Abstract
A fall restraint device for moving on a grid structure including a plurality of grid cells each having a length in a range 600-800 mm and a width in a range 400-600 mm, so defining a grid opening defined by a pair of adjacent tracks of a first set of parallel tracks and a pair of adjacent tracks of a second set of parallel tracks. The fall restraint device includes a frame having an upper portion configured for restraining at least one operative, a moving assembly mounted to a lower portion of the frame, the moving assembly being configured for moving the frame on the grid structure; wherein the frame has a weight less than 100 kg such that the moving assembly will be manually lifted clear of the grid structure by the at least one operative restrained to the upper portion of the frame.
Claims
1-35. (canceled)
36. A fall restraint apparatus for manually moving on a grid structure including a first set of parallel tracks and a second set of parallel tracks running transversely to the first set in a substantially horizontal plane and arranged in a grid pattern including a plurality of grid cells, each grid cell having a length in a range 600-800 mm and a width in a range 400-600 mm so defining a grid opening defined by a pair of adjacent tracks of the first set of parallel tracks and a pair of adjacent tracks of the second set of parallel tracks; the fall restraint apparatus comprising: a frame having an upper portion and a lower portion, the upper portion being configured for restraining at least one operative; and a moving assembly mounted to the lower portion of the frame, the moving assembly being configured for moving the frame on the grid structure; wherein the frame has a weight less than 100 kg such that at least a portion of the moving assembly will, in operation, be manually lifted clear of the grid structure by the at least one operative restrained to the upper portion of the frame.
37. The fall restraint apparatus of claim 36, wherein the moving assembly comprises: a rolling assembly.
38. The fall restraint apparatus of claim 37, in combination with the first and second sets of parallel tracks arranged in a grid pattern of a grid structure, wherein the rolling assembly comprises: a front wheel assembly and a rear wheel assembly having at least one wheel assembly, each wheel assembly of the front wheel assembly and the rear wheel assembly extends across the at least one grid cell such that each wheel assembly of the front wheel assembly and the rear wheel assembly will contact different tracks of the grid structure such that the fall restraint apparatus will be operative to move in any direction on the grid structure; and optionally, wherein a length of each wheel assembly of the front wheel assembly and the rear wheel assembly is greater than a length corresponding to a diagonal length across a grid opening.
39. The fall restraint apparatus of claim 38, wherein the wheel assembly of the front wheel assembly and/or the rear wheel assembly comprises: at least one elongated roller.
40. The fall restraint apparatus of claim 38, wherein each wheel assembly of the front wheel assembly and rear wheel assembly comprises: a plurality of wheels, the plurality of wheels being configured and arranged so as to be rotatable about a common axis; and optionally, wherein each wheel of the plurality of wheels is separated by a distance less than a width of a track of the first and the second set of tracks.
41. The fall restraint apparatus of claim, 38, wherein the front wheel assembly is separated from the rear wheel assembly by a wheelbase having a length greater than the length across at least one grid cell.
42. The fall restraint apparatus of claim 40, wherein the plurality of wheels are mounted to at least one shaft.
43. The fall restraint apparatus of claim 37, wherein the rolling assembly extends outwardly of the upper portion.
44. The fall restraint apparatus of claim 38, wherein the at least one wheel assembly of the front wheel assembly and the at least one wheel assembly of the rear wheel assembly extends transversely to the longitudinal direction of the upper portion.
45. The fall restraint apparatus of claim 44, wherein the frame comprises: an assembly of frame members arranged to form an interior open structure for accommodating at least one operative wherein the at least one operative restrained by the upper portion is configured to, in operation, manually walk on the grid structure within the open interior space; and optionally wherein the upper portion includes a pair of parallel side frame members, the parallel side frame members being connected together by at least one end frame member substantially perpendicular to the parallel side frame members to define a handle, the handle being supported above the wheel assembly by a plurality of supports such that at least one operative will manually hold onto the handle when walking on the grid structure; and optionally, wherein the upper portion of the frame includes a suspension frame member or suspension beam extending across the pair of parallel side frame members for supporting at least one operative.
