Note: Descriptions are shown in the official language in which they were submitted.
CA 02937669 2016-07-29
AUTOMATED PALLET STORAGE AND RETRIEVAL SYSTEM
TECHNICAL FIELD
[0001] The present disclosure generally relates to pallet load storage
structures having rails
for automatic load transporting vehicles and specifically relates to auxiliary
features for such
storage structures.
BACKGROUND
[0002] Storage structures for automated warehouses are used to store
palletized loads. The
design of these storage structures is usually based on traditional, non-
automated warehouse
storage structures, but with rails added to enable the use of motorized load
vehicles (i.e., carts or
robotic vehicles). Thus, horizontal rails are typically added to horizontal
beams that are
supported by vertical columns. These horizontal rails may form aisles and rows
within layered
tiers of the structure. Elevators and robotic vehicles may move loads
throughout the aisles and
rows to various storage positions in the structure. Aisles and rows may each
support robotic
vehicles having different characteristics, so aisle rails and row rails may
each need to be installed
in the structure to allow aisle carts and row carts to traverse their intended
courses. The addition
of robotic vehicle rails on top of the pallet shelving rack members is
redundant for structural
integrity and increases the labor needed for erection of the structure.
[0003] Traditional storage structures are also inherently laterally
unstable due to their loose
joints that are designed for ease of assembly and disassembly in order to
allow for quick changes
in structural member locations (i.e., elevations) to accommodate new and/or
future pallet sizes.
Diagonal struts between the horizontal members and vertical columns often must
be added to
provide rigidity against side impacts (e.g., from fork trucks), earthquakes,
and other incidents.
The diagonal supports increase the materials and labor expended to build and
maintain the
storage structure, thereby reducing the overall efficiency of the structure.
[0004] Additionally, simply adding vehicle rails to a traditional storage
structure may waste
valuable space in the warehouse structure.
[0005] Assembly of such storage structures can be labor intensive,
particularly related to
mounting auxiliary systems such as fire suppression systems and lighting to
the storage structure.
Typically, individual holes must be formed in the structural components of the
storage structure
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in order to accommodate mounting of such auxiliary systems. Formation of such
holes and
installation of auxiliary systems after assembly of the storage structure can
add significant time
and associated costs to construction. There is therefore a need for
improvements in at least some
aspects of automated storage systems.
SUMMARY
[0006] According to one aspect of the present disclosure, a multi-level
storage structure
includes a plurality of spaced apart vertical supports, a plurality of row
spacing members
connected to and laterally spacing apart the vertical supports, a plurality of
row rails connected to
and longitudinally spacing apart the vertical supports, the row rails being
configured to support
at least one row cart, and a plurality of aisle rails extending perpendicular
to the plurality of row
rails and configured to support at least one aisle cart. The multi-level
storage structure also
includes a plurality of pre-formed holes formed in at least one of the
vertical supports, row
spacing members, row rails, and aisle rails to mount at least one of a
lighting system, a fire
suppression system, a fall protection system, and at least one support brace
to the storage
structure, the plurality of pre-formed holes being formed prior to assembly of
the storage
structure.
[0007] In one example, the plurality of row spacing members may include the
plurality of
pre-formed holes, and the plurality of pre-formed holes may be configured to
receive at least one
of piping of the fire suppression system and light fixtures of the lighting
system. At least one of
the plurality of vertical supports and the plurality of row rails may include
the plurality of
pre-formed holes, and the plurality of pre-formed holes may be configured to
receive at least one
of electrical conduit and electrical wiring of the lighting system. The aisle
rails may include the
plurality of pre-formed holes, and the plurality of pre-formed holes may be
configured to receive
fasteners to connect the at least one support brace to the plurality of aisle
rails. The plurality of
pre-formed holes may be at least one of stamped holes and punched holes that
are formed during
manufacture of the in at least one of the vertical supports, row spacing
members, row rails, and
aisle rails. The multi-level storage structure may further include a plurality
of load rails
extending parallel to the plurality of row rails and configured to support at
least one loaded
pallet. The plurality of pre-formed holes being formed in the load rails by
stamping or punching
during manufacture of the load rails.
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[0008] Another embodiment is directed to a multi-level storage structure
that includes a
plurality of vertical supports, a plurality of row rails connecting vertical
posts positioned
longitudinally relative to each other and configured to support at least one
row cart, a plurality of
aisle rails extending perpendicular to the plurality of the row rails and
configured to support at
least one aisle cart, a plurality of load rails extending parallel to the
plurality of row rails and
configured to support at least one loaded pallet, and a carriage mounted to a
flange portion of at
least one of the plurality of aisle rails. The carriage is configured to move
longitudinally along a
length of the at least one of the plurality of aisle rails.
[0009] In one example, the at least one of the plurality of aisle rails may
include a wheel
support surface along a top portion thereof and a flange portion along a
bottom portion thereof.
The flange may include a T-shape construction for the carriage to be mounted
on. The storage
structure may include at least one lighting member mounted to the carriage.
The storage structure
may include at least one rechargeable battery mounted to the carriage. The
storage structure may
include at least one lighting member pivotally mounted to the carriage. The
carriage may further
include a safety harness mounting bracket configured to secure a worker's
safety harness.
[0010] A further embodiment is directed to a multi-level storage structure
that includes a
plurality of vertical supports, a plurality of row rails connecting vertical
posts positioned
longitudinally relative to each other and configured to support at least one
row cart, a plurality of
load rails extending parallel to the plurality of row rails and configured to
support at least one
loaded pallet, a plurality of aisle rails extending perpendicular to the
plurality of row rails and
configured to support at least one aisle cart, a plurality of row spacing
members connecting
vertical posts positioned laterally relative to each other, the plurality of
row spacing members
comprising pre-formed holes, and a fire suppression system positioned in the
pre-formed holes of
the plurality of row spacing members. The first suppression system includes a
plurality of pipes,
a plurality of T-joints extending from at least some of the plurality of
pipes, and a plurality of
sprinkler heads mounted to at least some of the plurality of T-joints.
