PRODUCT HANDLING SYSTEM

Abstract

A coupler includes a coupler frame, a handle, a first container gripper paddle, a second container gripper paddle, and an actuator system. The coupler frame includes a lower coupler frame face and an upper coupler frame face. The handle protrudes from the upper coupler frame face for releasable connection to an operative end of a robotic picking device. The first and second container gripper paddles are connected to the coupler frame for releasable connection to a container and arranged at opposite sides a centre plane oriented perpendicular to the lower coupler frame face. Each of the container gripper paddles includes a gripper protrusion located below the lower coupler frame face for insertion into a corresponding recess or aperture accessible within an inner volume of the container. The actuator system is for displacing the first and second container gripper paddles in opposite directions from the centre plane until the gripper protrusions have been removably inserted into the corresponding recesses or apertures.

Claims

1. A coupler comprising: a coupler frame comprising a lower coupler frame face and an upper coupler frame face, a handle protruding from the upper coupler frame face for releasable connection to an operative end of a robotic picking device, a first container gripper paddle and a second container gripper paddle, wherein the first and second container gripper paddles are connected to the coupler frame for releasable connection to a container and arranged at opposite sides a centre plane oriented perpendicular to the lower coupler frame face, wherein each of the container gripper paddles comprises a gripper protrusion located below the lower coupler frame face for insertion into a corresponding recess or aperture accessible within an inner volume of the container, and an actuator system for displacing the first and second container gripper paddles in opposite directions from the centre plane until the gripper protrusions have been removably inserted into the corresponding recesses or apertures.

2. The coupler in accordance with claim 1, wherein the actuator system comprises: a motor, a control system configured to control operation of the motor, and a displacement mechanism interconnecting the motor and the container gripper paddles.

3. The coupler in accordance with claim 2, wherein the displacement mechanism comprises; a first link connected at one end to the motor and the other end to one of the first and second container gripper paddles, and a second link connected at one end to the motor and the other end to the other of the first and second container gripper paddles, wherein the motor is configured to displace the first and second links.

4. The coupler in accordance with claim 3, wherein the displacement actuator further comprises: a rotary element connecting the first and second links to a rotary shaft of the motor, wherein the motor, the rotary element and the first and second links are configured such that the opposite directed displacements are achieved by rotating the rotary element clockwise or counterclockwise between 0 degrees and 180 degrees.

5. The coupler in accordance with claim 1, wherein the coupler further comprises a container abutment face for abutting an upper edge of the container, and wherein the actuator system is arranged above the container abutment face.

6. The coupler in accordance with claim 1, wherein each of the container gripper paddles comprises; an upper end pivotably connected to the coupler frame.

7. The coupler in accordance with claim 1, wherein the lower coupler frame face is rectangular with a width and a length, and wherein the gripper protrusions are aligned on a centre axis parallel to the lower coupler frame face and centered along the face's width or length.

8. The coupler in accordance with claim 1, wherein the coupler further comprises; a container sensor configured to sense when the lower coupler frame face is in contact with, and/or in proximity to, an opening frame of the container.

9. The coupler in accordance with claim 1, wherein the handle comprises a resilient mechanism allowing damping motion between the operative end of the robotic picking device and the coupler after connection.

10. A product handling system comprising: a storage and retrieval system for storing storage containers, a control system, a robotic picking device in signal communication with the control system, the robotic picking device comprising: a robotic base, a first robotic segment connected to the robotic base, and an operative end, a coupler connected to the operative end, the coupler comprising: a coupler frame comprising a lower coupler frame face and an upper coupler frame face, a handle protruding from the upper coupler frame face for releasable connection to an operative end of a robotic picking device, a first container gripper paddle and a second container gripper paddle, wherein the first and second container gripper paddles are connected to the coupler frame for releasable connection to a container and arranged at opposite sides a centre plane oriented perpendicular to the lower coupler frame face, wherein each of the container gripper paddles comprises a gripper protrusion located below the lower coupler frame face for insertion into a corresponding recess or aperture accessible within an inner volume of the container, and an actuator system for displacing the first and second container gripper paddles in opposite directions from the centre plane until the gripper protrusions have been removably inserted into the corresponding recesses or apertures, and an access and distribution station configured to deliver a storage container from within the storage and retrieval system, wherein the robotic base is arranged at a distance to allow the operative end to be moved to a position at least within reach of the storage container is to be delivered to the access and distribution station.