46. The fall restraint apparatus of claim 36, wherein the lower portion of the frame comprises: a sub-frame for supporting the moving assembly.
47. The fall restraint apparatus of claim 46, wherein the upper portion comprises: an assembly of H-frames.
48. The fall restraint apparatus of claim 36, wherein the upper portion of the frame comprises: A-frames, and a suspension frame member extending between the A-frames for supporting at least one operative.
49. The fall restraint apparatus of claim 48, wherein the frame comprises: a tow member configured for coupling or interfacing with a load handling device on the grid structure; and optionally, wherein the tow member is a tow bar having one end coupled to the upper portion of the frame and an other end configured for coupling or interface with a load handling device.
50. The fall restraint apparatus of claim 36, wherein the frame comprises: one or more anti-topple mechanisms either side of the frame configured for preventing toppling of the fall restraint apparatus on the grid structure, the one or more anti-topple mechanisms including a continuous stabilising surface extending between the front and rear wheel assemblies; and optionally, wherein the continuous stabilising surface includes one or more tethers tensioned between the front and rear wheel assemblies.
51. The fall restraint apparatus of claim 50, the frame comprising: a front end and an opposing rear end, the opposing rear end being wider than the front end and configured to allow a second fall restraint apparatus to be nested within the fall restraint apparatus.
52. A fall restraint apparatus of claim 38, in combination with an assembly, the assembly comprising: i) the first fall restraint apparatus: ii) a second fall restraint apparatus configured similar to the first fall restraint apparatus; and iii) a suspension beam or suspension frame member joining the first and second fall restraint apparatus together.
53. The assembly of claim 52, wherein the suspension beam or suspension frame member is mounted to the upper portion of the frame of each of the first and second fall restraint apparatus; and Optionally, wherein the suspension beam or suspension frame member is mounted to the upper portion of the first and/or second fall restraint apparatus by at least one pivotable joint; and optionally, wherein a winch is mounted to the suspension beam or the suspension frame member.
54. The fall restraint apparatus of claim 40, wherein a length of each wheel assembly of the front wheel assembly and the rear wheel assembly is greater than a length corresponding to a diagonal length across a grid opening; and wherein each wheel of the plurality of wheels is separated by a distance less than a width of a track of a first and a second set of tracks.
55. The fall restraint apparatus of claim 45, wherein: the upper portion includes a pair of parallel side frame members, the parallel side frame members being connected together by at least one end frame member substantially perpendicular to the parallel side frame members to define a handle, the handle being supported above the wheel assembly by a plurality of supports such that at least one operative will manually hold onto the handle when walking on the grid structure; and wherein the upper portion of the frame includes a suspension frame member or suspension beam extending across the pair of parallel side frame members for supporting at least one operative.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] Further features and aspects of the present invention will be apparent from the following detailed description of an illustrative embodiment made with reference to the drawings, in which:
[0044] FIG. 1 is a schematic diagram of a grid framework structure according to a known system.
[0045] FIG. 2 is a schematic diagram of a top down view showing a stack of bins arranged within the framework structure of FIG. 1.
[0046] FIG. 3 is a schematic diagram of a known robotic load handling device operating on the grid framework structure.
[0047] FIG. 4 is a schematic diagram of a load handling device according to a known system.
[0048] FIG. 5(a and b) are schematic perspective cut away views of the load handling device of
[0049] FIG. 4 showing (b) the container receiving space of the load handling device and (a) a container accommodating the container receiving space of the load handling device.
[0050] FIG. 6 is a perspective view of a fall restraint apparatus comprising a frame mounted to a rolling assembly according to an embodiment of the present invention.
[0051] FIG. 7(a and b) is a schematic drawing of a top plan view of a cell showing the dimensions of the grid cell opening.
