STORAGE SYSTEM, METHODS AND DEVICES

Abstract

A load handling device for operating in a storage system, a floor of the storage system including a network of tracks, or track network, based on a grid system, the tracks including a first set of track members extending in a first (x-) direction, and a second set of track members extending in a second (y-) direction, the second set of track members running transversely to the first set of track members in a substantially horizontal plane. The load handling device includes: a first set of wheels and a second set of wheels; and a support pad for receiving a storage container which support pad can be raised and or lowered in a vertical (z-) direction.

Claims

1. A load handling device configured for operating in a storage system, a floor of the storage system including a network of tracks, or track network, based on a grid system, the tracks including a first set of track members extending in a first (x-) direction, and a second set of track members extending in a second (y-) direction, the second set of track members running transversely to the first set of track members in a substantially horizontal plane, the load handling device comprising: a first set of wheels arranged for engaging with a track network having a first set of track members extending in a first direction; a second set of wheels arranged for engaging with a second set of track members extending in a second direction of the track network, wherein the load handling device is configured to be driveable in the first or second direction to any location on the track network; and a support pad for receiving storage container wherein the support pad is configured to be raised and or lowered in a vertical (z-) direction.

2. A load handling device according to claim 1, wherein the first set of wheels and or the second set of wheels comprise: two or more wheels on each side.

3. A load handling device according to claim 1, comprising: a suspension means for one or more of the wheels.

4. A load handling device according to claim 1, wherein the wheels are aligned in the first (x-) direction or aligned in the second (y-) direction and the wheels comprise: caster wheels.

5. A load handling device according to claim 1, comprising: a re-chargeable battery and or super capacitor for powering a drive motor; and inductive charging pads wherein the re-chargeable battery and/or super capacitor is charged through the inductive charging pads which are positioned on an underside of the load handling device.

6. A load handling device according to claim 1, comprising: a drive for having each or all the wheels of the first set of wheels and the second set of wheels.

7. A load handling device according to claim 1, comprising: locking means for locking one or more of the first set of wheels and the second set of wheels.

8. A load handling device according to claim 1, comprising: at least one or more of: a RFID reader; a scanner; and/or camera, for reading an identify tag or label.

9. A load handling device according to claim 1, wherein the load handling device in combination with a supported storage container, has a footprint that occupies only a single grid space in the storage system.

10. A load handling device according to claim 1, comprising: navigation means for monitoring and controlling motion along the track network.

11. A load handling device according to claim 1, comprising: a communication means for receiving instructions from a central control facility and for transmitting data.

12. A load handling device according to claim 1, comprising: a proximity sensor.

13. A control facility for controlling a load handling device according to claim 1, the control facility being configured for controlling the load handing device.

14. A method of using a storage system, a floor of the storage system including: a network of tracks, or track network, based on a grid system, the tracks including a first set of track members extending in a first (x-) direction, and a second set of track members extending in a second (y-) direction, the second set of track members running transversely to the first set of track members in a substantially horizontal plane, and at least one load handling device operating thereon, wherein the method comprises one or more steps of: lifting, transporting and depositing storage containers using a load handling device according to claim 1; depositing a storage container in a storage location; retrieving a storage container from a storage location; arranging storage containers in storage aisles according to required atmospheric conditions; and/or controlling the environment in storage aisles according to storage requirements of the storage container.

15. A load handling device according to claim 1, in combination with a storage system having a floor which comprises: a first set of track members extending in a first (x-) direction, and a second set of track members extending in a second (y-) direction, the second set of track members running transversely to the first set of track members in a substantially horizontal plane.

16. A control facility for controlling a load handling device according to claim 15, the control facility being configured for controlling the load handing device.

17. A load handling device according to claim 2, comprising a re-chargeable battery and or super capacitor for powering a drive motor; and inductive charging pads wherein the re-chargeable battery and/or super capacitor is charged through the inductive charging pads which are positioned on an underside of the load handling device.

18. A load handling device according to claim 17, comprising: a drive for having each or all the wheels of the first set of wheels and the second set of wheels.

19. A load handling device according to claim 18, comprising: navigation means for monitoring and controlling motion along the track network.

20. A load handling device according to claim 19, comprising: a communication means for receiving instructions from a central control facility and for transmitting data.