11. The product handling system in accordance with claim 10, wherein the first robotic segment is rotatably connected to the robotic base with a rotational robotic base axis or movably connected to the robotic base along at least a direction parallel to a floor onto which the storage and retrieval system is supported or a combination thereof.

12. The product handling system in accordance with claim 10, wherein the access and distribution station comprises: a storage system access opening through which a storage container may be transported between a storage location within the storage and retrieval system and an external area of the storage and retrieval system, and a conveyor having one end arranged adjacent to the storage system access opening, and wherein the robotic picking device is configured such that the operational end may be positioned at a location and an orientation allowing the coupler to retrieve a delivery container from within the storage container from the storage system access opening and that the retrieved delivery container may be placed onto the conveyor.

13. The product handling system in accordance with claim 10, wherein the storage and retrieval system comprises; a framework structure comprising a plurality of vertical upright members defining a plurality of storage columns for storing stacks of storage containers and at least one port column for transporting a storage container to the access and distribution station, a rail system arranged on the framework structure, the rail system comprising perpendicular tracks, the intersections of which form a grid having grid cells defining grid openings into the plurality of storage columns, and a remotely operated vehicle comprising drive means configured to travel along the rail system and a storage container lifting device for storing and retrieving storage containers through the grid openings.

14. A method for handling a delivery container by use of a product handling system in accordance with claim 10, wherein the method comprises; A. moving the operative end of the robot picking device with the coupler to a position in which the coupler may connect to the delivery container, B. connecting the coupler to the delivery container and C. raising the coupler with the delivery container connected thereto.

15. The method in accordance with claim 14, wherein the delivery container to be connected is stored within a storage container and wherein the method further comprises: transporting, prior to step A, the storage container with the delivery container stored therein from the storage and retrieval system to an external area through a storage system access opening, and raising, during step C, the operative end such that a lowermost part of the delivery container is higher than the uppermost part of the storage container.

16. The method in accordance with claim 15, wherein the method further comprises; placing, after step C, the delivery container onto a conveyor having one end arranged adjacent to the storage system access opening, and transporting the delivery container by use of the conveyor away from the storage system access opening.

17. The method in accordance with claim 14, wherein the method further comprises; transporting an incoming delivery container to the storage system access opening, moving the operative end of the robotic picking device with the coupler to a position in which the coupler may connect to the incoming delivery container, connecting the coupler to the incoming delivery container, moving the incoming delivery container to a position above a storage container to be stored within the storage and retrieval system, and placing the incoming delivery container into the storage container.

18. A computer-readable medium having stored thereon a computer program comprising instructions to execute a method for handling a delivery container by use of a product handling system comprising: a storage and retrieval system for storing storage containers, a control system, a robotic picking device in signal communication with the control system (600), the robotic picking device comprising: a robotic base, a first robotic segment connected to the robotic base, and an operative end, a coupler connected to the operative end, the coupler being in accordance with any one of the preceding claims, and an access and distribution station configured to deliver a storage container from within the storage and retrieval system, wherein the robotic base is arranged at a distance to allow the operative end to be moved to a position at least within reach of the storage container is to be delivered to the access and distribution station, wherein the method comprises: A. moving the operative end of the robot picking device with the coupler to a position in which the coupler may connect to the delivery container, B. connecting the coupler to the delivery container, and C. raising the coupler with the delivery container connected thereto.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0083] The following drawings depict exemplary embodiments of the present invention and are appended to facilitate the understanding of the invention. However, the features disclosed in the drawings are for illustrative purposes only and shall not be interpreted in a limiting sense.