[0052] FIG. 8 is a schematic top plan view of the rolling assembly of an embodiment of the present invention of the fall restraint apparatus travelling over the grid structure.
[0053] FIG. 9 is a schematic top plan view of the rolling assembly according to another embodiment of the present invention of the fall restraint apparatus travelling over the grid structure.
[0054] FIG. 10 is a perspective view of an elongated roller of a wheel assembly of the rolling assembly according to an embodiment of the present invention.
[0055] FIG. 11 is a perspective view of an operative restrained to the frame of the fall restraint apparatus via a harness according to an embodiment of the present invention.
[0056] FIG. 12 is perspective view of the fall restraint apparatus shown in FIG. 6 comprising a suspension beam and winch according to an embodiment of the present invention.
[0057] FIG. 13 is a top perspective view of a load handling device showing a hoist element at the top surface of the load handling device.
[0058] FIG. 14 is a schematic drawing of the fall restraint apparatus comprising a tow bar for towing a load handling device according to an embodiment of the present invention.
[0059] FIGS. 15a and 15b are perspective images showing 15a an operative restrained to the fall restraint apparatus walking on the grid structure, and 15b an operative restrained to the fall restraint apparatus steering the fall restraint apparatus by lifting at least a portion of the rolling assembly.
[0060] FIG. 16 is a schematic drawing of a fall restraint apparatus comprising an elongated suspension beam according to a second embodiment of the present invention.
[0061] FIG. 17 is a schematic view of a fall restraint apparatus according to a third embodiment of the present invention.
[0062] FIG. 18 is a schematic drawing showing an assembly of fall restraint apparatuses linked together by a suspension beam according to a fourth embodiment of the present invention.
[0063] FIG. 19 is a schematic drawing of a fall restraint apparatus according to a fifth embodiment of the present invention.
[0064] FIG. 20 is a schematic drawing of the fall restraint apparatus of FIG. 19 showing the rolling assembly in a stowed configuration.
[0065] FIG. 21 is a schematic drawing of a fall restraint apparatus with a different height to the one shown in FIG. 19.
[0066] FIG. 22 is a schematic drawing of the fall restraint apparatus shown in FIG. 21 on a grid structure.
[0067] FIG. 23 is a schematic drawing of an adaption of the fall restraint apparatus shown in FIG. 21 with a single suspension beam according to a sixth embodiment of the present invention.
[0068] FIG. 24 is a schematic drawing of a fall restraint apparatus according to a sixth embodiment of the present invention.
[0069] FIG. 25 is a schematic drawing of a plurality of the fall restraint apparatuses of FIG. 24 nested within each other.
DETAILED DESCRIPTION
[0070] It is against the known features of the storage system such as the grid framework structure and the load handling device described above with reference to FIGS. 1 to 5, the present invention has been devised. To enable to access the grid structure and travel on the tracks, it is paramount that any service vehicle devised is able to travel over the grid cells without any one of the wheels of the service vehicle entering or dropping into a grid cell. Various techniques in the art, discussed above, exist to allow a service vehicle to travel over the top of the grid structure. The easiest way would be to adopt a wheel assembly of a typical load handling device that is operative on the grid structure and a drive mechanism for driving the wheels, i.e. comprising a first set of wheels for engaging with the tracks extending in the X direction and a second set of wheels for engaging with the tracks extending in the Y direction. Such a wheel assembly is taught in the art, WO 2015/140216 (Ocado Innovation Ltd) and WO2020/151866 (Autostore Technology AS), and are discussed above. However, such an arrangement of wheels limits the service vehicle to travelling in either an X direction or in a Y direction on the grid structure. Therefore, to negotiate around obstacles or other load handling devices on the grid structure, the service vehicle must travel in either the X direction and/or Y direction in order to reach a location or desired destination on the grid structure. In a majority of cases, a route is planned comprising movements in the X and Y direction in order to reach the desired location on the grid structure. This not only represents a longer length of travel to reach the desired location on the grid structure but is time consuming.
