Note: Descriptions are shown in the official language in which they were submitted.
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A delivery vehicle, an automated storage and retrieval system and a method of
transporting storage containers between an automated storage and retrieval
grid
and a second location.
The present invention relates a remotely operated delivery vehicle for
transport of a
storage container between an automated storage and retrieval grid and a second
location for handling of the storage container by at least one of a robotic
operator and
human operator. The invention is also directed to an automated storage and
retrieval
system comprising an automated storage and retrieval grid and a delivery
system, as
well as a method of transporting a storage container between an automated
storage
and retrieval grid and a second location.
Background and prior art
Figs. lA and 1C disclose a typical prior art automated storage and retrieval
system 1
with a framework structure 100. Figs. 1B and 1D disclose a prior art container
handling vehicle 101 operating the system 1 disclosed in Figs. lA and 1C,
respectively.
The framework structure 100 comprises a plurality of upright members 102 and
optionally a plurality of horizontal members 103 supporting the upright
members 102.
The members 102, 103 may typically be made of metal, e.g. extruded aluminum
profiles.
The framework structure 100 defines a storage grid 104 comprising storage
columns
105 arranged in rows, in which storage columns 105 storage containers 106,
also
known as bins, are stacked one on top of another to form stacks 107.
Each storage container 106 may typically hold a plurality of product items
(not
shown), and the product items within a storage container 106 may be identical
or may
be of different product types depending on the application.
The storage grid 104 guards against horizontal movement of the storage
containers
106 in the stacks 107, and guides vertical movement of the storage containers
106,
but does normally not otherwise support the storage containers 106 when
stacked.
The automated storage and retrieval system 1 comprises a container handling
vehicle
rail system 108 arranged in a grid pattern across the top of the storage 104,
on which
rail system 108 a plurality of container handling vehicles 200,300 (as
exemplified in
Figs. 1B and 1D) are operated to raise storage containers 106 from, and lower
storage
containers 106 into, the storage columns 105, and also to transport the
storage
containers 106 above the storage columns 105. The horizontal extent of one of
the
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grid cells 122 constituting the grid pattern is in Figs. 1A and 1C marked by
thick
lines.
Each grid cell 122 has a width which is typically within the interval of 30 to
150 cm,
and a length which is typically within the interval of 50 to 200 cm. Each grid
opening
115 has a width and a length which is typically 2 to 10 cm less than the width
and the
length of the grid cell 122 due to the horizontal extent of the rails 110,111.
The rail system 108 comprises a first set of parallel rails 110 arranged to
guide
movement of the container handling vehicles 200,300 in a first direction X
across the
top of the frame structure 100, and a second set of parallel rails 111
arranged
perpendicular to the first set of rails 110 to guide movement of the container
handling
vehicles 200,300 in a second direction Y which is perpendicular to the first
direction
X. In this way, the rail system 108 defines grid columns above which the
container
handling vehicles 200,300 can move laterally above the storage columns 105,
i.e. in
a plane which is parallel to the horizontal X-Y plane.
Each prior art container handling vehicle 200,300 comprises a vehicle body and
a
wheel arrangement of eight wheels 201,301 where a first set of four wheels
enable
the lateral movement of the container handling vehicles 200,300 in the X
direction
and a second set of the remaining four wheels enable the lateral movement in
the Y
direction. One or both sets of wheels in the wheel arrangement can be lifted
and
lowered, so that the first set of wheels and/or the second set of wheels can
be engaged
with the respective set of rails 110, 111 at any one time.
Each prior art container handling vehicle 200,300 also comprises a lifting
device (not
shown) for vertical transportation of storage containers 106, e.g. raising a
storage
container 106 from, and lowering a storage container 106 into, a storage
column 105.
The lifting device comprises one or more gripping / engaging devices (not
shown)
which are adapted to engage a storage container 106, and which gripping /
engaging
devices can be lowered from the vehicle 201,301 so that the position of the
gripping
/ engaging devices with respect to the vehicle 201,301 can be adjusted in a
third
direction Z which is orthogonal the first direction X and the second direction
Y.
Conventionally, and also for the purpose of this application, Z=1 identifies
the
uppermost layer of the grid 104, i.e. the layer immediately below the rail
system 108,
Z=2 the second layer below the rail system 108, Z=3 the third layer etc. In
the
exemplary prior art grid 104 disclosed in Figs. lA and 1C, Z=8 identifies the
lowermost, bottom layer of the grid 104. Consequently, as an example, and
using the
Cartesian coordinate system X, Y, Z indicated in Figs. lA and 1D, the storage
container identified as 106' in Fig. lA can be said to occupy grid location or
cell
X=10, Y=2, Z=3. The container handling vehicles 101 can be said to travel in
layer
Z=0 and each grid column can be identified by its X and Y coordinates.
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Each container handling vehicle 200 comprises a storage compartment or space
(not
shown) for receiving and stowing a storage container 106 when transporting the
storage container 106 across the rail system 108. The storage space may
comprise a
cavity arranged centrally within the vehicle body, e.g. as is described in
W02014/090684A1, the contents of which are incorporated herein by reference.
Alternatively, the container handling vehicles 300 may have a cantilever
construction,
as is described in NO317366, the contents of which are also incorporated
herein by
reference.
The container handling vehicles 200 may have a footprint, i.e. an extent in
the X and
Y directions, which is generally equal to the lateral extent of a grid cell
122, i.e. the
extent of a grid cell 122 in the X and Y directions, e.g. as is described in
W02015/193278A1, the contents of which are incorporated herein by reference.
The
term "lateral" used herein may mean "horizontal".
Alternatively, the container handling vehicles 200 may have a footprint which
is
larger than the lateral extent of (lateral area defined by) a grid column 105,
e.g. as is
disclosed in W02014/090684A1.
The rail system 108 may be a single track system, as is shown in Fig. 2A.
Alternatively, the rail system 108 may be a double track system, as is shown
in
Fig. 2B, thus allowing a container handling vehicle 201 having a footprint
202,202'
generally corresponding to the lateral area defined by a grid column 112 to
travel
along a row of grid columns even if another container handling vehicle 200 is
positioned above a grid column neighboring that row. Both the single and
double
track system, or a combination comprising a single and double track
arrangement in
a single rail system 108, forms a grid pattern in the horizontal plane P
comprising a
plurality of rectangular and uniform grid locations or grid cells 122, where
each grid
cell 122 comprises a grid opening 115 being delimited by a pair of rails
110a,110b of
the first rails 110 and a pair of rails 111a,111b of the second set of rails
111. In Fig.
2B the grid cell 122 is indicated by a dashed box.
Consequently, rails 110a and 110b form pairs of neighboring rails defining
parallel
rows of grid cells running in the X direction, and rails 111a and 111b form
pairs of
neighboring rails defining parallel rows of grid cells running in the Y
direction.
As shown in Fig. 2C, each grid cell 122 has a width W, which is typically
within the
interval of 30 to 150 cm, and a length L, which is typically within the
interval of 50
to 200 cm. Each grid opening 115 has a width W, and a length L, which is
typically
2 to 10 cm less than the width K and the length L, of the grid cell 122.
In the X and Y directions, neighboring grid cells 122 are arranged in contact
with each
other such that there is no space there-between.
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In a storage grid 104, a majority of the grid columns are storage columns 105,
i.e.
grid columns 105 where storage containers 106 are stored in stacks 107.
However, a
grid 104 normally has at least one grid column which is used not for storing
storage
containers 106, but which comprises a location where the container handling
vehicles
200,300 can drop off and/or pick up storage containers 106 so that they can be
transported to a second location (not shown) where the storage containers 106
can be
accessed from outside of the grid 104 or transferred out of or into the grid
104. Within
the art, such a location is normally referred to as a "port" and the grid
column in
which the port is located may be referred to as a "delivery column" 119,120.
The
drop-off and pick-up ports of the container handling vehicles are referred to
as the
"upper ports of a delivery column" 119,120. While the opposite end of the
delivery
column is referred to as the "lower ports of a delivery column".
The storage grids 104 in Figs. lA and 1C comprise two delivery columns 119 and
120. The first delivery column 119 may for example comprise a dedicated drop-
off
port where the container handling vehicles 200,300 can drop off storage
containers
106 to be transported through the delivery column 119 and further to an access
or a
transfer station (not shown), and the second delivery column 120 may comprise
a
dedicated pick-up port where the container handling vehicles 200,300 can pick
up
storage containers 106 that have been transported through the delivery column
120
from an access or a transfer station (not shown). Each of the ports of the
first and
second delivery column 119,120 may comprise a port suitable for both pick up
and
drop of storage containers 106.