[0084] FIG. 1 is a perspective view of an automated storage and retrieval system.

[0085] FIG. 2 is a perspective view of a prior art container handling vehicle having a cantilever for carrying storage containers underneath.

[0086] FIG. 3 is a perspective view of a prior art container handling vehicle having a centrally arranged cavity for carrying storage containers therein.

[0087] FIG. 4 is a perspective view of a prior art container handling vehicle having an internally arranged cavity for carrying storage containers therein, wherein the cavity is offset from center relative to the X-direction.

[0088] FIG. 5 is a side view of a coupler with a delivery container, the coupler being in accordance with a first embodiment of the invention connected thereon, where FIG. 5A and FIG. 5B shows the coupler in a released and connected position, respectively.

[0089] FIG. 6 is a perspective side view of the coupler shown in FIG. 5.

[0090] FIG. 7 is a perspective view of a product handling system for handling delivery containers using a coupler in accordance with a first embodiment of the invention.

[0091] FIG. 8 is another perspective view of the inventive product handling system of FIG. 7.

[0092] FIG. 9 is a perspective view of an operative end of a robotic picking device constituting part of the inventive product handling system of FIGS. 7 and 8 and an inventive coupler connected thereon.

[0093] FIG. 10 are perspective views of a second example of a product handling system for handling delivery containers, wherein FIG. 10A and FIG. 10B shows the delivery container in a stored and lifted position, respectively.

[0094] FIG. 11 is a perspective view of an operative end of a robotic picking device constituting part of the product handling system of FIG. 10 connected to a coupler.

DETAILED DESCRIPTION OF THE INVENTION

[0095] In the following, different embodiments 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 scope of 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 methods as well, and vice versa.

[0096] FIGS. 5 and 6 show an embodiment where a tote contacting face 17 of a coupler 1 is abutting an opening frame/rim 22 of a delivery container 20, hereinafter called a tote. In the particular embodiment depicted in the figures, the coupler 1 includes a coupler frame 2 comprising a rectangular, horizontal coupler plate 2a having an lower coupler frame face 2 and an upper coupler frame face 2, tote abutment sensors 16 extending downwards from the corners of the coupler plate 2a and angled coupler plates 2b arranged between the coupler plate's corners and extending downwards from rims/boundaries of the coupler plate 2a.

[0097] The purpose of the abutment sensors 16 is to register abutment with the rim 22 of the tote 20 and may e.g. be mechanical sensors such as pressure activated sensors or electronical proximity sensors. In the former case, the extent of the tote abutment sensors 16 should be equal or longer than the extent of the angled coupler plates 2b, thereby ensuring that the tote abutment sensors 16 exerts pressure on the rim 22 at contact and/or detect proximity.

[0098] Furthermore, the coupler frame 2 comprises two upper blocks 2 fixed on opposite sides on the coupler plate 2a.

[0099] In the particular case where the tote 20 should be picked up from, or inserted into, a storage container 106, hereinafter called a bin, being higher and slightly wider than the tote 20, at least part of the angled coupler plates 2b may advantageously be slanted inwards in order to avoid undesired abutment between the plates' 2b rim and an upper rim of the bin 106 defining its opening.

[0100] The coupler 1 further comprises two container gripper paddles 3 (a first paddle 3a and a second paddle 3b), hereinafter called tote paddles, where each tote paddle 3a,3b has a gripper protrusion 3 at the lower end such as a ledge, rib or fold, and where the upper end 3 of each paddle 3 is attached pivotally and/or resiliently to respective upper blocks 2. If the upper blocks 2 are arranged on the upper face 2 as depicted in FIGS. 5 and 6, the coupler plate 2a should be designed with through-going openings having a position and size to allow sufficient horizontal movements of the tote paddles 3. Moreover, the tote paddles 3 are arranged such that the protrusions 3 are located at vertical height(s) of recesses/apertures 21 within inner walls of the tote 20 when the coupler frame 2 is abutting the opening frame/upper rim 22 of the tote 20.