[0071] In an attempt to reduce the travel distance to a desired location on the grid structure and not be limited by the tracks in the X direction and Y direction, WO2019/233749 (Autostore Technology AS), teaches the use of caterpillar tracks to straddle over the surface of the tracks, i.e. drive over the surface of the tracks. The caterpillar tracks are dimensioned to have a length that exceeds the length corresponding to the diagonal length across a maximum grid opening of the grid structure so as to be able to straddle or travel over the tracks without any portion of the caterpillar tracks falling into any of the openings of the grid cell. The caterpillar tracks comprises a longitudinal extending belt and is driven by a belt motor.
[0072] Referring to FIG. 7(a and b), the dimensions of a given grid cell is about 600-800 mm long and about 400-600 mm wide. The dimensions of the grid cell depends on the size of the containers or totes stored within the storage system and the ability of a load handling device operative on the grid structure to retrieve a storage container by lifting the storage container through a grid cell opening. This equates to a grid opening 14c having an area in the region of 3,600 cm.sup.2 to 6,400 cm.sup.2. Taking the width of a single track to be about 75 mm wide, and the longest length, Lg, of a given grid cell from the mid-point of a track to be about 760 mm long and the width, Wg, to be about 560 mm, this equates in a diagonal length, Dg, of about 944 mm and an area of a grid cell opening of about 4,256 cm.sup.2. Other dimensions of the grid cell include a length of 654 mm along the longest length, Lg, and a width, Wg, of about 454 mm. In FIG. 7(a and b), the longest length of the grid cell is along the X direction and the width which is the shorter of the two lengths is along the Y direction. To prevent the wheels of the service vehicle from falling into an opening of a grid cell and thereby causing the service vehicle to become stranded on the grid structure or the very least cause damage the tracks, the length of the rolling assembly should be greater than the length across the diagonal length, Dg, across a grid opening 14c or at the very least the greater than the longest length, Lg, across at least one grid cell. Taking the example above, the maximum diagonal length, Dg, of a grid cell is about 944 mm and the longest length. Lg, is about 760 mm.
[0073] The length of the caterpillar tracks extends over several grid cells and thereby, allows the service vehicle to be steered in any direction on the grid structure. However, WO2019/233749 (Autostore Technology AS) requires the use of caterpillar tracks in order to travel on the tracks. The caterpillar tracks are heavy and require a motor to drive the belt which adds to the weight of the caterpillar tracks. Thus, any service vehicle comprising caterpillar tracks would not be portable and requires one or more motors to drive the belt removing its ability to be launched quickly onto the grid structure.
[0074] FIG. 6 shows a fall restraint apparatus 60 according to an embodiment of the present invention. In contrast to the service vehicles known in the art, the fall restraint apparatus 60 of the embodiment of the present invention comprises a frame or frame structure 62 comprising an upper portion 64 with an open interior space 66 bounded by a plurality of vertical support frame members 68 and a lower portion 70 for mounting a rolling assembly 72. The rolling assembly 72 enables the fall restraint apparatus 60 of the present invention to be steered in any direction on the tracks (not shown) without any portion of the rolling assembly 72 falling into a grid opening. There are different embodiments of the rolling assembly according to the present invention to provide a rolling assembly that allows the fall restraint apparatus to be steered in any direction on the grid structure without any portion of the rolling assembly falling into a grid opening. In all of the different embodiments of the present invention, it is essential that the rolling assembly contacts the grid structure by at least two contact points on the grid structure and since the grid structure comprises a first set of parallel tracks extending in a first direction and a second set of parallel tracks extending in a second direction, the at least two contacts points is construed to mean that the rolling assembly contacts different tracks of the grid structure or different areas of the grid structure. The rolling assembly may also be freewheeling so as to enable an operative restrained to the frame to manually move the fall restraint apparatus on the grid structure, e.g. by walking on the grid structure. Further detail of the rolling assembly of the fall restraint apparatus according to the present invention is discussed below.