The second location may typically be a picking or a stocking station where
product
items are removed from or positioned into the storage containers 106. In a
picking or
a stocking station, the storage containers 106 are normally never removed from
the
automated storage and retrieval system 1 but are returned into the storage
grid 104
once accessed. For transfer of storage containers out or into the storage grid
104,
there are also lower ports provided in a delivery column, such lower ports are
e.g. for
transferring storage containers 106 to another storage facility (e.g. to
another storage
grid), directly to a transport vehicle (e.g. a train or a lorry), or to a
production facility.
For monitoring and controlling the automated storage and retrieval system 1
(e.g.
monitoring and controlling the location of respective storage containers 106
within
the storage grid 104; the content of each storage container 106; and the
movement of
the container handling vehicles 200,300 so that a desired storage container
106 can
be delivered to the desired location at the desired time without the container
handling
vehicles 200,300 colliding with each other), the automated storage and
retrieval
system 1 comprises a control system (not shown) which typically is
computerized and
which typically comprises a database for keeping track of the storage
containers 106.
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A conveyor system comprising conveyors may be employed to transport the
storage
containers between the lower port of the delivery column 119,120 and the
access station.
If the lower port of the delivery column 119,120 and the access station are
located at
different levels, the conveyor system may comprise a lift device for
transporting the storage
5 containers 106 vertically between the port and the access station.
The conveyor system may be arranged to transfer storage containers between
different
grids, e.g. as is described in W02014/075937A1, the contents of which are
incorporated
herein by reference.
Further, W02016/198467A1, the contents of which are incorporated herein by
reference,
disclose an example of a prior art access system having conveyor belts (Figs.
5a and 5b in
W02016/198467A1) and a frame mounted rail (Figs. 6a and 6b in W02016/198467A1)
for transporting storage containers between delivery columns and work stations
where
operators can access the storage containers.
When a storage container 106 stored in the grid 104 disclosed in Fig. lA is to
be accessed,
one of the container handling vehicles 200,300 is instructed to retrieve the
target storage
container 106 from its position in the grid 104 and to transport it to or
through the delivery
column 119. This operation involves moving the container handling vehicle
200,300 to a
grid location above the storage column 105 in which the target storage
container 106 is
positioned, retrieving the storage container 106 from the storage column 105
using the
container handling vehicle's lifting device (not shown), and transporting the
storage
container 106 to the delivery column 119. If the target storage container 106
is located
deep within a stack 107, i.e. with one or a plurality of other storage
containers positioned
above the target storage container 106, the operation also involves
temporarily moving the
above-positioned storage containers prior to lifting the target storage
container 106 from
the storage column 105. This step, which is sometimes referred to as "digging"
within the
art, may be performed with the same container handling vehicle 200,300 that is
subsequently used for transporting the target storage container 106 to the
delivery column,
or with one or a plurality of other cooperating container handling vehicles
200,300.
Alternatively, or in addition, the automated storage and retrieval system 1
may have
container handling vehicles 200,300 specifically dedicated to the task of
temporarily
removing storage containers 106 from a storage column 105. Once the target
storage
container 106 has been removed from the storage column 105, the temporarily
removed
storage containers can be repositioned into the original storage column 105.
However, the
removed storage containers may alternatively be relocated to other storage
columns 105.
When a storage container 106 is to be stored in the grid 104, one of the
container handling
vehicles 200,300 is instructed to pick up the storage container 106 from the
delivery
column 120 and to transport it to a grid location above the storage column 105
where it is
to be stored. After any storage containers positioned at or above the target
position within
the storage column stack 107 have been removed, the container handling vehicle
200,300
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positions the storage container 106 at the desired position. The removed
storage containers
may then be lowered back into the storage column 105 or relocated to other
storage
columns 105.
A problem associated with known automated storage and retrieval systems 1 is
that the
area surrounding the pick-up and drop-off ports may become congested with
container
handling vehicles 200,300 instructed to drop off or pick up storage containers
106. This
may seriously impede the operation of the automated storage and retrieval
system 1. In
small systems this situation may possibly be alleviated by adding delivery
columns to the
grid, as this will allow the container handling vehicles 200,300 to be
distributed among a
larger number of ports of delivery columns in order to avoid congestion.
However, if ports
and columns are added, the conveyor system infrastructure must normally be
increased.
This requires space, which may not necessarily be available. Also, adding
conveyor system
infrastructure is costly.
Another problem with prior art automated storage and retrieval systems 1 is
that the
separate drop-off ports and pick-up ports of the delivery columns 119,120
require the
container handling vehicles 200,300 to move to a storage column 105 after drop-
off to
retrieve a new storage container 106. Likewise, the container handling
vehicles 200,300
have to be empty of a storage container 106 when they are sent to a pick-up
port 120 to
pick up a storage container. This results in an inefficiency and causes
increased congestion
around the ports, as container handling vehicles 200,300 are moving around on
the grid
without a storage container 106 as payload. In addition, the delivery columns
119,120 may
take up space on the grid 104 which could be used for other purposes such as
the movement
of container handling vehicles 200,300.
In view of the above, it is desirable to provide an automated storage and
retrieval system,
and a method for operating such a system, that solve or at least mitigate one
or more of the
aforementioned problem related to use of prior art storage and retrieval
systems.
An objective of the invention is to provide an automated storage and retrieval
system which
is more effective than prior art systems by avoiding or at least reducing
congestion of
storage containers around the delivery column.
Another objective is to provide an automated storage and retrieval system that
increases
the availability of a delivery column for container handling vehicles
operating on a rail
system.
Yet another objective is to provide a high efficiency automated storage and
retrieval system
which are easy to install, and which delivery capacity can easily be increased
after
completed installation.
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Yet another objective is to provide an automated storage and retrieval system
which
increases the efficiency and facilitates the operation of storing and
retrieving items within
storage containers.
Summary of the invention
The invention is set forth in the independent claims and the dependent claims
describe
alternatives of the invention.
In one aspect, the invention is related to a remotely operated delivery
vehicle for
transport of a storage container between an automated storage and retrieval
grid,
configured to store a plurality of stacks of storage containers, and a second
location
for handling of the storage container by at least one of a robotic operator
and a human
operator, for example handling of items within the storage container.
The remotely operated delivery vehicle comprising;
- rolling devices being configured to move the remotely operated vehicle in
a horizontal plane,
- rolling device motors for driving the rolling devices, and
- a power source configured to provide propulsion power to the rolling
device motors.
The remotely operated delivery vehicle may further comprise a container
carrier
configured to receive the storage container from above and onto or at least
partly into
the container carrier, so that contents of the storage container are
accessible by the at
least one of the robotic operator and the human operator.
The rolling devices may be configured to move the remotely operated delivery
vehicle
along tracks of a delivery rail system comprising a set of parallel rails
arranged in a
horizontal plane (P1) and extending in a first direction (X), and a second set
of parallel
rails arranged in the horizontal plane (P1) and extending in a second
direction (1)
which is orthogonal to the first direction (X).
The rolling devices may be connected to a vehicle body or vehicle base
arranged
below the container carrier. The container carrier may be connected directly
to the
vehicle body and/or connected to said body via a structure. In all cases, the
container
carrier would be situated above the vehicle body of the delivery vehicle.
In yet another exemplary configuration, the container carrier and the vehicle
body
may be provided in one unit.
In the following the term "remotely operated delivery vehicle" is referred to
as the
"delivery vehicle" and the term "automated storage and retrieval grid" is
referred to
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as the "storage grid". The term "a storage container" is also known in prior
art as "a
bin".
The container carrier may be advantageously adapted such that it can receive a
storage
container from directly above the delivery vehicle, from a side of the
delivery vehicle
or a combination thereof.
In a preferable embodiment the container carrier is adapted receive a storage
container from a delivery column of a storage and retrieval grid, when the
delivery
vehicle is located directly below the delivery column.
The delivery vehicle may comprise a vehicle body comprising one or more
compartments for storing a power storage source such as a battery. The
compartment(s) may also be adapted to store components such as rail shift
motor, tilt
motor, actuators, controllers, etc. The rolling device, such as wheels or
driving belts,
may be connected to the vehicle body and may be operated by an electric motor.
