AUTOMATED STORAGE SYSTEM WITH FRAMEWORK MOUNTED MODULAR PLATE SYSTEM AND BRACING ARRANGEMENT

Abstract

An automated storage and retrieval system includes a framework structure constructed of a plurality of upright members connected by horizontal members to define a storage grid of storage columns, within which storage columns may be stacked a plurality of storage containers. The framework structure has a rail system arranged at the upper level of the framework structure, with parallel rails in a first direction and parallel rails in a second direction perpendicular to the first direction, upon which rails a plurality of wheeled container handling vehicles travel. The container handling vehicles are equipped with a gripping and lifting device for removing storage containers from the storage columns and replacing the storage containers in the storage columns. The upright members of the framework structure have corner sections directed towards an interior of a particular storage column. The corner sections include two vertically elongated, perpendicular corner guiding plates. The corner guiding plates of the upright members are proximate to a storage column forming a guide for corners of the storage containers stored in that storage column A bracing system includes a plurality of plate members mounted between adjacent upright members. The bracing plate members include a plate segment removably mounted between two retaining profiles. Each retaining profile has a shape adapted to engage an upright member. The retaining profiles of the plate members have a box shape adapted to be securely inserted between and essentially occupy the space between the corner guiding plates of two adjacent corner sections of an upright member. A plate segment of plate member is arranged to be connected to a flange of the inserted retaining profiles. The bracing plate members are arranged to provide structural support stability for the framework structure. The guiding plates have inwardly projecting ribs that engage corresponding grooves of the retaining profiles by snap fit.

Claims

1. An automated storage and retrieval system comprising: a framework structure constructed of a plurality of upright members connected by horizontal members to define a storage grid of storage columns, within which storage columns may be stacked a plurality of storage containers, the framework structure having a rail system arranged at the upper level of the framework structure, with parallel rails in a first direction X and parallel rails in a second direction Y perpendicular to the first direction, upon which rails a plurality of wheeled container handling vehicles travel, the container handling vehicles equipped with a gripping and lifting device for removing storage containers from the storage columns and replacing the storage containers in the storage columns, wherein the upright members of the framework structure have corner sections directed towards an interior of a particular storage column, the corner sections comprising two vertically elongated, perpendicular corner guiding plates, the corner guiding plates of the upright members proximate to a storage column forming a guide for corners of the storage containers stored in that storage column, and a bracing system comprising, a. a plurality of plate members mounted between adjacent upright members, b. the bracing plate members comprising a plate segment removably mounted between two retaining profiles, each retaining profile having a shape adapted to engage an upright member, wherein retaining profiles of the plate members have a box shape adapted to be securely inserted between and essentially occupy the space between the corner guiding plates of two adjacent corner sections of an upright member, c. wherein a plate segment of plate member is arranged to be connected to a flange of the inserted retaining profiles, d. and further wherein the bracing plate members are arranged to provide structural support stability for the framework structure, e. And further wherein the guiding plates have inwardly projecting ribs that engage corresponding grooves of the retaining profiles by snap fit.

2.-4. (canceled)

5. An automated storage and retrieval system according to claim 1, wherein plate members comprise an X-shaped plate segment connected between two retaining profiles.

6. An automated storage and retrieval system according to claim 1, wherein vertically adjacent plate members are fastened together, and the lowermost plate member is fastened to a floor upon which rests the framework structure.

7. An automated storage and retrieval system according to claim 1, wherein plate segments have lower and upper flanges, and where the upper and lower flanges of vertically adjacent plate segments are fastened together.

8. An automated storage and retrieval system according to claim 1, wherein plate members have a lower offset lip portion arranged to overlap a vertically adjacent plate member and be fastened together.

9. An automated storage and retrieval system according to claim 1, wherein the modular plate system comprises a plurality of rail interface plates adapted to secure the modular plate system to the rail system of the framework structure, said rail interface plates having a lower part arranged to overlap the uppermost plate member, and be connected thereto with self boring screws.

10.-12. (canceled)

13. A method of stabilizing a framework structure (100) of an automated storage and retrieval system as described in claim 1, comprising: a. proving a plurality of bracing plate members comprising two retaining profiles and a plate segment removably connected therebetween; b. installing two retaining profiles between two adjacent upright members at the lowermost level of the framework, c. connecting the plate segment to the two installed retaining profiles; d. installing additional bracing plate members above the first plate member to a desired height along a storage column; and e. arranging the bracing plate members in a desired number and pattern to stabilize the framework.

14. The method according to claim 13, wherein the retaining profiles and the upright members have reciprocal shapes permitting a snap fit between the profiles and the upright members, and wherein the retaining profiles have a flange to which the plate segments are fastened.