Description

[0157] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numerals are used for like features, and in which:

[0158] FIG. 1 is a representative drawing of a prior art storage system;

[0159] FIG. 2 is a representative drawing of a prior art storage system track arrangement;

[0160] FIG. 3a is a representative drawing of a prior art storage system load handling device;

[0161] FIGS. 3b and 3c are representative drawings of a prior art storage system load handling device with storage container;

[0162] FIG. 4 is a representative drawing of a prior art storage system with the load handling devices on a grid above the storage;

[0163] FIG. 5 illustrates the floor plan of the storage facility.

[0164] FIGS. 6 and 7 illustrate a portion of the storage floor shown in FIG. 5;

[0165] FIGS. 8 a-c illustrates a plan view of a long side, or y-z side, of a load handling device, with a storage container resting on the lifting pad;

[0166] FIGS. 9 a-c illustrates an elevation view of the short side, or x-z side, of the load handing device without a storage container and detailing the lifting pad;

[0167] FIG. 10 illustrates an elevation view of a short side, or x-z side, of a sub-chassis of the load handing device with the retaining flange removed;

[0168] FIGS. 11 a-c illustrates an elevation view of the long side, or y-z side, of the load handling device;

[0169] FIG. 12 illustrates a plan view of the underside, x-y, of the load handling device;

[0170] FIG. 13 is a schematic diagram of a controller for the storage system.

DETAILED DESCRIPTION OF DRAWINGS

[0171] The present invention may form part of a larger system. It will be appreciated that the system, methods and devices described herein are exemplary only, and other combinations and configurations of the apparatus and equipment described are anticipated by the inventors of the present disclosure without departing from the scope of the invention described here.

[0172] As noted above, FIGS. 1 to 4 are representative drawings of prior art storage systems.

[0173] The storage system, load handling devices, storage locations, methods of use and control facilities of the present invention are illustrated in the remaining drawings.

[0174] FIGS. 5-7 show schematic drawings of a storage floor. The storage floor is divided into a grid of units where each unit has a designated function. Aisles 2 are arranged across the width and length of the storage floor. Typically, access aisles 2 are two units wide and arranged across each end of the storage floor as shown in FIG. 3. Between the ends, the access aisles 2 are joined by storage aisles 2 running perpendicularly to the access aisles 2 and along the length of the storage floor. The storage aisles 2 are typically one unit wide. Adjacent to the storage aisles 2 are storage locations 1. The storage locations 1 may be accessed by load handling devices from either the access aisles 2 or the storage aisles 2.

[0175] As noted above, each storage location 1 is provided with trestles for supporting storage containers. When a load handling device is not transporting a storage container, the load handling device is able to move in x- and y-directions to any storage floor aisle or storage location, via any accessible route. However, the load handling device is able to move in one direction (x) through the storage locations, any attempt to traverse the storage location in the orthogonal direction could result in a collision between the load handling device and the support trestles.

[0176] As illustrated in FIG. 5, a maintenance area 3 is located through the centre of the designated storage location 1 area of the floor. Further maintenance areas 3 are located along the long sides of the floor and at some unit locations along the short sides of the storage floor. The short sides of the storage floor also provide grid unit locations for lay-bys, temporary storage, lift ingress positions, lift egress positions, lift shafts, and charging points. These maintenance areas 3 are not accessible by load handler devices and are not used for the repair of load hander devices.

[0177] FIGS. 6 and 7 show, in more detail, a portion of the storage floor as illustrated in FIG. 5.

[0178] FIG. 6 illustrates an end of the storage floor comprising two lift. As illustrated, the end row of the storage floor comprises two lift shafts 8. Adjacent to each lift shaft 8, on a first side is a lift ingress position 6 and a lift egress position 7. The lift ingress 6 and lift egress 7 are kept clear so that load handling devices may enter and leave the storage floor to be transported to other floors within the system. Between the lift areas, there is an additional maintenance area 3. The remainder of the unit locations along the end row of the storage floor alternative between lay-bys 4 and temporary storage locations 5 which may be used during operation of the system. Typically lay-bys 4 are used to allow load handling devices, unloaded or loaded with storage containers to pass when the aisles are congested. Lay-bys 4 may also be used to temporally locate malfunctioning load handing devices. Temporary storage locations 5 will typically comprise a pair of trestles. In this way, storage containers may be temporary placed on trestles while they await further transportation to other locations. It will be appreciated, that the temporary storage locations 5 are located relatively close to the lift shafts 8 so that they may be used as a waiting area for transportation between floors in the system. Temporary storage locations 5 may be used while load handling devices complete other tasks. Conveniently, as illustrated in FIGS. 3-5, temporary storage locations 5 arranged adjacent to access aisles which may be primarily used for transport.