The
electric motor may for example be arranged at least partly within the rolling
device
such as a hub motor. Further, the electric motor may comprise permanent
magnets
such as a brushless electric DC (direct current) motor. For example, the
electric motor
may comprise a rotor comprising one or more permanent magnets and a stator in
the
form of electrical windings wrapped around yokes. An electric motor comprising
stator magnets and rotor yokes / windings may also be envisaged. AC motors
would
also be a possibility.
The vehicle body may be a framework being similar to the framework disclosed
in
WO 2016/120075 Al, hereby incorporated by reference, though without a cavity
configured to store a storage container there within. The vehicle body may be
a height
corresponding substantially to a diameter of the rolling devices.
In operation, the delivery vehicle may be operated such that it is positioned
directly
below, or substantially directly below, a delivery port of a delivery column
of an
automated storage and retrieval grid, such that it can receive a storage
container from
above and into its container carrier.
Due to the above-mentioned rolling devices and the associated rolling device
motors
and power source, the delivery vehicle may be adapted for self-propelled
movement
to a second location. It may comprise a robotic vehicle.
The delivery vehicle may receive a storage container onto or into the
container carrier
from a conveyor belt or other delivery systems capable of transporting storage
containers. In this particular embodiment, the storage container may be slid
or lifted
onto the container carrier from at least one side of the delivery vehicle.
The delivery column may be referred to as a grid column which is used for
transport
of storage containers there through, hence being void of storage containers.
The
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storage grid may thus comprise a location of the storage grid where the
container
handling vehicle can drop off and/or pick up storage containers for further
transport
to/from a desired storage column. The delivery column may be situated at any
desired
location within the storage grid, but preferably at or near the storage grid's
perimeter.
The delivery column may comprise a pick-up or drop-off port situated at the
upper
level of the storage grid, i.e. the level where the container handling vehicle
are
operating, and a delivery port situated at a lower level/end of the storage
grid. At the
lower level / delivery port, the storage container can be inserted or removed
from the
delivery column, for example by aid of the delivery vehicle.
The delivery port may be an opening situated at the lowermost position of the
delivery
column allowing pick-up and/or drop-off of storage containers.
The storage containers may be transported through the delivery column by
lifting
means, for example in the form of a lifting device of the above mentioned
prior art
container handling vehicle.
Alternatively, the lifting means may be a dedicated lift configured to
transport storage
containers through the delivery column, for example a lift as disclosed in
patent
publication WO 2017/121515 Al, hereby incorporated by reference.
In one exemplary configuration, the storage containers may be transported in a
loop
between the delivery port and a predetermined second location. In this way,
any
storage container may be retrieved through the same delivery column as which
it is
deposited, or any other delivery column arranged for the same purpose.
Said loop may contain a plurality of circulating storage containers, thereby
reducing
or avoiding congestion on the rail system on one or more lateral sides of a
delivery
column.
A container handling vehicle may, after having deposited a storage container
in the
delivery column, pick up a new storage container for delivery to, or retrieval
from,
the same delivery column.
The remotely operated delivery vehicle may be configured to receive the
storage
container from a delivery port of the storage grid for transport to a second
location in
which the storage containers and/or product items within each storage
container can
be handled. Furthermore, the delivery vehicle may be configured to transport
the
storage container from the second location for delivery to the delivery port.
In both
cases, the storage container may be transported through the storage grid via
the
delivery column by lifting means / lifting device.
The second location may be any predetermined location appropriate for handling
of
the storage container by at least one of a robotic operator and human
operator, for
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example acting as a picking or stocking station where product items are
removed
from, or placed into, the storage containers. The second location may be
distant from
the storage system.
The robotic or human operator may be for example a picker provided for
handling the
5 goods/items within the container. The pickers will be picking items from,
or re-
stocking items within, the container, or they will be handling the entire
storage
container by replacing, removing and/or inserting containers into the storage
grid.
Further, the second location may be any predetermined location which allows
storage
containers to be accessed from a location outside and/or in connection with
the
10 storage grid.
The second location may be physically connected and/or in connection with the
storage grid. The delivery vehicle operates independently between the delivery
port
and the second location.
In general, the second location may be any predetermined location reachable by
the
delivery vehicle when operating on a delivery rail system.The delivery rail
system
may be arranged between the second location and the one or more delivery ports
of
the storage grid. In this way the storage containers may be transported on the
delivery
vehicles between the delivery port and the second location without
necessitating
costly and/or ineffective infrastructure such as conveyer belts and/or
human/robotic
intervention. As explained above, the transport may be on top of the container
carrier
of the delivery vehicle. Further, each delivery vehicle may move independently
in the
X and Y directions along the delivery rail system.
The delivery rail system may be arranged on a level below a container handling
vehicle rail system on which a plurality of container handling vehicles are
operating.
The delivery rail system, on which the delivery vehicles may operate, can be
arranged
in a grid pattern in the same way as, or similar to, the rail system of the
container
handling vehicles. The delivery rail system may extend across and below the
lower
level of the storage grid (below the delivery port(s)), covering at least one,
preferably
all, of the at least one delivery ports, as well as the distance from the
storage grid to
the second location.
Hence, the second location may be located at any predetermined location along
the
delivery rail system.
To get the most storage space for storage containers in the storage and
retrieval grid,
it may be advantageous to arrange the delivery rails system such that it
extends as
little as possible into the storage grid. That means that the storage and
retrieval grid
may comprise a plurality of storage columns extending from the upper level to
the
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base of the storage grid, thus allowing the greatest possible storage capacity
since the
entire storage column may be used for storage.
In order to maintain greatest possible storage capacity, the part of the
delivery rail
system extending into the storage grid may be kept as small (little extent) as
possible.
Thus, the delivery rail system and the delivery vehicle may occupy as little
space as
possible of the storage and retrieval grid, the space which may be used for
storage of
storage containers.
Each grid cell of the delivery rail system may have a size which is equal or
similar to
the size of the grid cells of the rail system for the container handling
vehicles. In
addition to facilitate production and ensure costs by allowing use of already
designed
and tested components, the required alignment of the delivery vehicle below
the upper
rail system for the container handling vehicle becomes easier to achieve.
A typical width of each grid cell of the delivery rail system is within the
interval of
30 to 150 cm, and a typical length is within the interval of 50 to 200 cm.
The widths and the lengths of each grid opening are typically 2 to 10 cm less
than the
widths and the lengths of the corresponding grid cell (fig. 2C).
Since the delivery vehicle may be operating directly under the container
handling
vehicles on top of the storage grid, its dimensions may naturally correspond
to the
grid cell size of the storage grid above. Many of the same considerations as
for the
container handling vehicles apply, for example the ability for the vehicles to
pass
each other on adjacent grid cells. But for the delivery vehicle the single
grid space
configuration also has other advantages such as to avoid interference with
upright
members of the storage grid.
The inventive automatic storage and retrieval system is more effective than
prior art
systems by avoiding, or at least reducing, congestion of storage containers
around the
delivery columns of the storage grid. Thus, the capacity of the entire storage
system
is increased by the addition of a dedicated delivery rail system since the
storage
containers may be immediately and continuously moved away from the area of the
delivery columns. This means that container handling vehicles do not need to
wait
for available delivery columns to drop off storage containers. In the same
way, the
container handling vehicles will continuously receive (pick up) storage
containers
from the delivery port for storage of the storage containers in the storage
grid.
The delivery rail system may comprise a first set of parallel rails arranged
in a
horizontal plane to guide movement of the delivery vehicle in a first
direction X
across the level of the delivery rail system, and a second set of parallel
rails arranged
in the horizontal plane perpendicular to the first set of rails to guide
movement of the
delivery vehicle in a second direction Y which is perpendicular to the first
direction
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X. In this way, the delivery rail system defines a grid pattern on which the
delivery
vehicle can move laterally. The grid pattern thus comprises a plurality of
adjacent
delivery vehicle grid cells, where each grid cell comprises a grid opening
defined by
a pair of neighboring rails of the first set or rails and a pair of
neighboring rails of the
second set of rails.