15. A method of creating a functional zone in a framework structure of an automated storage and retrieval system as described in claim 1, comprising: a. proving a plurality of functional plate members comprising two retaining profiles and a plate segment removably connected therebetween; b. installing a first plate member by connecting two retaining profiles between two adjacent upright members at the lowermost level of the framework and connecting the plate segment to the two installed retaining profiles; c. installing additional functional plate members above the first plate member to a desired height along a storage column; and d. arranging the plate members in the desired number and pattern to create a desired functional zone.

16.-17. (canceled)

18. The method according to claim 15, wherein the plate members are installed in a construction area of the framework while the storage and retrieval system is in operation, comprising the step of directing the vehicles to avoid the construction area as the plate members are installed.

19. An automated storage and retrieval system according to claim 6, wherein vertically adjacent plate members are fastened together by bolts.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Following drawings are appended to facilitate the understanding of the invention. The drawings show embodiments of the invention, which will now be described by way of example only, where:

[0041] FIG. 1 is a perspective view of a framework structure of a prior art automated storage and retrieval system.

[0042] FIG. 2 is a perspective view of a prior art container handling vehicle having a centrally arranged cavity for carrying storage containers therein.

[0043] FIG. 3 is a perspective view of a prior art container handling vehicle having a cantilever for carrying storage containers underneath.

[0044] FIG. 4 is a perspective view of a framework structure an automated storage and retrieval system where a preferred modular plate system of the invention comprises bracing plate members that function as a stabilizing arrangement for the framework.

[0045] FIG. 5 is a detailed view from FIG. 4.

[0046] FIG. 6 is a cross sectional view of a preferred bracing plate member according to the invention.

[0047] FIGS. 7A and 7B are cross sectional perspective views of a bracing plate member installed in the upright members of the framework structure.

[0048] FIG. 8 is a detailed perspective view of retaining profiles of the plate members of the modular plate system inserted between adjacent container guiding plates of the upright members.

[0049] FIG. 9 is a perspective view showing the bottom of a bracing plate member attached to the bottom of the framework structure.

[0050] FIG. 10 is a perspective view showing vertically-adjacent bracing plate members attached to each other along their upper and lower edges.

[0051] FIG. 11 is a perspective exploded view illustrating the sides of the bracing plate members attached to the upright members.

[0052] FIG. 12 is an exploded view illustrating the attachments from FIGS. 10 and 11.

[0053] FIGS. 13a and 13b are perspective views showing rail interface plate for connecting the modular plate system to the rail system upon which storage container vehicles travel.

[0054] FIG. 14 is a perspective view of a preferred embodiment of the invention where the plate members of the modular plate system are functional plate members, for example, fire barrier plates, insulated plates and the like for forming functional zones in a framework structure of an automated storage and retrieval system.

DETAILED DESCRIPTION OF THE INVENTION

[0055] 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.

[0056] The framework structure 100 of the automated storage and retrieval system 1 is constructed in accordance with the prior art framework structure 100 described above in connection with FIGS. 1-3, i.e. a number of upright members 102 and a number of horizontal members 103, which are supported by the upright members 102, and further that the framework structure 100 comprises a first, upper rail system 108 in the X direction and Y direction.

[0057] The framework structure 100 further comprises storage compartments in the form of storage columns 105 provided between the members 102, 103, where storage containers 106 are stackable in stacks 107 within the storage columns 105.

[0058] The framework structure 100 can be of any size. In particular it is understood that the framework structure can be considerably wider and/or longer and/or deeper than disclosed in FIG. 1. For example, the framework structure 100 may have a horizontal extent of more than 700×700 columns and a storage depth of more than twelve containers.

[0059] 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 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.

[0060] One embodiment of the automated storage and retrieval system as well as other aspects of the present invention will now be discussed in more detail with reference to FIGS. 4-14.

[0061] FIGS. 4 and 5 show a framework structure 100 comprising a plurality of upright members 102. FIGS. 4 and 5 further illustrate framework structure 100 with a modular plate system 12 comprising a plurality of plate members 14 installed between adjacent upright members 102. In the embodiment illustrated in FIG. 4-13, the plate members 14 are bracing plate members 16. The term “bracing plate” as used herein means a plate member with a shape and configuration, and made of a material, specifically intended to provide structural stability to the framework, whereby a plurality of such bracing plates can provide sufficient stability that the framework does not need to be censured to an external structure. A sufficient number and placement of bracing members is installed in order to provide structural stability for the framework structure. As illustrated, the bracing plate members may be installed along an outside row of upright members 102, or may be installed between upright members located in the interior of the framework structure.

[0062] FIGS. 6 -13 illustrate bracing plate members 16 and the manner in which the plate members 14 in general are installed between upright members 102. As shown in FIG. 6 a plate member, in this instance a bracing plate member 16, comprises a plate segment 18 connected intermediate two retaining profiles 20. FIG. 11 shows the assembly of the plate segment to the retaining profiles in exploded view. As shown, retaining profiles 20 have a flange 21 to which plate segments 18 are connected, for example by bolts 30.