[0011] The plurality of pipes with T-joints and sprinkler heads may be
insertable through the
pre-formed holes during assembly of the storage structure. The pre-formed
holes may include a
joint portion extending to an edge of the plurality of row spacing members and
sized to have the
T-joint pass therethrough, and a pipe portion formed continuous with the joint
portion and sized
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to have the pipe pass therethrough. The pipe portion may have a greater
maximum width
dimension than a maximum width dimension of the joint portion.
[0012] The plurality of aisle rails may be mounted directly to the
plurality of row rails, and
the plurality of row rails may be connected directly to the plurality of row
spacing members.
[0013] Another embodiment is directed to an automated aisle rail cart that
includes a base
structure, a left set of wheels configured to contact a first rail of storage
structure, and a right set
of wheels configured to contact a second rail of a storage structure. The left
set of wheels include
inner and outer flanges that extend along inner and outer surface of the first
rail, and the right set
of wheels is free of flanges. In another embodiment, the right set of wheels
includes inner and
outer flanges that extend along inner and outer surface of the first rail,
while the left set of
wheels is free of flanges. The right set of wheels and the left set of wheels
may be exchangeable
with each other on the automated rail cart.
[0014] The aisle rail cart may include a power collector extending
laterally from the base
structure and arranged to engage a power track mounted to one of the first and
second rails. The
aisle rail cart may include at least one position sensor mounted to the base
structure and arranged
to detect at least one position feature mounted to one of the first and second
rails. The at least
one position feature may include a bar code. The base structure may include a
recessed portion
sized to carry an automated row lift cart.
[0015] Another aspect of the present disclosure relates to a multi-level
storage structure that
includes a plurality of vertical supports, a plurality of row rails connecting
vertical posts
positioned longitudinally relative to each other and configured to support at
least one row cart, a
plurality of load rails extending parallel to the plurality of row rails and
configured to support at
least one loaded pallet, a plurality of aisle rails extending perpendicular to
the plurality of the
row rails and configured to support at least one aisle cart, and at least one
aisle cart stop
assembly. The at least one aisle cart stop assembly is mounted to one or more
of the plurality of
aisle rails and is configured to provide a longitudinal position stop for the
at least one aisle cart in
at least one direction of movement along the one or more of the plurality of
aisle rails.
[0016] The at least one aisle cart stop assembly may include a mounting
bracket configured
to connect the aisle cart stop assembly to the one or more of the plurality of
aisle rails, and a stop
member slidingly coupled to the mounting bracket and positioned to contact the
at least one aisle
cart. The stop member may be adjustable relative to the mounting bracket to
adjust a location of
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the longitudinal position stop. The at least one cart stop assembly may
further include a shock
absorber interposed between the mounting bracket and the stop member and
operable to
decelerate the aisle cart upon contact with the stop member.
[0017] The above summary is not intended to describe each embodiment or
every
implementation of embodiments of the present disclosure. The Figures and the
detailed
description that follow more particularly exemplify one or more preferred
embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings and figures illustrate a number of
exemplary
embodiments and are part of the specification. Together with the present
description, these
drawings demonstrate and explain various principles of this disclosure. A
further understanding
of the nature and advantages of the present invention may be realized by
reference to the
following drawings. In the appended figures, similar components or features
may have the same
reference label.
[0019] FIG. 1 is a perspective view of a storage structure according to an
embodiment of the
present disclosure.
[0020] FIG. 2 is a perspective view of a portion of a storage structure
shown in FIG. 1,
including an aisle cart carrying a row cart and a loaded pallet.
[0021] FIG. 3 is a perspective view of the storage structure shown in FIG.
1, including an
opposite view of the aisle cart carrying a row cart and a loaded pallet.
[0022] FIG. 4 is a perspective view of another portion of the storage
structure shown in FIG.
1, including a fire suppression system.
[0023] FIG. 4A is a perspective view of a row spacing member of the storage
structure
shown in FIG. 1.
[0024] FIG. 5 is a perspective view of the storage structure shown in FIG.
1, including a
mobile lighting assembly.
[0025] FIG. 6 is a perspective view of the storage structure shown in FIG.
1, including
additional lighting systems features.
[0026] FIG. 7 is a close-up perspective view of a portion of the aisle cart
carrying a row cart
and a loaded pallet shown in FIG. 2.
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[0027] FIG. 8 is close-up perspective view of another portion of the aisle
cart shown in FIG.
2.
[0028] FIG. 9 is a top perspective view of an aisle cart stop feature of a
storage structure in
accordance with the present disclosure.
[0029] FIG. 10 is a bottom perspective view of the aisle cart stop feature
shown in FIG. 9
[0030] While the embodiments described herein are susceptible to various
modifications and
alternative forms, specific embodiments have been shown by way of example in
the drawings
and will be described in detail herein. However, the exemplary embodiments
described herein
are not intended to be limited to the particular forms disclosed. Rather, the
instant disclosure
covers all modifications, equivalents, and alternatives falling within the
scope of the appended
claims.
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DETAILED DESCRIPTION
[0031] The present disclosure generally relates to a pallet storage support
structure and
related accessory features and systems for such support structures. The
support structure may
include a plurality of tiers or levels that each include a plurality of pallet
storage rows and at least
one aisle providing access to the rows. A plurality of automated row carts and
aisle carts provide
transport of pallets with associated loads throughout the support structure.
The support structure
may include a variety of pre-formed features that promote improved assembly
schedules for the
support structure and its accessory features and systems. Some example
accessory features and
systems for the support structure include fire suppression systems, lighting
systems, power
transfer systems, cart alignment/connection systems, safety harness connection
systems, and the
like, at least some of which may benefit from the pre-formed features.
[0032] The present disclosure provides examples, and is not limiting of the
scope,
applicability, or configuration set forth in the claims. Thus, it will be
understood that changes
may be made in the function and arrangement of elements discussed without
departing from the
spirit and scope of the disclosure, and various embodiments may omit,
substitute, or add other
procedures or components as appropriate. For instance, the methods described
may be performed
in an order different from that described, and various steps may be added,
omitted, or combined.