The delivery rail system may be a single track system. Alternatively, the rail
system
may be a double track system, for example where the two tracks in each rail
are
separated by a protrusion running midway. This double track system allows the
delivery vehicle to have a footprint to be equal or less than the lateral
extension of
the grid cell, thereby allowing the delivery vehicle to travel along a row of
grid cells
even if another delivery vehicle is positioned at a grid cell neighboring that
row. In
the double track system, each delivery vehicle is configured to run on an
inner rail of
each double tracked rail. The vehicle body does therefore not extend beyond
the
halfway point of the parallel rail.
The delivery rail system may typically be located on a ground floor level,
thereby
allowing easy access to the storage containers for human and/or robotic
operators.
However, the delivery rail system may be located at any level below the top
level of
the storage grid. In a preferable configuration, the entire delivery rail
system is
located at a level below the pick-up and/or drop-off port of the storage grid.
The delivery system may comprise an interface connectable to a third-party
storage,
production and distribution system.
The delivery system may be integrable with a third-party storage, production
and
distribution system such that storage containers can be transported between
the delivery
system and the third-party storage, production and distribution system.
The delivery system of the present invention may be connected to a third-party
storage, production and distribution system such as production facility, a
storage grid,
assembling facility, reception or shipping location, etc. The connection may
be by
means of a connectable rail system or a conveyor system comprising conveyors
employed to transport the storage containers between the delivery system and
the
third-party storage, production and distribution system. The delivery vehicle
may
comprise a weighing mechanism in order to measure the weight of the storage
container, for example a commercially available electronic weighing scale.
Such a
weighing mechanism may provide information concerning the content inside each
storage container such as the total weight, the number of units, the internal
weight
distribution and/or the location within the storage grid the storage container
should
be placed.
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For example, if a storage container is particularly heavy, it may be advisable
to place
this storage container deep within the storage grid. It may alternatively, or
in addition,
be advisable to transmit an alert signal to the human and/or robotic operator
which
should be handling the particular storage container.
The container carrier of the delivery vehicle may be a container supporting
device for
supporting the storage container from below.
The supporting device may be (or may comprise) a base plate, a conveyor,
and/or any
other structure that is able to carry a storage container from below.
In order to stabilize the storage container in the horizontal plane (P) the
supporting
device may comprise at least one elevated edge arranged at or near the
periphery of
the base plate, conveyor and/or the like.
The container supporting device may be arranged either for supporting the
storage
container from below or holding/suspending the storage container from the at
least
one elevated edge or a combination thereof.
The container supporting device may be at least any one of a lid, a tray, a
box or a
crate.
The supporting device may comprise a base plate with elevated edges such that
it
forms a compartment with a compartment size adapted to receive a storage
container.
The compartment may be adapted to receive at least a lower section of the
storage
container, for example at least the base of the storage container.
Further, the compartment may be arranged for fully containing the storage
container.
In a mixed storage container system, the size of the compartment of the
supporting device
may be adapted to correspond to the size of the largest storage containers of
the storage
grid, such that the compartment can receive both small and large size storage
containers.
The large size containers can be supported by a platform or a structure from
below, while
the small size containers can be supported by the elevated edges of the
compartment.
Further, the container carrier may comprise a conveyor.
The conveyor may comprise rolls with or without integrated motor(s) mounted
between supports for respective ends of the rolls (such as parallel railings).
The rolls
allow the storage container to be shifted into or out of the container
carrier. In
addition, the rolls provide support from below for the storage container while
situated
on the delivery vehicle.
Different kinds of conveyors may be used such as conveyor belts, wheels,
balls, rods
or any similar means adapted for the easy moving of storage container into or
out of
the container carrier.
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The container carrier of the delivery vehicle may comprise a displacement
device
arranged for moving the container carrier relative to the rolling devices of
the delivery
vehicle. The displacement device may in general move the container carrier in
any
direction, for example vertically, thereby acting as a lift device, and/or to
any side by
horizontal displacements and/or by tilting the container carrier around a
pivot axis
using a tilt device. The latter facilitates the handling or the picking
operation, in
particular during handling of a human operator. The tilting movement is
preferably
around one of the principal moving directions of the delivery vehicle, for
example
around the X and/or the Y direction.
The pivot axis may hence be parallel to a first set of rolling devices or
parallel to a
second set of rolling devices, or both.
The above embodiments allow the storage container situated on top of the
container
carrier to be tilted towards the user at the second location or at any
preferred location.
The tilted position of the storage container thereby allows a human operator
to easily
view the contents stored in the storage container, in addition to improving
the working
position of said operator while retrieving items and/or inserting items
from/to the
storage container. The tilting angle range may be from 2 to 60 relative to
one or
both sides of the pivot axis relative to the horizontal plane, more preferably
from 3
to 50 , even more preferably from 4 to 45 , even more preferably from 5 to
40 ,
even more preferably from 6 to 35 , even more preferably from 7 to 30 , even
more
preferably from 8 to 25 , even more preferably from 9 to 20 , for example 15
. The
ability to tilt the storage container allows inter alia a human operator to
view and/or
access the times within the storage container more easily.
In general, the tilting angle should not exceed a maximum tilting angle that
would
represent a significant risk of stored items / articles tipping out of the
storage
container in question. This maximum allowed tilting angle depends on the
amount
and size of items / articles within the storage container. A storage container
being
filled with items up to its upper rim will have a lower maximum tilting range
that a
storage container having items filling the containers' vertical height only
partly.
The displacement device may comprise a lifting arm connected to the container
carrier, which lifting arm is operated by a tilt motor situated in the vehicle
body. The
tilting arm may also be operated by a linear actuator. The operational range
of the
displacement device may be governed by a set maximum tilting range. For
example,
a tilting arm connected linear actuator may be configured to allow tilting up
to 30 ,
up to 25 , up to 20 or up to 15 . The tilting angle may be fixed or
adjustable. In the
latter case, any adjustment may be achieved by remote control and/or by manual
interaction by a human operator.
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A motor providing the necessary power to drive the delivery vehicle in the X
or Y
direction may be one or more dedicated electric, for example arranged at least
partly,
preferably fully, within the rolling device.
The rolling devices may be any device ensuring horizontal propulsion of the
delivery
5 vehicle, for example wheels and/or belts
In a preferred embodiment, the delivery vehicle comprises a wheel arrangement.
The
wheel arrangement may further comprisea first set of wheels, arranged at
opposite
portions of the vehicle body or vehicle base, for moving the delivery vehicle
along a
first direction (X) on a delivery rail system; and a second set of wheels,
arranged at
10 opposite portions of the vehicle body or vehicle base, for moving the
delivery vehicle
along a second direction (17) on the delivery rail system, the second
direction (17) being
perpendicular to the first direction (X).
The delivery vehicle may comprise a vehicle body and a wheel arrangement of
eight
wheels, where a first set of four wheels enable the lateral movement of the
delivery
15 vehicle in the first direction (X) and a second set of the remaining
four wheels enable
the lateral movement in the second direction (17). One or both sets of wheels
in the
wheel arrangement may be lifted and lowered, so that the first set of wheels
and/or
the second set of wheels can be engaged with the respective set of rails
provided on
the delivery rail system, at any one time.
As mentioned above, the delivery vehicle may have a footprint, i.e. an extent
in the
X and Y directions, which is generally equal to the horizontal extent of a
grid cell of
the delivery rail system i.e. the extent of a grid cell in the X and Y
directions.
Alternatively, the delivery vehicle may have a footprint which is larger than
the
lateral extent of a grid cell of the delivery rail system.
In a second aspect, the invention concerns an automated storage and retrieval
system.
The automated storage and retrieval system may comprise an automated storage
and
retrieval grid and a delivery system that may be arranged for transport of a
storage
container between the storage grid and a second location. The second location
may
be a location where a robot operator and/or a human operator handles the
storage
container, for example by storing and/or retrieving items there within.
The grid may comprise a container handling vehicle rail system for guiding a
plurality
of container handling vehicles, the rail system comprising a first set of
parallel rails
arranged in a horizontal plane and extending in a first direction, and a
second set of
parallel rails arranged in the horizontal plane and extending in a second
direction
which is orthogonal to the first direction, which first and second sets of
rails form a
grid pattern in the horizontal plane. The sets of rails define a grid
comprising a
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plurality of adjacent container handling vehicle grid cells, where each
container
handling vehicle grid cell comprises a container handling vehicle grid opening
defined by a pair of neighboring rails of the first set of rails and a pair of
neighboring
rails of the second set of rails; and a delivery column adapted for transport
of a storage
container arranged in a stack of storage containers beneath the container
handling
vehicle rail system between a container handling vehicle and a delivery port
situated
at a lower end of the delivery column.