[0179] FIG. 7 illustrates a corner of the opposite end of the storage floor, relative to FIG. 4, of FIG. 3. Similarly to the first end, for the majority of the end row, the grid unit locations alternate between lay-bys 4 and temporary storage locations 5. In addition, the end row comprises maintenance area 3 and charge point locations 9. Charge points locations 9 are used to re-charge the power resource of the load handling devices. Conveniently, the charge points 9, lay-bys 4 and temporary storage locations 5 are located adjacent to access aisles 2.

[0180] It will be understood that the specific layout of the storage floor may be adapted to the building in which it is located. The proportion of different types and use of unit grid locations may be adjusted according to availability and need. Further, it will be appreciated that other layouts of the storage floor are anticipated in order to provide a system which operates efficiently. The precise lay out will depend on, the total capacity required for the storage system and the size and shape of the building. Some sections of the storage floor may be divided by partition walls and controlling doors (not shown).

[0181] It will be appreciated that global or facility wide environmental control facilities may be located at the ends of the aisles, above the floor in the ceiling, or in maintenance areas.

[0182] FIG. 8-12 illustrate a load handing device 301 for use in the storage system. The load handing device 301 is used for lifting and depositing storage containers 200 in locations within the system. Further, the load handing device 301 is used to transport storage containers 200 between locations.

[0183] FIG. 8 illustrates a plan view of a long side, or y-z side, of a load handling device, with a storage containers resting on the lifting pad, in various configurations. In FIG. 8a the y-direction wheels 303 are deployed with the x-direction wheels held in a raised position, for forward and reverse movement in the y-direction. Typically, load handling devices will transit in y-direction in the configuration shown in FIG. 8a.

[0184] In FIG. 8b the x-direction wheels 307 wheels are deployed, with the y-direction wheel held in a raised position, for forward and reverse movement in the x-direction. Typically, load handling devices will transit in x-direction in the configuration shown in FIG. 8b. Although the storage containers support pad 308 is slightly raised in the configuration shown in FIG. 8b compared to the configuration shown in FIG. 8a, the bottom of the storage container 200, if carried, is still below the top of the trestles.

[0185] In this way, when carrying a storage containers 200 the load handling device may move along any unobstructed pathway along the track network 306—typically access aisles where no trestles are present. For example, to leave the storage containers 200 in a location having trestles such as a temporary storage location or a storage location, or to retrieve a storage containers 200 to transfer the storage containers to a new location.

[0186] If a load handling device is in transit without carrying or supporting a storage container 200, then it the load handling device may move along any pathway along the track network 306, in some cases beneath storage containers resting on trestles.

[0187] FIG. 8c shows the load handling device 301 of FIGS. 8a and 8b, between a pair of trestles 311. In this configuration, the support pad 310 and storage containers 200 are raised so that the bottom of the storage containers 200 is above the top of the trestles 311. In the configuration shown in FIG. 8c, the load handling device 301 can either move on to the next location, or lower the storage containers 200 on to the trestles 311 before moving away to the next task. How the support pad 310 moves from lowered and raised positions is discussed in more detail below, in connection with FIG. 9.

[0188] FIG. 9 illustrates a side elevation view of the short side, or x-z side, of the load handing device 301 without a storage containers 200, and showing the lifting pad 310 and mechanism in more detail.

[0189] FIG. 10 illustrates an elevation view of a short side, or x-z side, of the load handing device with the moving sub chassis removed. FIG. 20 illustrates an elevation view of the long side, or y-z side, of an alternate load handling device design where the lift of load (tray) support pad to clear the trestles is accomplished with a third electric or hydraulic ram (305), which is independent from the two direction change mechanism rams. FIG. 12 illustrates a plan view of the underside, x-y, of the load handling device.

