STORAGE SYSTEM, METHODS AND DEVICES

Abstract

A storage system is disclosed which includes: at least one storage floor having a track network, based on a grid system, the track network including a first set of track members extending in a first direction, and a second set of track members extending in a second direction, the second set of track 5 members running transversely to the first set of track members in a substantially horizontal plane. Storage aisles of the track network include storage locations for receiving storage containers. A load handling device operates on the track network for lifting and transporting storage containers. A storage location includes a support for supporting a storage container. A control facility controls and operates the storage system.

Claims

1-13 (canceled)

14. A storage system comprising: at least one storage floor including a track network, based on a grid system, the track network including a first set of track members extending in a first direction, and a second set of track members extending in a second direction, the second set of track members running transversely to the first set of track members in a substantially horizontal plane, wherein the track network includes access aisles and storage aisles, wherein the storage aisles include one or more storage locations for receiving storage containers; at least one load handling device configured for operating on the track network for lifting and transporting storage containers; and wherein a storage location includes a support means for supporting a storage container.

15. A storage system according to claim 14, wherein track network comprises: one or more temporary storage locations including support means for supporting a storage container.

16. A storage system according to claim 14, wherein the track network comprises at least one or more of: a charging bay, a passing lane, a siding; a lay-by, and/or a passing point

17. A storage system according to claim 14, comprising: partitioning means, wherein a floor of the storage system is divided by the partitioning means into chambers, and the partitioning means has openings or hatches through which load handling devices may pass.

18. A storage system according to claim 17, wherein the partitioning means comprise: a fire break means and/or wherein the partitioning means provide segregation between user access and robotic access within the storage system.

19. A storage system according to claim 14, comprising: two or more vertically arranged floors, wherein floors are interconnected by one or more lifts accessible from access aisles for transferring load handling devices between floors; and wherein floors include: at least one storage floor; and/or one or more sky-lobby floors for transferring between lifts.

20. A storage system according to claim 14, comprising at least one or more of: a control facility, environmental control facility means, safety systems, data collection means, data communication means, and/or communication systems.

21. A storage system according to claim 19, wherein each floor comprises: a maintenance area.

22. A storage system according to claim 21, wherein the maintenance area comprises: a mezzanine level above at least a portion of the storage locations.

23. A storage system according to claim 14, comprising: one or more work-stations, wherein each workstation includes at least one or more of a RFID reader, a scanner and/or a camera for reading an identity tag or label of a storage container.

24. A control facility for controlling and operating a storage system according to claim 14, wherein the control facility comprises at least one or more of: an environment control module; a task planner; a bot path planning module; a bot path clearance module; a communications module; a lift task planner; a bot charge state manager; a data storage and persistence module; a long term data storage module for providing data to machine learning algorithms ; a recovery, repair and or maintenance manager module to modify plans and schedules to facilitate recovery, repair and maintenance operations; and a machine learning and or artificial intelligence module configured and designed to fine tune the system based on its previous operational history.

25. A control facility according to claim 24, configured to control one or more of; air temperature, independently for one or more storage aisles, chambers or storage floors; air humidity, independently for one or more storage aisles, chambers or storage floors; gaseous composition of the atmosphere, independently for one or more storage aisles, or storage floors; and/or the control facility is configured to confirm a correct storage container is being handled at each stage; and/or the control facility is configured to create audit records of each operation on each storage container.

26. A load handling and/or recovery device for operating with a storage system which includes at least one storage floor including a track network, based on a grid system, the track network including a first set of track members extending in a first direction, and a second set of track members extending in a second direction, the second set of track members running transversely to the first set of track members in a substantially horizontal plane, wherein the track network includes access aisles and storage aisles, wherein the storage aisles include one or more storage locations for receiving storage containers, the load handling and/or recovery device being configured for operating on a track network for lifting and transporting storage containers; wherein a storage location comprises: a support means for supporting a storage container, the load handling and/or recovery device being configured to operate under control of a control facility which includes at least one or more of: a task planner; a bot path planning module; a bot path clearance module; a communications module; a lift task planner; a bot charge state manager; a data storage and persistence module; a long term data storage module for providing data to machine learning algorithms ; a recovery, repair and or maintenance manager module to modify plans and schedules to facilitate recovery, repair and maintenance operations; and a machine learning and or artificial intelligence module configured and designed to fine tune the system based on its previous operational history.

27. A storage system according to claim 15, wherein the track network comprises at least one or more of: a charging bay, a passing lane, a siding; a lay-by, and/or a passing point

28. A storage system according to claim 27, comprising: partitioning means, wherein the floor is divided by the partitioning means into chambers, and the partitioning means has openings or hatches through which bad handling devices may pass.