The delivery system may comprise a remotely operated delivery vehicle
comprising
a container carrier configured to support the storage container. The delivery
vehicle
may be adapted to transport the container carrier between a delivery port and
a second
location for handling of the storage container by at least one of a robotic
operator and
a human operator.
The delivery vehicle may comprise rolling devices connected to a vehicle body
or a
vehicle base arranged below the container carrier.
As described earlier, the delivery column may comprise a delivery port
situated at the
lowermost end of the delivery column. In operation, the storage container may
be
transported through the storage column and to the delivery port where it is
placed
onto or into a delivery vehicle. Accordingly, the delivery vehicle may deliver
a
storage container to the delivery port for transport through the delivery
column and
to be received by a container handling vehicle.
The delivery system of the automated storage and retrieval system may further
comprise a delivery rail system below the delivery port. The delivery rail
system may
further be arranged such that the delivery vehicle can operate on said rail
system when
moving between the delivery port and a predetermined second location.
Each of the at least one delivery rail system may comprise a first set of
parallel rails
arranged in a horizontal plane (P1) and extending in a first direction (X),
and a second
set of parallel rails arranged in the horizontal plane (P1) and extending in a
second
direction (Y) which is orthogonal to the first direction (X). The first and
second sets
of rails define a grid in the horizontal plane (P1) comprising a plurality of
adjacent
delivery vehicle grid cells, each delivery vehicle grid cell comprising a
delivery
vehicle grid opening defined by a pair of neighboring rails of the first set
of rails and
a pair of neighboring rails of the second set of rails.
Each of the first and second set of rails of the delivery rail system may be a
double
track rail comprising two parallel tracks separated by a protrusion running
midway.
Furthermore, each of the first and second set of rails of the container
handling vehicle
rail system may be a double track rail comprising two parallel tracks
separated by a
protrusion running midway.
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The remotely operated delivery vehicle may have a delivery vehicle footprint
with a
horizontal extent which is equal to or less than the horizontal extent of the
delivery
vehicle grid cell.
Moreover, at least one, preferably each, of the plurality of delivery vehicle
grid cells
of the delivery rail system may be arranged directly below a container
handling
vehicle grid cell of the container handling vehicle rail system. The delivery
rail
system may extend within the framework structure of the storage grid. The
second
location would thus be located inside the framework structure of the storage
grid.
The delivery rail system may extend to the outside the framework structure of
the
storage grid, preferably to the second location. When the second location is
located
outside the storage grid, they do not take up storage capacity of the grid.
The delivery rail system may comprise a first rail system located within the
framework structure of the storage grid, and a second rail system located
outside the
framework structure of the storage grid, and wherein the first and second rail
system
are connected such that the delivery vehicle may operate between said rail
systems.
The second location may be connected to the second rail system.
The second location may be situated at any location on the delivery rail
system at
which, or through which, storage containers can be deposited and/or retrieved.
Since
the second location can be any predetermined location on the delivery rail
system,
said second location can be moved, a new second location can be established /
opened,
or an existing second location can be removed / closed.
In a third aspect the present invention is directed to a method of
transporting a storage
container between an automated storage and retrieval grid and a second
location for
handling of the storage container by at least one of a robotic operator and
human
operator.
The automated storage and retrieval grid may comprise a container handling
vehicle
rail system comprising a first set of parallel rails arranged in a horizontal
plane and
extending in a first direction, and a second set of parallel rails arranged in
the horizontal
plane and extending in a second direction which is orthogonal to the first
direction, which
first and second sets of rails define a grid in the horizontal plane
comprising a plurality of
adjacent container handling vehicle grid cells, where each grid cell comprises
a container
handling vehicle grid opening defined by a pair of neighboring rails of the
first set of rails
and a pair of neighboring rails of the second set of rails; and a plurality of
stacks of storage
containers arranged in storage columns located beneath the container handling
vehicle rail
system, wherein each storage column is located vertically below a container
handling
vehicle grid opening.
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The system may further comprise a delivery column configured to receive a
storage
container from a container handling vehicle.
The method may comprise the step of:
- lowering the storage container through the at least one delivery column
to a
delivery port,
- positioning a delivery vehicle below the delivery port for receiving a
storage
container onto a container carrier, and
- delivering the storage container to the second location by operating the
rolling
devices of the remotely operated delivery vehicle on a delivery rail system.
The method may further comprise the step of tilting the container carrier at
the second
location, preferably within a tilting angle range between 2 and 60 relative
to the
horizontal plane (P ,P 1) or any of the tiling angle ranges mentioned above.
The second location may comprise a picking station and the tilting of the
storage container
may be for assisting with a picking operation.
The method may further comprise the step of operating the remotely operated
vehicle to
return to the delivery port by operating the rolling devices of the remotely
operated delivery
vehicle on the delivery rail system and lifting the storage container through
the delivery
column for storage of the storage container in the automated storage and
retrieval grid.
In a fourth aspect, the present invention concerns an automated storage and
retrieval
system comprising an automated storage and retrieval grid and a remotely
operated
carrier vehicle.
The automated storage and retrieval grid comprises a rail system for guiding
the
remotely operated container carrying vehicle operating on the rail system.
The rail system may comprise a first set of parallel rails arranged in a
horizontal plane
(P) and extending in a first direction (X) and a second set of parallel rails
arranged in
the horizontal plane (P) and extending in a second direction (Y) which is
orthogonal
to the first direction (X).
The first and second sets of rails form a grid pattern in the horizontal plane
(P)
comprising a plurality of adjacent grid cells, each grid cell comprising a
grid opening
defined by a pair of neighboring rails of the first set of rails and a pair of
neighboring
rails of the second set of rails. Each rail may comprise a pair of tracks,
where each
track is configured to guide a wheel in the first or second direction (X, Y).
The container carrying vehicle may include rolling means comprising a first
set of
wheels arranged symmetrically around a vertical mid plane of the vehicle
oriented in
the first direction (X) for moving the container carrying vehicle along the
first
direction (X) on the rail system and a second set of wheels arranged
symmetrically
around a vertical mid plane of the container carrying vehicle oriented in the
second
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direction (X) for moving the container carrying vehicle along the second
direction (17)
on the rail system. At least one of the first and second set of wheels are
vertically
displaceable relative to the rail system by means of a displacement motor.
The container carrying vehicle further comprises a container carrier adapted
to
support a storage container from below. The container carrier may be tiltable.
The automated storage and retrieval system according to the fourth aspect may
comprise any of the features mentioned in relation to the first, second and/or
third
aspect.
In particular, the rail system of the fourth aspect may comprise any of the
features
describing the automated storage and retrieval grid mentioned in relation to
the
second and/or third aspect.
Further, the container carrying vehicle of the fourth aspect may comprise any
of the
features describing the remotely operated delivery vehicle mentioned in
relation to
the first, second and/or third aspect.
For the fourth aspect of the present invention, one or more of the container
carrying
vehicles may cooperate with one or more container handling vehicles delivering
and
retrieving storage containers within underlying stacks. For example, the
container
carrying vehicles may have as a purpose to act as additional storage locations
for
storage containers such as storage containers required to be stored on the
grid for
short periods of time. At other times the container carrying vehicle may be
delivering
or retrieving storage containers between two locations.
Brief description of the drawings
The following drawings depict exemplary embodiments of the present invention
and are
appended to facilitate the understanding of the invention.
Fig. 1 A-D are perspectives view of a prior art automated storage and
retrieval system,
where Fig. lA and Fig. 1C shows the complete system and Fig. 1B and Fig. 1D
shows
examples of system operable prior art container handling vehicles.
Fig. 2 A-C is a top view of a container handling vehicle rail system, where
Fig. 2A
shows a single track system, Fig. 2B shows a double track system 2B and figure
2 C
shows a double track system indicated width and length of a container handling
vehicle grid cell.
Fig. 3 A-C is a side view of a remotely operated delivery vehicle according to
an
embodiment of the invention.
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Fig. 4 A-B is a perspective view of the remotely operated delivery vehicle of
Figure 3 A-
C.
Fig. 5 A-B is a perspective view of the remotely operated delivery vehicle of
Figure 3 A-
C, from the underside and from the above.