[0075] Referring to the particular embodiment of the fall restraint apparatus shown in FIG. 6, the frame 62 comprises an assemblage of frame members 74 connected together to provide an open interior structure 66 for accommodating at least operative within the open interior structure. The frame members 74 are connected together via a suitable fastener 76 to bear the load of at least one operative restrained to the frame 62. Suitable fasteners for connecting the frame members 74 together include but is not limited to welding, one or more bolts, adhesive etc. To provide a lightweight frame that can be lifted by at least one operative restrained to the frame 62, the frame members 74 can be tubular members with sufficient strength to bear the load of the at least one operative restrained to the frame. Example of tubular frame members include but is not limited to aluminium tubular frame members or an alloy comprising aluminium. Other examples of frame members, include the use of plastic materials or a composite material, e.g. carbon fibre reinforced plastic. The use of carbon fibre reinforced plastic materials for the frame members not only provides a strong frame sufficient to support at least one operative restrained to the frame but also helps to provide a lightweight frame so that the fall restraint apparatus of the present invention can easily be launched on the grid structure and manoeuvred in any direction on the grid structure. The combination of the use of lightweight materials and the open structure of the frame, provides a frame that is less than 100 kg, preferably, less than 60 kg, more preferably, less than 30 kg. Since the weight of the rolling assembly represents a small portion of the total weight of the fall restraint apparatus, the frame together with rolling assembly provides a lightweight fall restraint apparatus having a weight less than 100 kg, preferably less than 60 kg, more preferably less than 30 kg. The fall restraint apparatus 60 in the particular embodiment of the present invention shown in FIG. 6 comprising aluminium based tubular frame members is about 25 kg.
[0076] The lightweight frame 62 enables an operative within the open structure 66 of the frame to lift the frame and steer the fall restraint apparatus 60 on the grid structure. Steering the fall restraint apparatus 60 may involve lifting the frame 62 so that at least a portion of the rolling assembly 72 is lifted clear of the tracks rather than trying to rotate the fall restraint apparatus when the rolling assembly 72 is in full contact with the tracks. In the particular embodiment shown in FIG. 6, the frame 62 represents a greater proportion of the weight of the fall restraint apparatus and therefore, a lightweight frame results in a lightweight fall restraint apparatus. Thus, the lightweight fall restraint apparatus can be provided by the combination of the weight of the frame and the weight of the rolling assembly.
[0077] In the particular embodiment of the present invention shown in FIG. 6, the upper portion 64 of the frame comprises at least one pair of parallel side frame members and a pair of parallel end frame members which are shorter than the parallel side frame members and which are fixed substantially perpendicular to the parallel side frame members in a common horizontal plane to define a rectangular frame structure. The parallel side frame members and the end frame members are arranged so as to provide the interior open space 66 for accommodating at least one operative (see FIGS. 11 and 15(a and b)). The rectangular frame structure of the upper portion 64 permits one or more operatives to be accommodated within the open interior space 66. The parallel side frame members and/or end frame members also provides a handle for the at least one operative to hold onto the frame whilst walking on the grid structure. The handle defined by the parallel side frame members and the end frame members are supported above the tracks by the plurality of support frame members or down frame members 68. As demonstrated in FIG. 11, the height of the parallel side frame members 74 is at about the operative's waist level so that the operative restrained within the open structure 66 can easily reach out and grip the parallel side frame members 74 when walking on the grid structure. In the particular embodiment of the present invention shown in FIG. 6, the frame members 74 are tubular members, e.g. aluminium tubes, but the frame members can be a bar or other materials discussed above. To increase the structural rigidity of the frame, one or more bracing members are used to brace parallel frame members. In the particular embodiment shown in FIG. 6, the frame members are assembled to provide opposing H-frames either side of the open structure 66. Other types of bracing members can be used to increase the structural rigidity of the frame, these include but are not limited to diagonal bracing members. The frame of the particular embodiment of the present invention can be envisaged to resemble a Zimmer? frame for the at least one operative to walk on the grid structure whilst holding the parallel side frame members 74.