Also, features described with respect to certain embodiments may be combined
in other
embodiments.
[0033] Referring now to the figures in detail, FIG. 1 shows a perspective
view of a storage
structure 100 for use in an automated storage facility. The storage structure
100 may comprise
vertical columns 102 connected to each other by row cart rails 104, row load
rails 106, and row
spacing members 108. The row cart rails 104 support row carts 206 (see FIG.
2). The row load
rails 106 support pallets 126 on which loads 128 are stored.
[0034] The storage structure 100 also includes a plurality of aisle rails
110 with aisle rail
spacing members 112 positioned therebetween. The aisle rails 110 are arranged
generally
perpendicular to the row cart rails 104 and row load rails 106. The aisle rail
spacing members
112 are arranged generally parallel with the row cart rails 104 and row load
rails 106, and the
row spacing members 108 are arranged parallel with the aisle rails 110. FIG. 1
shows an aisle
rail 110 associated row rails 104 with a given tier 118. At least some of the
aisle rails 110 are
incomplete or partially missing for some of the tiers 118. At least some of
the grating 124
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extending between pairs of the aisle rails 104 is removed in FIG. 1 in order
to more clearly see
other features of the storage structure 100.
[0035] The storage structure 100 provides a plurality of rows 114 defined
by the row cart
rails 104 and row load rails 106, a plurality of aisles 116 defined by the
aisle rails 110, and a
plurality of tiers or levels 118 that each include at least one row 114 and
one aisle 116. An
elevator assembly 120 transports pallets 126, which carry loads 128, to and
from various tiers
118. Aisle carts 122 move the pallets 126 with loads 128 along the aisles 116
to and from
elevator assembly 120 and between rows 114. Row carts 206 (see FIG. 2) move
the pallets 126
with loads 128 to and from the aisle carts 122 along the row cart rails 104.
Generally, the row
cart rails 104 extend in a Y direction, the aisle rails 110 extend an X
direction, and the tiers 118
are separated in a Z direction.
[0036] The row load rails 106, alone or in combination with the row cart
rails 104, provide
interconnection of vertical columns 102. The storage structure 100 may be
assembled without the
use of additional support structures extending between the vertical columns in
the Y direction
except for the row cart rails 104 and/or row load rails 106. The storage
structure 100 may
provide interconnection of the vertical columns 102 in a lateral or X
direction without the use of
additional support structures besides the row spacing member 108. The row
spacing members
108 may support the aisle rails 110 in addition to the row cart rails 104.
Additional details
concerning these and other features of the storage structure 100 related to
assembly of the
vertical columns 102, row cart rails 104, row load rails 106, row spacing
members 108 and aisle
rails 110 are disclosed in U.S. Patent Application No. 62/089,738, filed on 9
December 2014 and
entitled "Structure for Automated Pallet Storage and Retrieval."
[0037] The design of storage structure 100 may support a compact storage
system since only
a small amount of space is needed between the loads 128 in the X direction to
accommodate the
thickness of the vertical columns 102, row cart rails 104 and row load rails
106. The space
between loads 128 in the Z direction may also be minimized due to the
relativity small amount of
structure located between the tiers 118 in the form of the row spacing members
108, which
overlap with the row cart rails 104. For example, space is saved because the
row cart rails 104
and row load rails 106 do not need to be mounted to redundant horizontal
members.
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[0038] While traditional rack structures are adjustable so that the
distances between vertical
columns and horizontal members may be adapted to many different sized loads,
the storage
structure 100 of the present disclosure may be specifically designed to fit a
certain size or width
of load since in an automated warehouse, row carts, aisle carts, pallets and
elevator device are
usually only one universal size in each warehouse. Thus, the distance between
row cart rails 104
and aisle rails 110 may be consistent throughout the storage structure 100 to
accommodate a
single size of row carts 206, aisle carts 122, and pallets 126. The
adjustability of traditional
storage rack structures allows single shelves or tiers storage space to be
adjusted if needed. This
is beneficial when each position is loaded individually by a forklift vehicle.
However, in a
structure for automated vehicles, the elevation of all load pallet positions
in a single level may
beneficially be the same because non-uniform pallet positions may prevent
automated access to
all rails. Furthermore, converting a traditional storage structure to an
automated storage structure
is typically expensive. Doing so requires converting tiers that have various
heights to have the
same vertical positions, and this can only be done with great expenditure of
labor and additional
new rail-related materials. The conversion also eliminates the adjustability
of the storage
structure. In the end, cost savings realized by the adjustability of the
original installation may be
lost and further changes to the converted structure are not allowed. For these
reasons, it may be
beneficial to implement a storage structure of the present disclosure that
eliminates adjustable
tiers and superfluous support members in favor of a more minimal, yet
structurally sound,
storage facility that can still provide support for automated load-moving
vehicles (e.g., aisle carts
122 and row carts 206).
100391 FIGS. 2 and 3 show close-up perspective views of the storage
structure 100 including
the aisle cart 122 and row cart 206. The row cart 206 is positioned and
carried on the aisle cart
122. Row cart 206 includes a lift structure 208 having a support surface that
supports pallet 126
with load 128. Row cart 206 operates to raise and lower the pallet 126
relative to the row cart
rails 104. Aisle cart 122 moves along aisle rails 110 until the row cart 206
is aligned with a pair
of row cart rails 104. Lift structure 208 then operates to raise the pallet
126 above a support
surface of row load rails 106, and row cart 206 moves onto the row cart rails
104 to position the
pallet 126 with load 128 at a desired location along the length of the row
load rails 106. Lift
structure 208 then operates to lower the pallet 126 with load 128 onto the
support surfaces of the
row load rails 106, and row cart 206 returns to aisle cart 122. One aisle cart
122 may operate in
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conjunction with a plurality of row carts, wherein a separate row cart 206
operates with one or
more rows 114. Typically, only a single row cart 206 is positioned within a
given row 114 at a
time. A row cart 206 may wait within a given row 114 until an aisle cart 122
is made available to
carry the row cart 206 to a different row 114, or to the elevator assembly 120
to be transported to
a different aisle 116.