5 Fig. 6 A is a cross sectional view of the remotely operated delivery
vehicle of Figure 3
A-C.
Fig. 6 B is a perspective view of the remotely operated delivery vehicle of
Figure 3 A-C
disclosing the operation of the wheels.
Fig. 7 A-C is a perspective view of another embodiment of the remotely
operated
10 delivery vehicle having a container carrier with a compartment for
holding the storage
container.
Fig. 8 A-B is a perspective view of another embodiment of the remotely
operated
delivery vehicle having a container carrier provided with conveyors.
Fig. 9 A-B is a perspective view of an exemplary embodiment of an automated
storage
15 and retrieval grid and a delivery system according to the present
invention.
Fig. 10 A-B is a perspective view of another embodiment of an automated
storage and
retrieval grid and a delivery system according to the present invention.
Fig. 11 A is a perspective view of another embodiment of an automated storage
and
retrieval grid with delivery columns and delivery port.
20 Fig. 11 B is a side view of another automated embodiment storage and
retrieval grid and
a delivery system according to the present invention.
Fig.12 is a top view of a double track delivery rail system of the automated
storage
and retrieval system according to Fig. 9-12.
Detailed description of the invention
In the following, embodiments of the invention will be discussed in more
detail with
reference to the appended drawings. It should be understood, however, that the
drawings are not intended to limit the invention to the subject-matter
depicted in the
drawings. Furthermore, even if some of the features are described in relation
to the
system only, it is apparent that they are valid for the delivery vehicles and
related
methods as well, and vice versa. Hence, any features described in relation to
the
delivery vehicle only, and/or related methods, are also valid for the system.
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With reference to Figs. 1A-D the storage grid 104 of each storage structure 1
constitutes a framework 100 of in total 143 grid columns 112, where the width
and
length of the framework corresponds to the width and length of 13 and 11 grid
columns 112, respectively. The top layer of the framework 100 is a rail system
108
onto which a plurality of container handling vehicles 200,300 are operated.
The framework 100 of the storage system 1 is constructed in accordance with
the
above mentioned prior art framework 100 described above, i.e. a plurality of
upright
members 102 and a plurality of horizontal members 103 which are supported by
the
upright members 102, and further that the horizontal members 103 includes a
container handling vehicle rail system 108 of parallel rails 110,111 in the X
direction
and the Y direction, respectively, arranged across the top of storage columns
105.
The horizontal area of a single grid cell 122, i.e. along the X and Y
directions, may
be defined by the distance between adjacent rails 110 and 111, respectively
(see also
Fig. 2). In Figs. lA and 1C, such a grid cell 122 is marked on the rail system
108 by
thick lines.
The container handling vehicle rail system 108 allows the container handling
vehicles
200,300 to move horizontally between different grid locations, where each grid
location is associated with a grid cell 122.
In Figs. lA and 1C the storage grid 104 is shown with a height of eight cells.
It is
understood, however, that the storage grid 104 can in principle be of any
size. In
particular it is understood that storage grid 104 can be considerably wider
and/or
longer than disclosed in Figs. 1A and 1C. For example, the grid 104 may have a
horizontal extent of more than 700x700 grid cells 122. Also, the grid 104 can
be
considerably deeper than disclosed in Figs. lA and 1C. For example, the
storage grid
104 may be more than twelve grid cells deep.
The storage container vehicles 200,300 may be of any type known in the art,
e.g. any
one of the automated container handling vehicles disclosed in W02014/090684
Al,
in NO317366 or in W02015/193278A1.
The rail system 108 may be a single track system, as is shown in Fig. 2A.
Alternatively, the rail system 108 may be a double track system, as is shown
in
Fig. 2B. Details of the single and double track system are disclosed this
specification
under the section of background and prior art.
Fig 3 A-C shows an embodiment of a remotely operated delivery vehicle 30
according
to the present invention, hereinafter referred to as a delivery vehicle 30.
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The delivery vehicle 30 is configured for transport of one or more storage
container
106 (not shown) between an automated storage and retrieval grid 104 (not
shown)
configured to store a plurality of stacks 107 of storage containers 106,
hereinafter
referred to as a storage grid 104, and a second location for handling of the
storage
container (106) by at least one of a robotic operator and human operator (not
shown).
The delivery vehicle 30 may be configured for transport of only one storage
container
106,or may be configured for transport of more than on storage containers
simultaneously.
Said delivery vehicle 30 comprises; a vehicle body 31, rolling devices 32
connected
to the vehicle body 31, rolling device motors for driving the rolling devices
32 in a
horizontal plane (P 1), and a power source 43 connected to the rolling device
motors.
The power source 43 should provide sufficient power to the rolling device
motors to
propel the rolling devices 32 over a set route from the storage grid 104, for
example
to the second location.
The delivery vehicle 30 may further comprise a container carrier 35 mounted
above
the vehicle body 31. The container carrier 35 should be configured to receive
the
storage container 106 onto or within the container carrier 35 such that the
storage
container 106 is hindered to move relative to the container carrier in the
horizontal
direction.
The container carrier 35 may comprise a container supporting device supporting
the
storage container 106 from below. The form of the container supporting device
may
be any that ensure stable support, for example in the shape of a cup, a
cradle, a seat,
a frame, a holder or a platform.
In Fig. 3 A-C the container carrier 35 is disclosed in the form of a storage
container
receiving compartment having a bottom / base and side walls. The volume of the
compartment is in this exemplary configuration such that it may receive and
contain
the entire horizontal extent of the storage container and at least a part of
the vertical
extent of the storage container. Figs. 3-6 shows examples of container
carriers 35
containing an entire storage container 106 and Fig. 7 A-C shows an alternative
container carrier 35 containing a part of the storage container 106.
The particular configuration of the container carrier 35 disclosed in Figs 3-6
allows
the delivery vehicle 30 to transport of a storage container 106 having
different
heights.
Note that the size of the compartment within the container carrier 35 may
easily be
adapted for receiving and supporting a multiple number of storage containers
106 in
one operation.
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Fig. 3 B and C shows a particular configuration of the delivery vehicle 30,
where the
container carrier 35 may be set in a tilted position relative to the vehicle
body 31 and
the horizontal plane (P1). The container carrier 35 may be tilted by means of
a
dedicated displacement device 41. The tilting may be around a pivot axis
directed in
the principal moving direction of the delivery vehicle 30. If the delivery
vehicle 30
is moving on perpendicular rails (see below), these principal directions would
be in
either the X direction or the Y direction.
The tilting of the displacement device 41 may for example be obtained by a
lifting
arm 45 coupled to the vehicle body 31 and the container carrier 35. Further,
the lifting
arm 45 may be driven by a dedicated tilt motor (not shown) or the rolling
device
motor or both.
Fig. 4 A-B shows additional perspective views of the delivery vehicle 30. The
rolling
device 32 comprises in this exemplary configuration:
-a first set of wheels 32a arranged at opposite portions of a vertical centre
plane
through the vehicle body 31 for moving delivery vehicle 30 along a first
direction,
for example along an X-direction on a delivery rail system; and
-a second set of wheels 32b arranged at opposite portions of a vertical centre
plane
through the vehicle body 31 for moving the delivery vehicle 30 along a second
direction, for example along a Y-direction on the delivery rail system
perpendicular
to the first direction X.
An example of a delivery rail system will be further described in figure 9-12.
Fig. 5 A and B shows the delivery vehicle 30 from below and from above,
respectively. As clearly seen in Fig. 5 A the vehicle body 31 of the delivery
vehicle
comprises an internal component receiving recess or compartment for containing
30 components such as one or more dedicated tilt motors 41, one or more
rail shift motors
42, one or more power storage sources such as a battery 43 and one or more
control
cards such as CPU and/or Power PCB 44. The above-mentioned components are thus
located within the vehicle body 31, below the container carrier 35.
As best disclosed in Fig. 5 B the storage container receiving compartment of
the
container carrier 35 has in this particular configuration a rectangular bottom
plate or
base plate with vertical side walls. The vertical side walls can be of any
height as
long as they ensure that the storage container 106 is restricted to move along
the base
plate of the container carrier.
For example, the size of the compartment 35 may correspond to the size of a
storage
container 106, thereby fully containing the storage container 106.