29. A storage system according to claim 28, wherein the partitioning means comprise: a fire break means and/or wherein the partitioning means provide segregation between user access and robotic access within the storage system.

30. A storage system according to claim 29, comprising: two or more vertically arranged floors, wherein floors are interconnected by one or more lifts accessible from access aisles for transferring load handling devices between floors; and wherein floors include: at least one storage floor; and/or one or more sky-lobby floors for transferring between lifts.

31. A storage system according to claim 20, comprising at least one or more of: a control facility, environmental control facility means, safety systems, data collection means, data communication means, and/or communication systems.

32. A control facility for controlling and operating a storage system according to claim 31, wherein the control facility comprises at least one or more of: an environment control module; a task planner; a bot path planning module; a bot path clearance module; a communications module; a lift task planner; a bot charge state manager; a data storage and persistence module; a long term data storage module for providing data to machine learning algorithms a recovery, repair and or maintenance manager module to modify plans and schedules to facilitate recovery, repair and maintenance operations; and a machine learning and or artificial intelligence module configured and designed to fine tune the system based on its previous operational history.

33. A control facility according to claim 32, configured to control one or more of: air temperature, independently for one or more storage aisles, chambers or storage floors; air humidity, independently for one or more storage aisles, chambers or storage floors; gaseous composition of the atmosphere, independently for one or more storage aisles, or storage floors; and/or the control facility is configured to confirm a correct storage container is being handled at each stage; and/or the control facility is configured to create audit records of each operation on each storage container.

Description

DETAILED DESCRIPTION OF DRAWINGS

[0169] 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.

[0170] As noted above, FIGS. 1 to 4 are representative drawings of prior art storage systems.

[0171] The storage system, load handling devices, storage locations, methods of use and control facilities of the present invention are illustrated in the remaining drawings.

[0172] 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.

[0173] 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.

[0174] 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.

[0175] FIGS. 6 and 7 show, in more detail, a portion of the storage floor as illustrated in FIG. 5.

[0176] 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.

[0177] 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.

[0178] 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).

[0179] 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.

[0180] 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.

[0181] 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.

[0182] 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.

[0183] In this way, when carrying a storage containers 200 the load handling device may move along any unobstructed pathway along the track network 306typically 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.

[0184] 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.

[0185] 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 FIGS. 9a-c.

[0186] FIGS. 9a-c 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. 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.

[0187] 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. 9a-c and 10.

[0188] 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.

[0189] One or more displacement sensors 304, 326 may monitor the distance travelled by the load handling device in the y- and x- directions respectively.

[0190] 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.

[0191] FIGS. 11a-c 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.

[0192] 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.

[0193] 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.

[0194] 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.

[0195] 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.

[0196] S1602 shows a Storage Container Task Manager, to plan and send instructions to load handling devices and workstations.

[0197] S1603 shows an Environment Controller Module to manage and control environmental parameters in aisles, on a storage floor and within chambers.

[0198] 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.

[0199] 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.

[0200] 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.

[0201] S1609 shows a Load Handling Device Selection & Path Planning Module, to plan routes for load handling devices to complete tasks.

[0202] 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.

[0203] S1611 shows a Load Handling Device Communication Module, for receiving instructions from other modules and for transmitting data to other modules.

[0204] S1612 shows a Lift Task Planner Module, for providing capability to move load handling devices between floors.

[0205] S1613 shows a Lift communication Module, for receiving instructions from other modules and for transmitting data to other modules,

[0206] S1614 shows a Workstation Controller Module(s), for planning and executing tasks to process storage containers.

[0207] 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

[0208] 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.

[0209] The vertical scalability of the facility is only limited by building technology or construction practices, rather than by the storage facility and system itself.

[0210] 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.

[0211] 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.

[0212] It will be appreciated that the number of storage locations on the side-aisles may be optimised based on the intended use.

[0213] It will be appreciated that the load handling devices are simple and accordingly may provide improvements in reliability compared with other systems.

[0214] 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.

[0215] 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.

[0216] 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.

[0217] 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.

[0218] Within the system, fire suppression is easily engineered, and within storage areas firewalls are easily engineered, thereby improving the safety of the system.

[0219] 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.

[0220] 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.

[0221] 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.

[0222] 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.

[0223] 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.

[0224] 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).

[0225] In this document, the word connect and its derivatives are intended to include the possibilities of direct and indirection connection. For example, x is 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.

[0226] 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 x is composed of y will be used, meaning that x includes only y and nothing else.