[0101] An actuator system 5-9, which also forms part of the coupler 1, is arranged at least partly within the volume set by the lower face 2 of the horizontal coupler plate 2a and the angled coupler plates 2b. The actuator system 5-9 is configured such that it may displace the first and second tote paddles 3a,3b in opposite directions by remote operation. The actuator system 5-9 may alternatively be protruding partly or fully from said volume.

[0102] In the particular embodiment shown in FIGS. 5 and 6, the actuator system 5-9 includes a motor 5, a control system 7 allowing control of the operation of the motor 5 and signal communication with a control system 600, a rotary disc 6 connected to the motor 5 and two links/displacement arms 9a,9b connecting the rotary disc 6 to each of the tote paddles 3a, 3b.

[0103] The motor 5, the rotary disc 6 and the control system 7 are fixed to the lower face 2 of the coupler plate 2a by a motor support 8 in the form of an angle bracket. The motor 5 may for example be a DC motor.

[0104] The two links/displacement arms 9a,9b are in FIGS. 5 and 6 configured and sized in the following way:

[0105] A first end of the first link 9a and a first end of the second link 9b are pivotably connected to the rotary disc 6 at opposite sides of the disc's 6 horizontal rotational axis, while a second end of the first link 9a and a second end of the second link 9b are pivotably connected to the first tote paddle 3a and the second tote paddle 3b, respectively.

[0106] The positions, angles and lengths of the tote paddles 3 are adjusted such that the protrusions 3 are aligned at the same vertical level as the gripping structure (recesses/apertures) 21 of the tote 20 when in the position shown in FIG. 5.

[0107] Furthermore, the actuator system 5-9 is configured such that the horizontal deflections of the tote paddles 3 are sufficient to switch the tote paddles 3 between a lock position where the protrusions 3 are inside the respective recesses/apertures 21 and a release position where the protrusions 3 are outside the respective recesses/apertures 21. In this way, a controllable gripping/releasing operation of the tote 20 is achieved.

[0108] As best seen in FIG. 5A and FIG. 5B, the particular configuration with opposite positioned first ends on the rotary disc 6 result in an equal displacement of the links 9a,9b, and a corresponding equal pivoting of the tote gripper paddles 3a,3b, when the motor 5 rotates the rotary disc 6 an angle necessary for achieving the desired gripping of the tote 20, preferably within a range of 70-100?, for example 90?.

[0109] The coupler 1 further comprises a handle 15 arranged on top of the coupler frame 2. In the particular embodiment shown in FIGS. 5-6, the handle 15 comprises vertical suspensions 15 attached at one end to the coupler frame 2 and a horizontal handle plate 15 to the opposite end.

[0110] FIGS. 7-8 show an example of a practical use of the above described coupler 1 in accordance with a first embodiment of a product handling system arranged adjacent a drop-off port column 119 of an automated storage and retrieval system 100.

[0111] Alternatively, or in addition, such a product handling system may be arranged on top of the automated storage and retrieval system 100, i.e. next to, or within, the rail system shown in FIG. 1.

[0112] This first embodiment product handling system comprises a robotic picking device 400 capable of picking up totes 20 inside bins 106 by use of the coupler 1, an access and distribution station 500 and a control system 600 enabling remote operation of the product handling system via suitable transmitters and sensors (not shown). The station 500 shown in FIGS. 7,8 and 10 includes a container basket 501 configured to temporarily store/hold a bin 106 and a storage system access opening 502 through which the container basket 501 may be guided, for example by use of a dedicated container basket displacement mechanism (not shown).

[0113] The station 500 may further include a conveyor system 503 located at least partly outside the framework 101 of storage and retrieval system 100. The conveyor system 503 may comprise a first conveyor belt 503a and a second conveyor belt 503b arranged parallel to each other. As illustrated in FIG. 7, by placing an end of each of the conveyor belts 503a,b next to the access opening 502, simultaneous transport of totes 20 to and from the container basket 501 is made possible, thereby increasing the overall efficiency of the product handling system. In FIG. 7, incoming totes are marked with reference sign 20.