[0040] A pair of the row cart rails 104 arranged to receive row carts 206
may be mirror
images of each other. Similarly, a pair of row load rails 106 arranged to
receive a pallet 126 with
load 128 may be mirror images of each other. A pair of aisle rails 110
arranged to receive an
aisle cart 122 may be mirror images of each other. Additional details
regarding aisle rails 110
and their features are described in further detail below.
[0041] Referring now to FIG. 4, a fire suppression system 400 of the
storage structure 100 is
shown and described in further detail. The fire suppression system 400
includes piping 402
having a plurality of T-joints 404, and sprinkler heads 406 mounted to the T-
joints 404. The
piping 402 may be mounted to the row spacing members 108, which extend between
vertical
columns 102 in a lateral direction (e.g., X direction). An elongate pipe may
extend along the
length of an entire row 114. Piping 402 may extend along the rows 114 of
multiple tiers 118. The
piping 402 is shown extending along a lateral side of the vertical columns
102. FIG. 5 shows a
cap 534 mounted at a termination point for piping 402. Other piping segments
of fire suppression
system 400 may extend in other directions such as, for example, vertically
along one of the
vertical columns 102, or extend horizontally through pre-formed holes formed
in any of the row
cart rails 104, row load rails 106, aisle rails 110, and the like.
[0042] Referring again to FIG. 4, the row spacing members 108 may include a
piping
aperture 408 and inlet opening 410 to accommodate the piping 402 and T-joints
404. The piping
aperture 408 may have a width dimension W1 (see FIG. 4a) that substantially
matches an outer
diameter of the piping 402. In the opening 410 may have width W2 (see FIG. 4a)
that
substantially matches a maximum width of the T-joint 404. The width W2 is less
than the width
WI. As such, the piping 402 is held within piping apertures 408 as the piping
402 is fed
longitudinally through a plurality of row spacing members 108. The width W2
permits the
T-joints 404 to pass through the inlet openings 410 as the piping 402 is fed
through each piping
aperture 408.
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[00431 The piping aperture 408 and inlet opening 410 may be pre-formed in
the row spacing
member 108 during manufacture of the row spacing member 108 (i.e., prior to
assembly of
storage structure 100). In one example, the row spacing members 108 are roll
formed or extruded
members and the piping aperture 408 and inlet opening 410 are pre-punched
during
manufacturing. The inlet opening 410 may extend to a peripheral edge of the
row spacing
member 108. The size and shape of the piping aperture 408 and inlet opening
410 may be
modified to accommodate any desired size and shape for piping 402 and
associated T-joints 404
or other coupling structures that provide mounting of sprinkler heads 406 to
piping 402.
[0044] Providing a slide through arrangement for the fire suppression
system 400 as part of
mounting to row spacing members 108 may significantly reduce labor because
separate pipe
hangers are not required. The piping 402 may be installed after the vertical
columns 102 are
arranged vertically and already coupled to other vertical columns 102 with row
spacing members
108, row cart rails 104 and row load rails 106. Alternatively, the piping 402
of fire suppression
system 400 may be pre-assembled with sections of the storage structure 100
that include a
plurality of longitudinally spaced apart vertical columns 102 with row spacing
members 108,
row cart rails 104 and row load rails 106 pre-assembled together lying flat on
a floor surface
before being tipped up for final assembly with other portions of storage
structure 100 that are
already in a vertically upright position. Such pre-assembly of a fire
suppression system 400 is
typically not possible when using pipe hangers. Accordingly, the fire
suppression system 400 in
combination with the pre-formed piping aperture 408 and inlet opening 410 of
the row spacing
members 108 may reduce overall schedule for assembling storage structure 100.
Furthermore,
these features related to the fire suppression system 400 and its assembly
with storage structure
100 may facilitate maintenance repairs and the like. For example, cap 534
shown in FIG. 5 may
be removed so that piping 402 can be pulled out longitudinally along row 114
and removed from
an opposite end of row 114 from where aisle rails 110 are located without
having to disconnect
the individual piping segments from each other.
[0045] Referring again to FIG. 5, a lighting system 500 is shown and
described. Lighting
system 500 may include a plurality of electrical conduits 502 and at least one
light fixture 504.
Additional conduits 502 and light fixtures 504 are shown in FIG. 6 positioned
at various
locations in the storage structure 100. The conduit 502 may extend through
holes formed in any
of the vertical columns 102, row cart rails 104, row load rails 106, row
spacing members 108 and
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aisle rails 110. FIG. 6 shows a plurality of conduit apertures 602 formed in
the end portions of
row cart rails 104. FIG. 5 shows a conduit aperture 530 formed in vertical
column 102.
[0046] The light fixtures 504 may be mounted at any desired location
including, for example,
to the aisle rail spacing members 112 (see FIGS. 5 and 6) and to the row
spacing members 108
(see FIG. 6). In other embodiments, the conduits 502, which carry electrical
wiring to power the
light figures 504, may be replaced with other types of wire carrying
structures or wiring that does
not require a wire conduit.
[0047] The conduit aperture 602 formed in row spacing members 108, as well
as other
conduit apertures formed in other structures such as the conduit aperture 530
formed in vertical
column 102, may be pre-formed in those structures prior to assembly of the
storage structure
100. In some examples, the conduit apertures may be formed using a stamping
process. Other
possible methods include milling, drilling, punching, cutting, and the like.
Significant labor
saving may be possible by being able to insert the electrical conduit through
pre-formed holes
formed in various support feature of storage structure 100 when conduit
hangers are not required.
Further, forming the conduit apertures as pre-formed apertures during
manufacture of a given
structure member may reduce time that may otherwise be needed to drill holes
in those structural
members during assembly of storage structure 100 and mounting of the lighting
system 500 to
the storage structure 100.