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The delivery vehicle may have a footprint, i.e. an extent in the X and Y
directions,
which is generally equal to the horizontal extent of a grid cell of the
delivery rail
system i.e. the extent of a grid cell in the X and Y directions. Accordingly,
the size
of the base plate of the compartment 35, in the X and Y direction, may be
within these
given perimeters.
In case of a container carrier 35 being configured to support a multiple
number of
storage containers 106, the size of the vertical walls may in one example be
the height
of each storage container 106 and the size of the base plate may be the sum of
the
cross-sectional area of all storage containers 106 measured relative to their
outer
lateral extremities.
Fig. 5 B further shows that the container carrier 35 may comprise a dedicated
holding
device 46,47,49 for the one or more storage containers 106 to allow storage
containers
106 of different vertical heights to be stored in the same delivery vehicle
30. In the
exemplary configuration shown in Fig. 5 B the holding device comprises a
support
element 46 having a top surface 49 and connected to an actuator lever 47. The
support
element 46 is connected to the inner walls of the container carrier 35, for
example at
the upper half of the container carrier 35.
The holding device may be arranged in the following exemplary way.
The storage container holding device comprises a support element 46 having a
top
surface 49 at one end and connected to an actuator lever 47 at the opposite
end. The
support element is pivotably connected to an inner top part of a side wall of
the
compartment 35. The actuator lever 47 is arranged with an inclined angle such
that it
protrudes into the compartment 35, and such that during introduction of the
storage
container 106 into the compartment 35, a bottom edge of the storage container
106
will push the actuator levers 47 from the protruding position in which it is
in contact
with the bottom edge of the storage container, to a substantial vertical
position.
Since the actuator lever 47 is pivotably connected to the support element 46,
the
movement of the actuator lever 47 provides a corresponding movement of the top
surface 49 provided at the opposite end of the support element 46.
Accordingly,
during introduction of the storage container 106 into the compartment 35, the
top
surface 49 will move from a first position in which it is not in contact with
a top edge
of the storage container, to a second position in which it is in contact with
the top
edge of the storage container, when the storage container 106 is fully
accommodated
in the compartment 35. Wherein in the second position, the top edge (not
shown) of
the storage container is supported by the top surface 49.
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The actuator lever 47 may be pre-tensioned by a spring (not shown), such that
the
actuator levers 47 return to their non-actuated position (protruding position)
when the
storage container 106 is lifted off, or out of, the compartment 35.
By supporting the storage container 106 via the external top edge (not shown)
of the
5 storage container 106, the storage container 106 is always held at a
predetermined
level relative the base plate of the compartment 35.
The support element 46, the top surface 49 and the actuator lever 47 can be
made in
one piece.
Fig. 6 A shows a perspective side view of the delivery vehicle 30 where the
container
10 carrier 35 is tilted around a rotational axis directed in one of the
principal moving
direction of the storage container 106, i.e. the first or the second direction
as described
above.
The tilting of the displacement device 41 may for example be obtained by a
lifting
arm 45.
15 The container carrier 35 can be tilted towards one of the longitudinal
sides such that
the storage container 106 can be easily accessed by a human operator
responsible for
picking items from within the container carrier 35.
The displacement device 41 is in Fig. 6 A shown with an L-shaped lifting arm
45
20 connected at one side to the vehicle body 31 and the opposite side
connected to a
structure fixed to the container carrier 35. The latter end of the arm 45 may
also be
connected directly to the container carrier 35.
The tilt motor 41 is seen arranged fully inside the vehicle body 31 and is
connected
25 to the lifting arm 45, directly or indirectly, for moving the lifting
arm 45 between a
lower position in which the container carrier 35 is not tilted relative to the
horizontal
plane (P) and an upper position in which the container carrier 35 is tilted
relative to
the horizontal plane (P). Note that the horizontal plane (P) may be defined as
the
plane set up by the particular configurations of the wheels 32a,32b of the
rolling
device 32.
Fig. 6 B shows the delivery vehicle 30 as described above with the vehicle
body 31
and the rolling device 32 of eight wheels 32a,32b. As for the delivery vehicle
shown
in Figs. 3-5, the first set of four wheels 32a enable lateral or horizontal
movement of
the delivery vehicle 30 in a first direction and the second set of the
remaining four
wheels 32b enable the lateral or horizontal movement in the second direction
which
may be perpendicular to the first direction.
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If used on a delivery rail system 50 (see below) one or both sets of wheels
32a,32b of
the rolling device 32 should be lifted and lowered so that the first set of
wheels 32a
and/or the second set of wheels 32b can be engaged with the respective set of
rails
provided on the delivery rail system 50 any one time.
Figure 7 A-C shows another exemplary configuration of a remotely operated
delivery
vehicle 30 according to the invention. Similar to the container carrier 35
described
above, the container carrier 35 of this configuration is a container
supporting device
for supporting the storage container 106 from below.
The container supporting device hence comprises a base plate provided with
side
walls along the outer circumference or periphery of the base plate, thereby
defining
a compartment. The horizontal extent of the compartment is adapted to be large
enough to receive one or more storage containers 106 and small enough to
substantially hinder movements of the one or more storage containers 106 when
inserted. However, in contrast to the exemplary configuration of the delivery
vehicle
30 shown in Figs. 3-6, the one or more side wall of the container supporting
device
has a vertical height less than the vertical height of each storage container
106. In
fact, in order to achieve the purpose of the side walls of the container
carrier 35 (to
substantially prevent horizontal movement when inserted) it is sufficient with
only a
small vertical protrusion upwards from the base plate, for example less than 5
% of
the height of the side walls of the storage container 106.
Figure 8 A-B shows yet another exemplary configuration of the remotely
operated
delivery vehicle 30. In this configuration the container carrier 35 comprises
a base
plate, a conveyor 36 arranged on the base plate and two parallel side walls
protruding
upwards from the base plate. The rolling device 32 and the vehicle body 31 are
equal
or similar to the rolling device 32 and the vehicle body 31 described above in
connection with Figs. 3-7.
The conveyor may be set up by inter alia a plurality of parallel oriented
rolls 36 having
a common longitudinal direction perpendicular to the two side walls. In this
way the
rolls 36 allow one or more storage containers 106 to be shifted into or off
the container
carrier 35 while being guided by the side walls. The conveyor may be connected
to a
conveyor motor allowing rotation of one or more of the rolls.
Alternatively, the side walls are omitted, allowing the storage containers 106
to have
a horizontal offset relative to a vertical center plane oriented perpendicular
to the
rolls longitudinal direction. Hence, the storage containers 106 may be
arranged such
that it extends beyond the end of the rolls in the rolls longitudinal
direction.
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In yet another alternative configuration, the conveyor may comprise a
plurality of
rolling balls within or on the base plate of the container carrier 35 allowing
the one
or more storage containers 106 to roll on top of the balls. With this
configuration, and
with no side walls present, the storage container 106 may be moved in any
direction
above the base plate.
Perspective views of an automated storage and retrieval system are shown in
Fig. 9
A and B. The inventive system comprises storage grid 104 and a delivery system
140
including the above described delivery vehicle 30.
The storage grid 104 is equal or similar to the prior art storage grid 104 as
described
above, i.e. a storage grid 104 comprising a rail system 108; a plurality of
stacks 107
of storage containers 106, a plurality of container handling vehicles 300 for
lifting
and moving storage containers 106 stacked in the stacks 107 and a delivery
column
119,120 configured to receive a storage container 106 from a container
handling
vehicle 300.
The rail system 108 comprises a first set of parallel trails 110 arranged in a
horizontal
plane (P) and extending in a first direction (X) and a second set of parallel
rails 111
arranged in the horizontal plane (P) and extending in a second direction (Y)
which is
orthogonal to the first direction (X). The first and second sets of rails 110,
111 form
a grid pattern in the horizontal plane (P) comprising a plurality of adjacent
grid cells
122. Each grid cell 122 displays a grid opening defined by a pair of
neighboring rails
of the first set of rails 110 and a pair of neighboring rails of the second
set of rails
111.
The plurality of stacks 107 are arranged in storage columns 105 located
beneath the
rail system 108, wherein each storage column 105 is located vertically below a
grid
cell 122.
Each container handling vehicle 200,300 is configured to move on the rail
system 108
above the storage columns 105.
Further, the delivery system 140 comprises one or more of the delivery
vehicles 30
as described above, i.e. delivery vehicles 30 configured to receive and
support one or
more storage containers 106 for transport between one or more delivery columns
119,120 and one or more predetermined positions outside the storage grid 104.