[0114] In the alternative configuration where the robotic picking device 400 is arranged at the level of the rail system 108, such container basket 501 and access opening 502 would not be present since the robotic picking device 400 handles the totes 20 directly from within the respective bins 106. Any conveyor belts 503 may in such configurations extend between the rail system 108 and the tote delivery area such as the floor of the storage and retrieval system 100.

[0115] With particular reference to FIG. 8, the robotic picking device 400 comprises in this first embodiment [0116] a robotic base 401 fixed on a platform/floor 700 or on/at the rail system 108, [0117] a first robotic segment 402 connected with a vertical orientation to the robotic base 401 such that controlled horizontal displacement in direction to/from the storage system 100, or along one direction of the rail system 108, is achieved, [0118] a second robotic segment 403 connected with a horizontal orientation to the first robotic segment 402 such that controlled vertical displacement is enabled (i.e. perpendicular to the floor 700/rail system 108) and [0119] an operative end 405 connected at least indirectly to the second robotic segment 403.

[0120] The operative end/robotic gripper 405 is further configured to allow connection to the handle 15 of the coupler 1.

[0121] The orientations vertical/horizontal is hereinafter measured relative to the platform/floor 700 of the robotic base 401 when the robotic picking device 400 is arranged at the lower end of the drop-off port column 119 or relative to the rail system 108 when the robotic picking device 400 is arranged thereon. Note that the conveyor system 503 and/or the framework 101 of the storage volume of the storage and retrieval system 100 may be supported on the same platform/floor 700 or alternatively to other platforms arranged at different vertical levels. Note also that the rail system 108 and the platform/floor 700 are normally oriented parallel to each other.

[0122] The controlled horizontal and vertical displacements may be achieved by known displacement devices such as motorized linear actuators and/or hydraulic cylinders. The connecting end of the second robotic segment 403 may for example be guided along vertical rods forming part of the first robotic segment 402.

[0123] The robotic picking device 400 is further arranged such that the operative end 405 may be maneuvered to a position centered above the container basket 501 or alternatively above a tote containing bin 106 on top of a stack 107 in a storage column within reach of the operative end 405.

[0124] With the particular setup described above, and with the coupler 1 connected to the operative end 405 of the robotic picking device 400, any tote 20 stored within respective bin 106, which again may be stored within the container basket 501, can be picked up via remote operation of the coupler 1 and at least one of the first and second robotic segments 402,403. In the embodiment shown in the figures, this operation takes place when the container basket 501 has been placed in a pick-up position outside the access opening 502.

[0125] Note that the bins 106 designed to contain the totes 20 may stay within the container basket 501 at any time during operation or alternatively in the uppermost location within the storage column 105.

[0126] FIG. 9 shows in further detail the operating end 405 of the robotic picking device 400 in accordance with the first embodiment, where the operating end 405 is fixed to the handle 15 of the coupler 1. Due to the vertical suspensions 15, the abutment of the coupler 1 with the upper rim 33 of the tote 20 does not create excessive force onto the operating end 405 and/or the tote 20.

[0127] With reference to the vertical displacement between the first and second robotic segments 402,403, the coupling structure at the end of the second robotic segment 403 remote of the operating end 405 is depicted with vertical oriented tracks 403 to ensure stable and precise vertical guidance along vertical rods of the first robotic segment 402.

[0128] FIGS. 10-11 show a second embodiment a product handling system using the above-mentioned coupler 1. The second embodiment is near identical to the first embodiment in structure and operation except the use of another type of robotic picking device 400, namely a multi-joint type robotic picking device.