[0048] The conduit apertures may be formed with a shape and size that
substantially matches
an outer perimeter dimension of the conduit typically used for lighting system
500. In some
embodiments, the conduit apertures may be formed with different shapes and
sizes that permit
additional adjustment of the conduit position, ease of assembly of the
conduits, or
accommodation of different sized and shaped conduit structures for various
lighting system 500
designs. The conduit apertures may be used for other purposes in additional to
a lighting system
and related electrical conduit. For example, the conduit apertures may be used
to carry wiring or
associated conduit for other purposes such as a local area network, sensor
systems, powering of
aisle carts 122 and/or row carts 206, control systems, and the like. In one
embodiment, the
conduit apertures may be also be used to receive piping 402 of fire
suppression system 400.
[0049] Again referring to FIG. 5, a mobile lighting assembly 506 is shown
and described. A
mobile lighting assembly 506 may include a carriage 508, a battery pack 510,
end light members
512, adjustable light members 514, and a swivel mount 520 for mounting the
adjustable light
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members 514 to the carriage 508 and/or battery pack 510. The carriage 508 may
slide along a
T-flange 522 of aisle rail 110. Carriage 508 includes a track sized and shaped
to mount to the
T-flange 522. Carriage 508 may be arranged and configured to slide along a
length of the aisle
rail 110 to various longitudinal positions to provide a mobile lighting source
for use, for
example, during maintenance and/or operation of storage structure 100. In some
embodiments,
carriage 508 may include a low friction bearing surface such as, for example,
a wear pad,
bearings, rollers, or the like. Carriage 508 or T-flange 522 may comprise low
friction materials,
coatings of such low friction materials or coatings to reduce friction at the
interface with
T-flange 522.
[0050] Battery pack 510 may comprise one or more rechargeable batteries.
The batteries may
provide power for operating light members 512, 514. Battery pack 510 may
provide a power
source for other purposes such as, for example, powering maintenance equipment
and the like. In
one embodiment, storage structure 100 may include a recharging station
positioned at one end of
the aisle rails 110. The mobile lighting assembly 506 may be moved to the
charging station and
charged when not in use.
[0051] End light members 512 may be mounted to the carriage 508 and/or
battery pack 510
at any desired location to provide lighting in specific directions. The end
light members 512 and
adjustable light members 514 may comprise low energy lighting such as, for
example, LED
lighting.
[0052] Swivel mount 520 may provide an adjustment in a position and/or
orientation of
adjustable light member 514. Swivel mount 520 provides adjustment of
adjustable light member
514 about one axis of rotation. Other configurations are possible to provide
additional
adjustability of a position and/or orientation of the adjustable light members
514 (e.g., a ball and
socket pivot structure that provide rotation about multiple rotation axes).
[0053] Carriage 508 may include a safety strap connection member 516 having
an aperture
518. The connection member 516 may be used as an anchor point for a worker's
safety strap
while the worker is performing maintenance on storage structure 100. In one
example, a worker
may be able to attach a lanyard, which is attached to a fall protection
harness being worn by the
worker, to the connection member 516. The worker may be able to connect his
lanyard and
associated fall protection harness to a connection member 516 located at a
tier 118 above where
he is working, or within the tier that he is working (e.g., the worker is
standing on the aisle rail
13
CA 02937669 2016-07-29
110 to which the carriage 508 is mounted). Storage structure 100 may include a
plurality of
carriages 508 that each comprise one or more connection members 516. The
carriage 508 may or
may not include a battery pack 510 and associated light members 512, 514. Some
of the
carriages 508 may be used solely for the connection member 516 mounted
thereto. Providing a
plurality of carriages 508 with connection members 516 on a single rail or
pair of rails may
permit a plurality of workers to have a connection point for their fall
protection harnesses while
working in a common area. A single aisle rail 110 may support a plurality of
carriages 508 with
connection members 516 mounted thereto. A single carriage 508 may include a
plurality of
connection members 516. Each connection member 516 may accommodate two or more
safety
straps, lanyards, harnesses, etc.
[0054] Providing the mobile connection members 516 mounted to carriages 508
may provide
an improvement over former arrangements wherein a track is added to the upper
portions of the
aisle to accommodate safety tie-offs. The use of the safety strap connection
members 516
disclosed herein may save labor and reduce overall schedule for building
storage structure 100
and later maintenance of storage structure 100.
[0055] The mobile lighting assembly 506 may be used in combination with the
lighting
system 500 described with reference to FIGS. 4-5 above. Alternatively, one or
the other of
lighting system 500 and mobile lighting assembly 506 may be used. By using
solely the mobile
lighting assembly 506, a significant cost and time savings could be available
by eliminating the
need to provide lighting system 500 and its associated conduits, apertures,
light fixtures, etc.
Typically, the light provided by lighting system 500 and/or mobile lighting
assembly 506 is most
needed during assembly of storage structure 100 and maintenance thereof. The
lighting is
typically only required when a worker is in the area. Since a worker is
typically required to
tie-off with a safety harness to a secure point while performing work in a
particular portion of
storage structure 100, providing a mobile lighting unit along with the mobile
connection member
516 may address both the lighting and the safety needs for a given worker.
[00561 FIG. 6 shows row cart rails 104 include mounting slots 604 that
slide over the row
spacing members 108 to provide a positive connection and support for the row
cart rails 104. The
mounting slots 604 may extend to and be open along a bottom edge of row cart
rails 104 for easy
insertion of row spacing member 108. The mounting slots 604 may be pre-formed
in row cart
14
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rails 104 to match a specific row spacing member 108 design. In other
arrangements, a mating
slot may be formed in row spacing member 108 to receive a portion of row cart
rails 104.