[0078] The lower portion 70 of the frame comprises the rolling assembly 72 so as to enable the fall restraint system 60 to be manually driven on the grid structure. In the particular embodiment shown in FIG. 6, the lower portion 70 of the frame is connected to the upper portion 64 of the frame. The lower portion of the frame comprises a sub-frame 78 for mounting the rolling assembly 72. The rolling assembly is mounted to the sub-frame 78 such that the rolling assembly 72 has a width that extends across the length of one or more grid cells, more preferably one or more grid openings. For improved stability of the fall restraint apparatus 60 on the grid structure, in the particular embodiment of the present invention, the rolling assembly has a width, W, that extends across the longest length of at least two grid cells (see FIG. 6, FIG. 15a and FIG. 15b. Taking into consideration the longest length of grid cell to be 760 mm, this equates to a width of about 2?760 mm (1520 mm). Ideally, the width of the rolling assembly should have a length that extends across the maximum diagonal length of a given grid cell so as to enable the fall restraint apparatus 60 to be steered in any direction on the grid structure. In the particular example described above, this equates to a length of about 944 mm. The rolling assembly 72 shown in FIG. 6 comprises a front wheel assembly 73a and a rear wheel 73b, each wheel assembly of the front wheel assembly 73a and the rear wheel assembly 73b extending transversely to the longitudinal direction of the upper portion.
[0079] The width of the rolling assembly is chosen so as to prevent any portion of the rolling assembly falling into a grid opening and this can be demonstrated in the schematic drawing shown in FIGS. 8 and 9 in conjunction with FIG. 7(a and b). In both examples of the fall restraint apparatus 160, 260, the rolling assembly 172, 272 comprises a front wheel assembly 173a, 273a and a rear wheel assembly 173b, 273b, each wheel assembly of the front wheel assembly 173a, 273a and the rear wheel assembly 173b, 273b extending transversely to the length L of the upper portion. The wheel base which is the distance between the front and rear wheel assemblies extends beyond the length of one or more grid cells so as to permit an operative restrained to the upper portion of the frame to gain access to a grid opening. In the examples shown in FIGS. 8 and 9, the width of the front and rear wheel assemblies is such that each wheel assembly of the front and rear wheel assemblies is in contact with two different areas of the grid structure denoted by the reference A and B in FIGS. 8 and 9. As the grid structure is made up of a first set of parallel tracks extending a first direction and a second set of parallel tracks extending in the second direction, then each wheel assembly of the front and rear wheel assembly contacts different tracks of the grid structure in order to prevent any portion of the rolling assembly falling into a grid opening. There are numerous ways to achieve this. The first is shown in FIG. 8, and shows each wheel assembly of the front and rear wheel assembly comprises a single elongated roller having a length that extends across the maximum diagonal length Dg of a single grid opening 14c. The second example is shown in FIG. 9 and shows each wheel assembly of the front and rear wheel assemblies comprising a plurality of wheels. The plurality of wheels of the front and rear wheel assembly are arranged to rotate about a respective common rotational axis F-F (front axis) and R-R (rear axis). In both examples shown in FIGS. 8 and 9, the length Lw of each wheel assembly of the front and rear wheel assembly is such that the wheel assembly of the front and rear wheel assembly contacts two different tracks of the grid structure. For the purpose of the present invention, the length of each wheel assembly of the front and rear wheel assembly corresponds to the width, W, of the rolling assembly as shown in FIG. 6. In the particular embodiment shown in FIG. 6, each wheel assembly of the front and the rear wheel assembly extends outwardly of the upper portion 64 of the frame to sit on different areas of the grid structure, i.e. at least two different tracks. In the case where the wheel assembly comprises a plurality of wheels, the separation D between the wheels of the plurality of wheels is optionally less that the width of a single track, Lt, to prevent a track entering between the plurality of wheels (see FIG. 9). In both examples shown in FIGS. 8 and 9, the length of the wheel assembly of the front and rear wheel assemblies denoted by the reference, Lw, is greater than the maximum diagonal length of a grid opening 14c denoted by the reference, Dg. As a result, each wheel assembly of the front and rear wheel assembly contacts different tracks of the grid structure.