[0190] As shown in FIG. 9a, a ram mounting 327 is mounted to the load handling device chassis. The ram 331 illustrated comprises a first stage 329 and a second stage 330, nested within the first stage 329. It will be appreciated that the ram 331 is of a telescoping type. The upper extremity of the second stage 330 is mounted to a sub-chassis 312. In this way, the sub-chassis 312 may move up and down with the ram 331. The sub-chassis 312 is contained within a retaining flange 317, 323 and guided with needle or roller bearing 324, shown in FIGS. 9 and 10.

[0191] In FIG. 9a, the ram 331 is fully compressed or nested and the wheels 307 are in an x-direction drive position, and the support pad 310 is at the maximum height. In FIG. 9b, the ram 331 is partially expanded or raised, and the wheels 307 are in a drive position, and the support pad 310 is at the minimum height for x-direction drive. In FIG. 9c, the ram 331 is fully extended and the wheels 307 are in a raised position (for y-direction drive by the wheels 303). In this way, the same mechanism is used to raise and lower the support pad 310 and control the x-y direction of the load handling device 301.

[0192] One or more displacement sensors 304, 326 may monitor the distance travelled by the load handling device in the y- and x-directions respectively.

[0193] FIG. 10 illustrates a side elevation view of a short side, or x-z side, of the load handing device with the moving sub chassis removed.

[0194] FIG. 11 illustrates a side elevation view of the long side, or y-z side, of an alternate load handling device design where the lift of storage container support pad to clear the trestles is accomplished with a third electric or hydraulic ram 305, which is independent from the two direction change mechanism rams.

[0195] FIG. 12 illustrates a plan view of the underside, x-y, of the load handling device 301. As may be seen, wheels 303 are arranged along the along the long sides of the device 301 for y-direction travel, and wheels 307 are arranged along the short sides of the device attached to the sub-chassis 312 held within the retaining frame 317. At the centre of the device 301 a camera 316 is positioned for monitoring the positioning and travel of the device 301.

[0196] FIG. 13 is a schematic diagram of a controller for the storage system. As noted above, the controller or control facility may comprise a number of software programs running on separate computing devices, interlinked by communication facilities. Any suitable architecture is anticipated as would be well understood by a person skilled in the art. Accordingly, the controller is shown as a number of separate modules.

[0197] S99 shows an Interface to the Storage & Retrieval Demand, to allow an operator or interfaced order management system to input desired actions of the system to be communicated to other modules of the system.

[0198] A is not shown. S1601 shows a Storage System Planner/Manager, to collectively manage the components of the storage system, to plan tasks to work towards desired outcomes of the system and to send instructions to other modules.

[0199] S1602 shows a Storage Container Task Manager, to plan and send instructions to load handling devices and workstations.

[0200] S1603 shows an Environment Controller Module to manage and control environmental parameters in aisles, on a storage floor and within chambers.

[0201] S1606 shows a Load Handling Device Charge State Manager Module, to schedule load handling devices visits charge points when necessary, to ensure that load handling devices are not re-tasked before they have adequate charge from the charge points, and to ensure the load handling devices are not selected to undertake a task for which they do not have adequate battery or supercapacitor charge.

[0202] S1607 shows a Recovery, Repair and Maintenance Manager Module, to manage the operational capability of the fleet of load handling devices and manage necessarily work to maintain functionality.

[0203] S1608 shows an Operator Interface, for users to link to components of the system to provide inputs for desired operations, data, and feedback to the operator.

[0204] S1609 shows a Load Handling Device Selection & Path Planning Module, to plan routes for load handling devices to complete tasks.

[0205] S1610 shows a Load Handling Device Path Clearance Module, to ensure that during execution of the planed routes do not conflict and are free of obstruction.

[0206] S1611 shows a Load Handling Device Communication Module, for receiving instructions from other modules and for transmitting data to other modules.

[0207] S1612 shows a Lift Task Planner Module, for providing capability to move load handling devices between floors.

[0208] S1613 shows a Lift communication Module, for receiving instructions from other modules and for transmitting data to other modules,

[0209] S1614 shows a Workstation Controller Module(s), for planning and executing tasks to process storage containers.