[0057] Referring now to FIG. 7, the aisle cart 122 is shown in further
detail. Aisle cart 122
includes a base 700, a pair of double flange wheels 702 each having a pair of
flanges 704, a pair
of no-flange wheels 202 (see FIG. 2), a power collector 802 (see FIG. 8), and
a position sensor
706. The double flange wheels 702 and no-flange wheels 202 ride along wheel
tracks 708 of the
aisle rails 110. Wheel tracks 708 include inner and outer radius surfaces 710.
The flanges 704 of
double flange wheels 702 extend around the radius surfaces 710 and contact
opposing side
surfaces of the wheel track 708 to maintain connection of the aisle cart 122
with its associated
aisle rail 110. The no-flange wheels 202 are able to move laterally relative
to the wheel track 708
to account for variations in distance between a pair of the aisle rails 110
along the length of aisles
116. The use of double flange wheels on one side of the aisle cart 122 may
help eliminate
"crabbing" problems found in vehicles with single flanges on all four wheels
(e.g., on wheels
positioned on opposite sides of the aisle cart 122). The problem of "crabbing"
relates to the
wheels spreading laterally outward due to lateral pressures imposed on the
wheels and their
respective flanges caused by variations in spacing between the aisle rails
110. In at least some
examples, crabbing may result in one or more of the cart wheels moving off of
the wheel track
708 of a respective aisle rail 110, or at least additional wear occurring on
the flanges 704. When
all wheels of the aisle cart 122 include a single flange, misalignments of the
aisle rails 110 (i.e.,
resulting in non-parallel and/or non-coplaner orientations) may cause the
flanges to bind against
the wheel track 708 or the entire aisle cart 122 to be turned slightly. As a
result, wear to the
flanges may be accelerated and/or the position sensor 706 may misread a
location of the aisle
cart.
[0058] When two double flanged wheels 702 are provided on one side of the
aisle cart 122
with no-flange wheels 202 positioned on an opposite side of the aisle cart
122, the aisle cart 122
may be better able to maintain a fixed position laterally relative to the
wheel track 708 upon
which the double flanged wheels 702 are supported with limited lateral forces
being applied to
the flanges. When the position sensor 706 is located on the same side of the
cart as the double
flanged wheels 702, the position sensor 706 may be better able to accurately
determine a position
of the aisle cart 122 relative to the wheel track 708 on that side of the
aisle cart 122. As
mentioned above, the no-flange wheels 202 are able to move laterally relative
to the wheel track
708 upon which flange wheels 202 are supported to avoid application of lateral
forces to the
flanges 704 on the double flanged wheels 702.
[0059] Providing the wheel track 708 with radius surfaces 710 may reduce
friction between
the flanges 704 and the wheel track 708 as compared to other wheel track 708
designs. The
radius surfaces 710 may be formed with significant precision and accuracy so
as to reduce
friction at the interface with double flanged wheels 702.
[0060] The power collector 802 (see FIG. 8) interfaces with a power track
804 that is
mounted to at least one of the aisle rails 110 (see FIG. 8). The power track
804 may transfer
electrical power to the power collector 802 for operation of aisle cart 122.
FIG. 8 shows a single
power collector 802 positioned on a single side of aisle cart 122 for
interaction with a power
track 804 positioned on just one of the aisle rails 110 of the pair of aisle
rails that support aisle
cart 122. Other embodiments are possible including, for example, using more
than one power
collector 802 on a single aisle cart 122, providing the power collectors 802
on both sides of the
aisle cart 122, and the like. The aisle rails 110 may include a plurality of
pre-formed holes that
are used to mount the power collector's power tracks 804 and/or power
collectors 802. The
pre-formed holes may be formed during manufacture of the aisle rails 110 prior
to be delivered
to an installation site.
[0061] Position sensor 706 may be mounted to base 700 of aisle cart 122 at
a position and
with a given orientation that permits interaction with a position locating
feature mounted at
another location on storage structure 100. For example, position sensor 706
may be mounted on
a side surface of base 700, as show in FIG. 7, and oriented facing a bar code
526 positioned
along an inner surface of aisle rail 110, as shown in FIG. 5. Position sensor
706 may "read" the
bar code 526 to determine a location of the aisle cart 122 along the length of
aisle rail 110. Many
other types of position sensors are possible including, for example, an RF
transmitter/receiver, a
laser, and the like. Additional details regarding position sensors and related
methods of
determining a position of an automated cart in a storage structure 100 are
disclosed in U.S.
Patent Application No. 61/931,416, filed on 24 January 2014 and entitled
"Apparatus for
Positioning and Automated Lift Storage Cart and Related Methods," and U.S.
Patent Application
No. 61/948,311 filed, on 5 March 2014 and entitled "Automated Lifting Storage
Cart."
16
Date recue/Date received 2023-03-06
CA 02937669 2016-07-29
[0062] The bar code 526 shown in FIG. 5 includes a plurality of bar codes
positioned
adjacent to each other along the length of aisle rail 110. Other embodiments
may include bar
codes that are positioned further spaced apart than those shown in FIG. 5.
Other embodiments
utilize other technology including, for example, transceivers and other active
sensor devices. In
one embodiment, the bar codes 526 may be replaced with a passive sensor that
is energized upon
receiving a signal from position sensor 706, and the passive sensor generates
a signal once
energized. In some embodiments, the aisle cart 110 may include a bend or other
feature formed
in a sidewall thereof to assist in locating the bar code 526 at a proper
elevation for sensor 706 to
read properly.
[0063] FIGS. 9 and 10 show a pair of aisle cart stop assemblies 802 for use
with the storage
structure 100 described above. The aisle cart stop assemblies 802 may provide
a position stop for
the aisle carts 122 disclosed herein. The aisle cart stop assemblies 802 may
provide as a safety
feature that helps ensure that the aisle carts 122 remain positioned on the
aisle rails 110 (i.e. do
not unintentionally roll of an end of the aisle rails 110), such as during an
equipment failure or
the like. The aisle cart stop assemblies 802 may be separately mounted to
individual aisle rails
110, such as at an end portion of the aisle rails 110 as shown in FIG. 10. The
aisle cart stop
assemblies 802 may each include a stop member 804, a mounting bracket 806, and
a shock
absorber 808, which provides improved deceleration of the aisle cart 122 upon
contact with the
stop member 804.
