each door in more rigid relationship to its frame. A plurality of doorframe units may be integrated into a complete housing fascia assembly, or alternatively each doorframe unit may be integrated with the internal walls of its respective locker so as to form a rigid box shaped insert. Alternatively or additionally, each locker comprises at least one internal side wall which is spaced apart from the corresponding side wall of the housing so as to define a vertical structural cavity in the housing. The cavity may accommodate a vertical rigidifying element forming part of the housing or part of the doorframe units, as well as accommodating the locks of the interchangeable locker doors. Each door may be extended across the vertical cavity for additional security.

Each locker unit housing might be for example generally square or horizontally elongate rather than columnar as shown, and the width of the insert units as well as or instead of their height might be variable. Many further adaptations may be made within the scope of the claims. * *. * * I I... I... * S * S.. I...

S I S. S I..

S

I S

S S I 55 I. S

S S $ S.

Claims (9)

1. An automated lockerbank including a lock controller, a user interface, and at least one locker unit, the locker unit having an outer housing comprising at least a structural framework defining two sides, a front, a back, a top and a base, the locker unit further including a plurality of internal walls dividing the housing into a plurality of lockers, each locker having a doorframe, a door, and a lock controlled by the lock controller for locking the door to the frame; * characterised in that there are provided at least two alternative types of door, each :: door type having different dimensions, S...

and the locker unit is adaptable to define at least two alternative locker * 20 configurations comprising different combinations of lockers having doors of the :: said at least two alternative types; and in that each door is mounted in a doorframe to form a doorframe unit and the doorframe unit is releasably mounted on the housing.

2. An automated lockerbank according to claim 1, characterised in that each doorframe unit is formed integrally with a plurality of the said internal walls defining a respective one of the lockers so as to form an individual locker insert unit, the individual locker insert unit being releasably and interchangeably mounted in the housing.

3. An automated lockerbank according to claim 2, characterised in that a locker insert unit release mechanism is provided whereby all of the locker insert units of the housing may be secured and released together from a single point.

4. An automated lockerbank according to claim I, characterised in that a plurality of doorframe units are joined together to form an integral fascia assembly, the fascia assembly being releasably and interchangeably mounted on the housing, and the internal walls are adaptable to conform to the door configuration of the fascia assembly. S...

*

5. An automated lockerbank according to any of claims 1 - 4, characterised in that : the lock controller and the user interface are adapted to be releasably mounted on the housing in place of a doorframe unit. * . * S

* .

6. An automated lockerbank including a lock controller, a user interface, and at least one locker unit, the locker unit having an outer housing comprising at least a structural framework defining two sides, a front, a back, a top and a base, the locker unit further including a plurality of internal walls dividing the housing into a plurality of lockers, each locker having a doorframe, a door, and a lock controlled by the lock controller for locking the door to the frame; characterised in that there are provided at least two alternative types of door, each door type having different dimensions, and the locker unit is adaptable to define at least two alternative locker configurations comprising different combinations of lockers having doors of the said at least two alternative types; and in that the internal walls define a vertical array of lockers, each locker having at least one internal side wall extending from the doorframe towards the back of the housing, and each of the said internal side walls of the lockers are spaced apart from one * side of the housing so as to define a vertical structural cavity which extends from :: the base to the top of the housing. ****

*

7. An automated lockerbank according to claim 6, characterised in that each lock * 20 is arranged within the structural cavity. *

S S S 5

* * 8. An automated lockerbank according to claim 6 or claim 7, characterised in that each door extends laterally between the sides of the housing and across the structural cavity.

9. An automated lockerbank substantially as described and illustrated.