[0210] S1615 shows an Interface To Workstations, to allow for user input and communication from the system to automated workstations and to operators working at manual workstations.

Further Comments

[0211] It will be appreciated that, the storage system described herein provides a moderate to high density storage facility. Accordingly, the facility provides an efficient and cost effective use of land.

[0212] The vertical scalability of the facility is only limited by building technology or construction practices, rather than by the storage facility and system itself.

[0213] It will be appreciated that, advantageously, the storage arrangement is relatively simple in design, with minimal interaction or connectivity required between mechanical components. storage It may be possible to construct the facility within existing buildings, or within multi-function buildings.

[0214] It will be appreciated that the arrangement of storage locations advantageously provides for rapid or random access to each of the storage containers while maintaining a relatively high density of storage.

[0215] It will be appreciated that the number of storage locations on the side-aisles may be optimised based on the intended use.

[0216] It will be appreciated that the load handling devices are simple and accordingly may provide improvements in reliability compared with other systems.

[0217] It will be appreciated that the cost and or number of MHE requirement, or load handling devices, may be minimised by optimisation of the system's control facility.

[0218] It will be appreciated that control of temperature, humidity and gaseous composition eg. nitrogen concentration of the atmosphere on an aisle-by-aisle basis; or part of aisles e.g. galleries or chambers basis, may provide efficiencies and simplifications. Accordingly, a cost benefit may follow.

[0219] It will be appreciated that very large containers such as shipping containers are difficult to store and retrieve in a cubic storage and retrieval system such as described in the existing art. It will be appreciated that failure of a Z-lift hoist would require a difficult recovery of a container and or load handling device within the system. The substantially single layer system disclosed herein avoids this problem while providing a high density storage and retrieval system.

[0220] Advantageously, the system readily supports full automation at the workstations as the load handling devices provide conveyance through workstations. The workstation may be automated or robotic.

[0221] Within the system, fire suppression is easily engineered, and within storage areas firewalls are easily engineered, thereby improving the safety of the system.

[0222] The storage and retrieval system described above with reference to the figures allows control of the growing environment. In addition, the modular nature of the system allows for efficient use of space and is ready scalability. The length, width and height of the track grid system can be chosen to fit the available space.

[0223] Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and/or shown in the drawings, whether or not particular emphasis has been placed thereon.

[0224] It will be appreciated that a storage system, method and devices can be designed for a particular application using various combinations of devices and arrangements described above. It will be appreciated that the features described herein above may all be used together in a single system. In other embodiments of the invention, some of the features may be omitted. The features may be used in any compatible arrangement. Many variations and modifications not explicitly described above are possible without departing from the scope of the invention as defined in the appended claims.

[0225] In this document, the term “load handling device” and “bot” may be used interchangeably. The storage container may be a tray and the load handling device may be a tray handling device. The load handling device is a type of MHE or material handling equipment.

[0226] In this document, the language “movement relative to a gap” is intended to include movement within the gap, e.g. sliding along the gap, as well as movement into or out of a gap.

[0227] In this document, the language “movement in the n-direction” (and related wording), where n is one of x, y and z, is intended to mean movement substantially along or parallel to the n-axis, in either direction (i.e. towards the positive end of the n-axis or towards the negative end of the n-axis).

[0228] In this document, the word “connect” and its derivatives are intended to include the possibilities of direct and indirection connection. For example, “xis connected to y” is intended to include the possibility that x is directly connected to y, with no intervening components, and the possibility that x is indirectly connected to y, with one or more intervening components. Where a direct connection is intended, the words “directly connected”, “direct connection” or similar will be used. Similarly, the word “support” and its derivatives are intended to include the possibilities of direct and indirect contact. For example, “x supports y” is intended to include the possibility that x directly supports and directly contacts y, with no intervening components, and the possibility that x indirectly supports y, with one or more intervening components contacting x and/or y.

[0229] In this document, the word “comprise” and its derivatives are intended to have an inclusive rather than an exclusive meaning. For example, “x comprises y” is intended to include the possibilities that x includes one and only one y, multiple y's, or one or more y's and one or more other elements. Where an exclusive meaning is intended, the language “xis composed of y” will be used, meaning that x includes only y and nothing else.