[0064] The stop member 804 may include an abutment portion 810 that is
arranged to
contact the aisle cart 122 to stop longitudinal movement of the aisle cart 122
at a predetermined
location along a length of the aisle rails 110. The stop member 804 may also
include an
attachment portion 812 that is coupled to the mounting bracket 806. The
attachment portion 812
may be coupled to the mounting bracket 806 with the shock absorber 808. In at
least some
embodiments, the stop member 804 may include one or more 90 angled portions,
wherein the
abutment portion 810 extends at a 90 angle relative to other portions of the
stop member 804.
[0065] The mounting bracket 806 is mounted to an individual aisle rail 110
via, for example,
a plurality of mounting holes 816 formed in the aisle rails (see FIG. 10). The
mounting holes 816
may be formed in the aisle rails 110 during manufacture of the aisle rails
and/or at a time and/or
location prior to assembling the storage structure 100. The mounting bracket
806 may include
one or more support slots 814 through which at least a portion of the stop
member 804 extends.
17
CA 02937669 2016-07-29
The support slots 814 may orient the stop member 804 in an upright position
with the abutment
portion 810 arranged in a path of movement of the aisle cart 122. The support
slots 814 also
allow stop member 804 to slide parallel to the travel of aisle cart 122 and
parallel to a
deceleration force provided by shock absorber member 808.
[0066] The shock absorber 808 is operably interposed between the stop
member 804 and the
mounting bracket 806. The adjustment member 808 may operate to move the stop
member 804
axially (e.g., longitudinally) relative to the mounting bracket 806 and
associated aisle rail 110 to
which the mounting bracket 806 is mounted. The shock absorber 808 may be
connected at one
end to the stop member 804 and at an opposite end to the mounting bracket 806.
In at least some
embodiments, the shock absorber 808 may have a length adjustment feature which
when
actuated moves portions of the stop member 804 towards or away from portions
of mounting
bracket 806 to adjust a stop position for aisle cart 122. The shock absorber
808 may be adjustable
to increase or decrease a shock absorbing property of the shock absorber.
[0067] The aisle cart stop assembly 802 may extend longitudinally from a
free end of the
aisle rail 110 to which it is mounted (see FIG. 10). In other embodiments, the
aisle cart stop
assembly 802 may be mounted at any location along the length of the aisle rail
110 to which it is
mounted to provide a longitudinal position stop for the aisle cart at any
desired location along the
length of the aisle rail 110.
[0068] The aisle cart stop assembly 802 may be pre-assembled to aisle
subassemblies
constructed flat on a floor surface and then lifted and set in place similar
to the fire suppression
piping and lighting systems disclosed herein. Providing pre-assembly of the
aisle subassemblies
may provide time savings as compared to separately bolting aisle rail, cross
members, grating,
and aisle cart stop assemblies 802 in place by carrying them up to each level
individually.
[0069] In further embodiments, the aisle cart stop assembly 802 may be
configured and
arranged to be used on one of the row rails 102 of the storage structure 100
instead of on an aisle
rail 110. The aisle cart stop assembly 802, when mounted to a row rail 102,
may provide a
longitudinal position stop for a row cart 206 that moves along the row rails
102. The aisle cart
stop assemblies 802 may function as a safety feature that helps ensure that
the row carts 206
remain positioned on the row rails 102 (i.e., does not unintentionally roll
off an end of row rails
102), such as during an equipment failure or the like.
18
CA 02937669 2016-07-29
[0070] Various methods of operating components of storage structure 100,
methods of
assembling at least portions of storage structure 100, and methods of storing
palleted loads 128
using the storage structure 100 may be possible in accordance with the present
disclosure.
According to one embodiment, a plurality of piping apertures are formed in row
spacing
members 108 of a storage structure 100. The piping apertures 408 may be pre-
formed during
manufacture of the row spacing member 108 itself. The row spacing members 108
may be
mounted to a vertical column 102 for use in the storage structure. A plurality
of vertical columns
102 may be interconnected with one or more row load rails 106 and/or row cart
rails 104 while
the vertical columns 102 are arranged horizontally on a ground surface. A
piping member 402 of
a fire suppression system 400 may be inserted through the piping apertures 408
prior to or after
rotating the vertical columns 102 into a vertical position. T-joints 404 of
the fire suppression
system 400 may extend through inlet openings 410 that are formed in the row
spacing members
108 adjacent to and continuous with the piping apertures 408. The piping 402
and related
T-joints 404 may be inserted longitudinally through the plurality of piping
apertures 408 and
inlet openings 410 of a plurality of row spacing members 108 that are mounted
to the vertical
columns 102 prior to or after rotating the vertical columns 102 into a
vertical position.
[0071] Another example method relates to mounting a lighting system to a
storage structure
100. The method may include pre-forming a plurality of conduit apertures 530,
602 in various
structural components of the storage structure 100 including, for example,
vertical columns 102,
row cart rails 104, row load rails 106, row spacing members 108 and aisle
rails 110. After
assembling the structural elements of the storage structure 100 together, the
method may include
inserting one or more electrical conduits 502 through the conduit apertures.
The method may
also include mounting one or more light fixtures to at least one of the
structural elements of the
storage structure 100, and connecting the light fixtures to wiring that
extends through the
conduit.
[0072] A further method is directed to providing a mobile lighting assembly
and/or providing
lighting at a workspace at a storage structure 100. The mobile lighting
assembly may include a
carriage 508 to which one or more light members is mounted. The mobile
lighting assembly 506
may include a battery pack 510 to power the lighting members. The carriage may
be movable
along one or more structural members of the storage structure 100 such as, for
example, a
T-flange 522 of an aisle rail 110. The mobile lighting assembly 506 may be
moved along the
19
CA 02937669 2016-07-29
structural element to a desired location. One or more of the lighting members
may be adjustably
mounted to the carriage 508 to direct light in a specific direction. The
mobile lighting assembly
506 may be powered via the battery pack or a hard wired connection.