[0063] As shown in FIG. 9, plate segment 18, in the case of a bracing plate member 16, is a plate with preferably four essentially triangular cutouts 22 to form an X shaped pattern, although any shape that provides structural stability can be employed. Other examples of such shapes may be a plate with a plurality of circular cut outs, a plate in the shape of triangular struts, or a solid plate, however a plate with cutouts is preferred. Such cutouts reduce the weight of the plate segment, while the shape of the plate is designed to provide stability. For example the illustrated X shape is shown to provide excellent structural stability. The material of the plate segment 18 in the case of a bracing plate member 16 is preferably metal, most preferably aluminum. In the case where the plate member is a functional plate member, the plate segment 18 will be made of a material appropriate to the desired function. For example, a fire resistant plate member, and insulated plate member etc.

[0064] Retaining profiles 20 are preferably extruded aluminum profiles having a length equal to all of, or at least part of the length of the sides of the plate segment 18. Retaining profiles 20 have a cross sectional shape adapted specifically to fit between two adjacent container guiding plates 9 of corner sections 8, as shown in FIGS. 7A, 7B and 8. In one embodiment, upright members 102 are extruded aluminum profiles having a box shape that fits securely and essentially occupies the space between corner guiding plates 9, with corner guiding plates 9 being relatively thin extruded aluminum having a degree of flexibility whereby they may be slightly spread apart to permit insertion of retaining profiles 20. In one embodiment guiding plate 9 have an inwardly projecting rib 24. Retailing profiles 20 have two corresponding grooves 25 arranged to receive inwardly projecting ribs 24, thereby laterally securing the plate member between two upright members, for example in a snap fit manner. It should be understood that other sets of reciprocal shapes for the container guiding plates 9 and retaining profiles 20 could be employed that provide a secure engagement, provided that the retaining profiles 20 may easily attach to the upright members between adjacent container guiding plates.

[0065] As illustrated in FIG. 9, plate segment 18, at least in the embodiment where the plate member is a bracing plate member 16, comprises a lower flange 26. Lower flange 26 is equipped with a plurality of bolt holes 28, through which bolts 30 may be used to secure the bracing plate member to a floor 32 upon which the framework structure rests. Other attachment means could also be employed. As will be discussed in connection with another embodiment of the invention below, the plate members may in some uses have a function other than or in addition to providing stability to the framework structure. Plate members with such additional or different function are herein referred to as “functional” plate members. In some embodiments it may not be necessary to bolt the functional plate members to the floor or to the framework structure.

[0066] The installation of the plate system is now described. It should be understood that the order of the following steps may be rearranged.

[0067] The plate system is installed by attaching two retaining profiles 20 to two adjacent upright members 102 at the lowest level of the framework structure. The retaining profiles 20 are connected to upright members 102 by inserting the retaining profiles between guide plates 9, which is possible due to the relative flexibility of guide plates 9. In one embodiment, guide plates 9 have ribs that snap into corresponding grooves in the retaining profiles.

[0068] As shown in FIG. 11, a plate segment is then connected to the retaining profiles 20 by bolts 30 through predrilled alignment holes in flange 21. The preinstallation of the retaining profiles, together with flange 21, provides easy access to attach the plate segment. The plate segment is then bolted to the floor through predrilled holes in a lower flange part 26.

[0069] A next highest plate member is then installed above the first installed plate member. In the case of a bracing arrangement the vertically adjacent plate members are preferably bolted together. FIG. 12A, and FIGS. 12B and 12C illustrate alternate embodiments for connecting the vertically adjacent plate members.

[0070] As shown in FIG. 12A, plate segments 18 in one embodiment are equipped with a lower flange 26 and an upper flange 34 that project at about 90 degrees. Vertically adjacent plate segments can thus be bolted together as shown in FIGS. 10 and 12 through predrilled, alignment holes. In an alternate embodiment shown in FIGS. 12B and C, plate segment 18 has an offset lip 35 arranged to overlap the adjacent plate segment 18.

[0071] In order to attach the modular plate system 12 to the upper rail system 108 of the framework 100, at least in the case where the plate system has a stabilizing function, a rail interface plate 36 is provided as shown in FIGS. 13A and B. Rail interface plate 36 has an offset upper portion 38 arranged to engage with and be connected to rail system 108 and a lower part 37 arranged to overlap the uppermost plate member 16. Self boring screws 40 are used to secure the lower part 37 of interface plate 36 to the uppermost plate member 16 rather than employing predrilled holes, since misalignment or height differences would often prevent the upper holes from aligning properly. The self boring screws allow any height difference or other misalignment of the framework structure to be accounted for by the interface plates. As discussed below, in the case where the plate members 14 have a function which does not have to provide stabilization, it may not be necessary to secure the modular plate system 12 to the rail system 108.