[0129] The multi-joint robotic picking device 400 comprises a robotic base 401 connected to a fixed platform/floor 700, a first robotic segment 402 rotatable connected to the robotic base 401, preferably with a vertical rotational axis C.sub.RB oriented perpendicular to the platform/floor 700, a second robotic segment 403 rotatably connected to the first robotic segment 402, preferably with a horizontal rotational axis oriented parallel to the platform/floor 700, a third robotic segment 404 rotatably connected to the second robotic segment 403, an operative end/robotic gripper 405 forming part of, or being rotationally coupled to, the third robotic segment 403 and the coupler 1 as described above connected, preferably removably, to the operative end/robotic gripper 405.

[0130] All of the joints, i.e. the rotatable connection points described above, are equipped with remotely and/or autonomously operated rotary mechanisms, thereby allowing the multi-joint robotic picking device 400 to pick up a tote 20 with product items 80 from within a bin 106, and place the tote 20 onto the first conveyor belt 503a transporting the tote 20 away from the framework 101 of the storage and retrieval system 100. Likewise, the multi-joint configuration allows the robotic picking device 400 to pick an empty tote 20 from the second conveyor belt 503b transporting the tote 20 towards the framework 101 and place the empty tote 20 into the bin 106. In the configurations shown in the figures, the particular bin 106 is arranged inside the container basket 501.

[0131] FIG. 11 shows in further details the connection of the coupler 1 with the operating end/robotic gripper 405.

[0132] In the preceding description, various aspects of the coupler for releasable coupling to a container, a product handling system using such a coupler, an automated storage and retrieval system and associated methods 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.

TABLE-US-00001 Reference numerals: 1 Coupler 2 Coupler frame 2a Horizontal coupler plate 2b Angled coupler plate 2 Lower coupler frame face/lower face 2 Upper coupler frame face/upper face 2 Upper end gripper block/upper block 3 Container gripper paddle/ Tote gripper paddle 3a First container gripper paddle/first paddle 3b Second container gripper paddle/ second paddle 3 Gripper protrusion 3 Upper end of gripper paddle/ upper end of tote paddle 5 Motor (for displacing gripper paddles 3) 6 Rotary disc (rotationally connected to motor 5) 7 Control system 8 Motor support/angle bracket 9 Gripper displacement means 9a First link 9b Second link 15 Handle/connection device 15 Resilient mechanism/vertical suspension 15 Handle plate 16 Delivery container sensor/tote abutment sensor 17 Container contacting face/tote contacting face 20 Delivery container/tote 20 Incoming delivery container/incoming tote 21 Gripping structure/formation within delivery container, recess/aperture 22 Opening frame of a delivery container/ rim/upper edge 80 Product items 100 Storage and retrieval system 101 Framework/storage grid 102 Upright members of framework structure 105 Storage column 106 Storage container/bin 106 Particular position of a storage container/ target storage container 107 Stack 108 Rail system 110 Parallel rails in first direction (X) 111 Parallel rail in second direction (Y) 112 Access opening 119 First port column/drop-off port column 120 Second port column/pick-up port column 200 Container handling vehicle with cantilever 201 Vehicle body of the vehicle 200 202a Drive means/wheel arrangement, first direction (X) 202b Drive means/wheel arrangement, second direction (Y) 210 Storage container lifting device 300 Container handling vehicle with internal cavity, occupying a single cell 301 Vehicle body of the vehicle 300 302a Drive means/wheel arrangement, first direction (X) 302b Drive means/wheel arrangement, second direction (Y) 350 Container handling vehicle with internal cavity, occupying more than a single cell 351 Vehicle body of the vehicle 350 352a Drive means/wheel arrangement, first direction (X) 352b Drive means/wheel arrangement, second direction (Y) 360 Storage container lifting device 362 Gripper element/claw 400 Robotic picking device 401 Robotic base 402 First robotic segment 403 Second robotic segment 403 Verticle tracks 404 Third robotic segment 405 Robotic gripper/operative end 500 Access and distribution station 501 Container support/container basket 502 Storage system access opening 503 Conveyor system 503a First conveyor belt 503b Second conveyor belt 600 Control system 700 Platform/floor X First direction Y Second direction Z Third direction C.sub.RB Rotational robotic base axis/vertical rotational axis