The
predetermined positions may for example be a second location or a conveyor
line or
a transport vehicle such as a truck.
The delivery system 140 may further comprise a delivery rail system 50
situated
below a delivery port 150 of the one or more delivery columns 119,120.
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As shown in Fig. 9 A-B, the delivery rail system 50 may be constructed in the
same
way or a similar way as the rail system 108 for the container handling
vehicles
200,300.
Hence, the delivery rail system 50 may comprise a first set of parallel rails
51
arranged in a horizontal plane (P 1 ) and extending in a first direction (X),
and a second
set of parallel rails 52 arranged in the horizontal plane (P 1 ) and extending
in a second
direction (Y) which is orthogonal to the first direction (X).
The delivery may also be a double rail system, as is shown in Fig. 2B, thus
allowing
a delivery vehicle 30 having a footprint generally corresponding to the
lateral area
defined by a delivery grid column to travel along a row of grid columns even
if
another delivery vehicle 30 is positioned above a grid column neighboring that
row.
Both the single and double rail system, or a combination comprising a single
and
double rail arrangement in a single rail system, forms a grid pattern in the
horizontal
plane P1 comprising a plurality of rectangular and uniform grid locations or
grid cells,
where each grid cell comprises a grid opening being delimited by a pair of
rails of the
first rails and a pair of rails of the second set of rails.
The pair of rails in the X-direction defines parallel rows of delivery grid
cells running
in the X direction, and the pairs of rails in the Y direction defines parallel
rows of
delivery grid cells running in the Y direction.
Accordingly, each delivery grid cell has a width W, which is typically within
the
interval of 30 to 150 cm, and a length Lc which is typically within the
interval of 50
to 200 cm. Each grid opening 115 has a width W, and a length L, which is
typically
2 to 10 cm less than the width K and the length Lc of the delivery grid cell.
The delivery rail system 50 can be fully or partly integrated into the storage
grid 104.
However, it is considered advantageous for ensuring an effective operation
that the
delivery rail system 50 has a horizontal extent that covers a delivery port
150 below
at least one of the delivery columns 119,120.
Fig. 9 A and B shows a delivery rail system 50 extending from a location
inside the
storage grid 104 to a location outside the storage grid 104. One or more
second
locations, i.e. a structure for picking and placing items in the storage
containers 106,
may be arranged somewhere at the periphery of the part of the delivery rail
system
50 located outside the storage grid 104. Alternatively, or in addition, a
conveyor may
be arranged at or near the same periphery of the delivery rail system 50.
Figure 10 A-B shows the inventive automated storage and retrieval system in a
larger
scale, where a plurality of delivery columns 119,120 with their respective
delivery
ports are arranged at different locations within the storage grid 104.
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The delivery rail system 50 may be arranged such that it connects the
plurality of
delivery columns 119,120 provided at the different locations within the
storage grid
104.
In the particular system shown in Fig. 10 the delivery rail system 50 may be
divided
into three interconnected zones, where a first zone is located within a first
part of the
storage grid 104, a second zone is located within a second part of the storage
grid
104, and an intermediate zone is located outside the storage grid 104 and
allows the
delivery vehicles 30 to move from the first zone to the second zone. The first
and
second zones are divided by a plurality of storage columns 105.
Figure 11 A shows a plurality of delivery columns 119,120 of a storage grid
104.
Each delivery column 119,120 is arranged with a delivery port 150 located at
the
lowermost level/end of the delivery column 119,120.
A side view of the automated storage and retrieval system us shown in Figure
11 B.
The system 1 comprises an automated storage and retrieval grid 104 and a
delivery
system 140. The delivery system 140 comprises a delivery vehicle 30 adapted to
move
on a delivery rail system 50 located below a delivery port 150 of a delivery
column
119,120 of a storage grid 104 (Figure 11 A). A container handling vehicle
200,300
operates on a rail system 108 for pick-up and drop-off of storage containers
through
the delivery column 119,120. The delivery vehicle 30 is operated such that it
can
receive or deliver a storage container 106 to the delivery port 150. The
container
storage columns 105 are shown in the figures 9-11 contain no storage
containers 106.
In operation, the storage columns 105 are filled, or almost filled, with
storage
containers 106 stacked one on top of another.
The delivery system may benefit from many of the considerations provided for
the
rail system 108 and the container handling vehicles 200,300 of the storage
grid 104.
As shown in figure 10 and lithe upright members 102 of the storage grid 104
are
finished short and suspended on a mezzanine level 151 which itself has upright
posts
152 that may be stepped out from the delivery columns 119,120, typically to a
horizontal position located adjacent to the position of the vertical side
walls of the
rails 110,111 framing the corresponding grid cell 122. Consequently, the
adoption of
the delivery system 140 may result in a slight loss of storage space in the
storage grid
104. However, the benefit is increased delivery efficacy of storage containers
106 in
the automated storage and retrieval system 1 since the congestion of the
storage
containers 106 at the delivery columns 119,120 is avoided or at least reduced.
The
number of delivery columns 119,120 and the size of the mezzanine level 151
(its
extent) in the X and Y direction may be customized according to the size of
the
storage system and the desired efficiency of the system.
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Fig. 12 shows the delivery rail system 50 as a double track rail system, i.e.
identical
to the double track rail system of the container handling rail system 108
disclosed in
Fig. 2C. As for the container handling rail system 108, each delivery vehicle
grid cell
53 has a width K which is typically within the interval of 30 to 150 cm, and a
length
5 L, which is typically within the interval of 50 to 200 cm. Each delivery
vehicle grid
opening 54 has a width Wo and a length L, which is typically 2 to 10 cm less
than the
width W, and the length L, of the grid cell 53.
In the X and Y directions, neighboring delivery vehicle grid cells 53 are
arranged in
contact with each other such that there is no space there-between.
10 In the preceding description, various aspects of the delivery vehicle
and the
automated storage and retrieval system according to the invention have been
described with reference to the illustrative embodiment. For purposes of
explanation,
specific numbers, systems and configurations were set forth in order to
provide a
thorough understanding of the system and its workings. However, this
description is
15 not intended to be construed in a limiting sense. Various modifications
and variations
of the illustrative embodiment, as well as other embodiments of the system,
which
are apparent to persons skilled in the art to which the disclosed subject
matter
pertains, are deemed to lie within the scope of the present invention.
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Reference numerals:
30 Delivery vehicle
31 Vehicle body
32 Rolling device
32a First set of wheels
32b Second set of wheels
35 Container carrier
36 Rolls
37,37' Delivery vehicle footprint
41 Displacement device
42 Tilt motor
43 Power source
44 Controller
45 Lifting arm
46 Support element
47 Actuator lever
50 Delivery rail system
51 First set of parallel rails
51a First neighboring rail of first set
lb Second neighboring rail of first set
52 Second set of parallel rails
52a First neighboring rail of second set
52b Second neighboring rail of second set
53 Delivery vehicle grid cell
54 Delivery vehicle grid opening
P1 Horizontal plane of delivery rail system
100 Framework structure
102 Upright members of framework structure
103 Horizontal members of framework structure
104 Storage grid / three-dimensional grid
105 Storage column
106 Storage container
107 Stack
108 Rail system / Container handling vehicle rail system
110 First set of parallel rails in first direction (X)
110a First neighboring rail of first set
110b Second neighboring rail of first set
111 Second set of parallel rails in second direction (Y)
111a First neighboring rail of second set
111b Second neighboring rail of second set
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115 Grid opening / Container handling vehicle grid opening
119 Delivery column
120 Delivery column
122 Grid cell / Container handling vehicle grid cell
140 Delivery system
150 Delivery port
151 Mezzanine level
152 Upright post
200 First container handling vehicle
201 Wheel arrangement
202,202' Container handling vehicle footprint
300 Second container handling vehicle
301 Wheel arrangement
X First direction
Y Second direction
P Horizontal plane of rail system
Wo Width of container handling vehicle grid opening
Wc Width of container handling vehicle grid cell
Lo Length of container handling vehicle grid opening
Lc Length of container handling vehicle grid cell
Wod Width of delivery vehicle grid opening
Wcd Width of delivery vehicle grid cell
Lod Length of delivery vehicle grid opening
Lcd Length of delivery vehicle grid cell