[0072] As can be appreciated by FIGS. 5-13, the present invention according to one aspect provides a method for stabilizing the framework structure of an automated storage and retrieval system. According to the method, a plurality of bracing plate members 16 are installed, comprising plate segments 18 attached between two retaining profiles 20. Retaining profiles 20 are inserted between guide plates 9 of adjacent upright members 102 of an assembled framework structure 100 and plate segment 18 bolted to the retaining profiles. The lowermost bracing plate member is attached to floor 32 of the framework structure, and vertically adjacent bracing plate members are bolted together as shown in FIGS. 12A-C. At the uppermost level, rail interface plates 36 connect the plate system to rail system 108 with rail interface plates 36 and self boring screws 40 used to compensate for any misalignment of the framework structure.

[0073] FIG. 14 illustrates an embodiment of the modular plate system 12 where the plate members 14 are functional plate members 42, defined as plate members having a function other than or in addition to a stabilizing function. For example, the functional plate members 42 may be insulated plates having the function of creating a refrigerated zone in the storage and retrieval system. The functional plate members 42 may also be fire retardant plates having the function of creating a fire barrier. In this embodiment the plate segment 18 is made of or comprises a material appropriate for the given function, and attached between retaining profiles 20 as described above.

[0074] According to one aspect, the invention therefore provides a method of creating a functional zone 44 in a storage and retrieval system, by providing a plurality of functional plate segments 18 to form, together with retaining profiles 20, a plurality of functional plate members 42. The functional plate members 42 may be retrofitted to an existing storage structure, for example, in order to provide some new functionality or to reconfigure some previously installed functionality. A sufficient number of functional plate members 42 are installed between upright members 102 as described above in order to form the desired size and shape of the functional zone 44. Functional zone 44 may be, for example, an insulated zone, a refrigerated zone, a fire barrier or zone, a sound proof zone or any zone that may be defined by the functional nature of the plate members.

[0075] Since the functional plate members may not always perform a stabilizing function it may not be necessary to bolt the functional plate members 42 together and/or to the framework structure or floor as described above in all situations, although it should be understood that the functional plate members could also simultaneously have a stabilizing function, in which case bolting would be preferred. Because the functional plate members may be easily inserted into place, functional zones may be created, removed, resized and repurposed at will even in an operational storage system by programming the storage vehicles to avoid the area being created, resized or repurposed.

LIST OF REFERENCE NUMBERS

[0076] Prior Art (FIGS. 1-4):

[0077] 1 Prior art automated storage and retrieval system

[0078] 100 Framework structure

[0079] 102 Upright members of framework structure

[0080] 103 Horizontal members of framework structure

[0081] 104 Storage grid

[0082] 105 Storage column

[0083] 106 Storage container

[0084] 106′ Particular position of storage container

[0085] 107 Stack

[0086] 108 Rail system

[0087] 110 Parallel rails in first direction (X)

[0088] 110a First rail in first direction (X)

[0089] 110b Second rail in first direction (X)

[0090] 111 Parallel rail in second direction (Y)

[0091] 111a First rail of second direction (Y)

[0092] 111b Second rail of second direction (Y)

[0093] 112 Access opening

[0094] 119 First port column

[0095] 120 Second port column

[0096] 201 Prior art storage container vehicle

[0097] 201a Vehicle body of the storage container vehicle 201

[0098] 201b Drive means/wheel arrangement, first direction (X)

[0099] 201c Drive means/wheel arrangement, second direction (Y)

[0100] 301 Prior art cantilever storage container vehicle

[0101] 301a Vehicle body of the storage container vehicle 301

[0102] 301b Drive means in first direction (X)

[0103] 301c Drive means in second direction (Y)

[0104] 304 Gripping device

[0105] 500 Control system

[0106] X First direction

[0107] Y Second direction

[0108] Z Third direction

[0109] 8 Corner section

[0110] 9 Container guiding plate

[0111] 11 Corner of a storage container

[0112] 12 Modular plate system

[0113] 14 Plate members

[0114] 16 Bracing Plate member

[0115] 18 plate segment

[0116] 20 Retaining profiles

[0117] 21 Flange

[0118] 22 cutouts

[0119] 24 inwardly projecting rib

[0120] 25 groove

[0121] 26 lower flange

[0122] 28 bolt holes

[0123] 30 bolts

[0124] 32 floor

[0125] 34 upper flange

[0126] 36 Rail interface plate

[0127] 37 Lower part of interface plate

[0128] 38 offset upper portion of interface plate

[0129] 40 self boring screws

[0130] 42 functional plate member

[0131] 44 Functional zone