[0073] A further method may be directed to providing a mobile safety strap
connection
member for a storage structure 100. A safety strap connection member 516 may
be mounted to a
carriage 508 that is supported on one or more structural members of the
storage structure 100
(e.g., a T-flange 522 of an aisle rail 110 or a portion of row rails 104). The
connection member
516 may provide a connection point for a lanyard of a worker's safety harness.
The connection
member 516 may be moved to a workspace by sliding the carriage 508 along the
structural
member (e.g., aisle rail 110). A plurality of carriages and associated
connection members 516
may be positioned along a single structural element (e.g., aisle rail 110) to
facilitate a safety
connection for a plurality of different workers operating in a common
workspace. A single
carriage 508 may include a plurality of safety strap connection members 516.
[0074] A yet further method is directed to a method of maintaining
connection of an
automatic vehicle and/or cart of a storage structure to one or more wheel
tracks/rails of the
storage structure 100. In one example, the automated vehicle is an aisle cart
122 that rides upon
wheel tracks 708 of a pair of aisle rails 110. Wheels along one side of the
aisle cart 122 may each
include a pair of flanges 704 that ride along opposing side surfaces of the
wheel track 708 and
maintain contact with a radius surface 710 of the wheel track 708. Wheels
along an opposing
side of the aisle cart are free of flanges and may move laterally relative to
the wheel track 708
upon which the no-flange wheels 202 are supported. The double flanged wheels
702 with flanges
704 maintain a connection of the aisle cart 122 to the aisle rails 110 without
significant lateral
forces being applied to the flanges 704 even in the presence of variations in
spacing between the
pair of aisle rails 110 along their lengths. The wheels with flanges may be
exchanged with
wheels free of flanges (e.g., switch with wheels on an opposite side of the
aisle cart 122).
[0075] Other methods in accordance with the present disclosure relate to
assembling portions
of the storage structure 100 and/or creating subassemblies of the storage
structure 100 as part of
assembling the entire storage structure 100. In one example, a first
subassembly is formed with a
plurality of longitudinally spaced vertical columns 102 that are connected
together with a
plurality of row load rails 106. This first subassembly may be assembled while
lying flat on a
CA 02937669 2016-07-29
ground surface an then later rotated/tilted into an upright position awaiting
connection to another
subassembly of components.
[0076] A second subassembly may include a plurality of longitudinally
spaced apart vertical
columns 102 that are interconnected with a plurality of row load rails 106. A
plurality of row
spacing members 108 are also connected to the vertical columns 102, and a pair
of row cart rails
104 are connected to each row spacing member 108. The second subassembly may
be assembled
while its vertical columns 102 are lying flat on a ground surface and then
later rotated/tilted up
into an upright position and arranged adjacent to the first subassembly. The
row spacing
members 108 are then connected to the vertical columns 102 of the first
subassembly.
[0077] A third subassembly that is substantially identical to the second
subassembly may be
assembled while its vertical columns 102 are lying flat on a ground surface
and then
rotated/tilted up into an upright position adjacent to either the first
subassembly (on an opposite
side from the second subassembly) or the second subassembly and connected to
the vertical
columns 102 of the first or second subassembly. This assembly process can be
repeated with
additional subassemblies that are similar to the second and third
subassemblies to create the
desired number of rows and a total width of the storage structure 100.
Additionally, assemblies
of first, second, third, etc. subassemblies may be stacked vertically to
create a desired number of
tiers and total height for the storage structure 100.
[0078] A fourth subassembly may be formed with a plurality of aisle rails
110 and aisle rail
spacing members 112. A plurality of grating members 124 may also be connected
to the aisle
rails 110 and/or aisle rail spacing members 112 as part of the fourth
assembly. Each fourth
subassembly may also include at least one aisle cart stop assembly 802. The
fourth subassembly
may be mounted to the row cart rails 104 and/or row spacing members 108 of the
second or third
subassemblies. The fourth subassembly may be interposed between two separate
assemblies that
each include first, second, third, etc. subassemblies.
[0079] Formation of subassemblies as part of constructing storage structure
100 may provide
a number of efficiencies related to, for example, being able to assemble
components of the
subassembly while those components are arranged on a ground surface before
being oriented in
an upright position. Further, all components of a given subassemblies may be
moved (e.g.,
rotated) into an upright position in a single movement/step rather than having
to lift and position
each individual component separately.
21
CA 02937669 2016-07-29
[0080] The pre-formed apertures, slots (e.g., mounting slots 604), etc.
formed in the vertical
columns 102, row cart rails 104, row load rails 106, row spacing members 108,
aisle rails 110,
and aisle rail spacing members 112 may facilitate easier assembly of
components of a given
subassembly, and may facilitate easier connection of one subassembly to
another subassembly.
In at least some embodiments, some subassemblies may be able to achieve a
positive connection
with another subassembly without the use of fasteners, welding, or the like
because of the
pre-formed apertures, slots, etc.
[0081] The present description provides examples, and is not limiting of
the scope,
applicability, or configuration set forth in the claims. Thus, it will be
understood that changes
may be made in the function and arrangement of elements discussed without
departing from the
spirit and scope of the disclosure, and various embodiments may omit,
substitute, or add other
procedures or components as appropriate. For instance, the methods described
may be performed
in an order different from that described, and various steps may be added,
omitted, or combined.
Also, features described with respect to certain embodiments may be combined
in other
embodiments.
[0082] Various inventions have been described herein with reference to
certain specific
embodiments and examples. However, they will be recognized by those skilled in
the art that
many variations are possible without departing from the scope and spirit of
the inventions
disclosed herein, in that those inventions set forth in the claims below are
intended to cover all
variations and modifications of the inventions disclosed without departing
from the spirit of the
inventions. The terms "including:" and "having" come as used in the
specification and claims
shall have the same meaning as the term "comprising."
22