[0080] However, the present invention is not limited to the wheel assembly configuration shown in FIGS. 8 and 9, and other configurations of the wheel assembly are applicable in the present invention so as to contact two different tracks of the grid structure. In the particular embodiment shown in FIG. 6, the front and rear wheel assembly 73a, 73b comprises two rollers 80 that are rotatable about a common rotational axis, F-F and R-R. The wheels of front and rear wheel assemblies are respectively rotatable about one or more common shafts or axles. In the particular embodiment in FIG. 6, two rollers 80 are rotatably mounted on separate shafts at the front 73a and the rear 73b wheel assembly and are sufficiently separated so that each roller 80 of the front and the rear wheel assembly contacts a track of the grid structure. The length of each roller is less that the longest length of a grid cell, e.g. 700 mm, but the overall length of the two rollers including the separation between the rollers exceeds the length of the maximum diagonal length, Dg, of the grid opening 14c. An example of a single roller 80 for moving the frame of the fall restraint apparatus on the grid structure is shown in FIG. 10, and comprises a stainless steel roller 82 rotatably mounted on as shaft 84 which in turn is rotatably mounted to the lower portion 70 of the frame. The stainless steel roller 82 comprises an outer rubber sleeve 86 so as to prevent damage to the tracks, in particular the profiles of the tracks, when the fall restraint apparatus of the present invention is moved across the grid structure.
[0081] An operative 88 can be restrained to the upper portion 64 of the frame 62 via a suitable harness 90. In the particular embodiment shown in FIG. 11, an operative 88 wearing a suitable harness 90 can be attached to the upper portion 64 of the frame 62 via one or more fasteners (not shown). Commercially available harnesses for restraining the operative to the upper portion of the frame include DBI-SALA?ExoFit?. Examples of secure fasteners to restrain the operative to the upper portion of the frame include but are not limited to carabiners or shackles. The at least one operative can be restrained to the upper portion of the frame by being attached to one of the parallel side frame members or end frame members of the frame 62. The frame 62 of the fall restraint apparatus functions like a Zimmer? frame enabling an operative to walk safely on the tracks whilst holding onto the upper portion of the frame, in particular the parallel side frame members. However, should an operative accidently slip into a grid cell, the operative can be restrained to the frame via an inertia reel 92 coupled to the frame 62, in particular to the upper portion of the frame. The inertia reel 92 prevents the operative restrained to the upper portion of the frame from falling too far into a grid cell. Other methods of restraining an operative and thereby, preventing the operative from falling into a grid opening are applicable in the present invention including various harnesses or ropes.
[0082] The fall restraint apparatus of the present invention can be used as a recovery apparatus should a person be injured on the grid structure or having fallen down a grid opening. In the particular embodiment shown in FIG. 12, the frame 62 comprises a winch 94 attached to a suspension frame member or suspension beam 96. The suspension frame member or suspension beam 96 is sufficiently strong to bear the weight of an operative which can weigh as much as 100 kg or more. In the particular embodiment of the present invention shown in FIG. 12, the suspension beam 96 extends across the open structure 66 onto the parallel frame members in the upper portion of the frame and is removably supported or fixed to the parallel frame members via inwardly turned ends 98. The winch 94 enables an injured person to be suspended from the suspension beam 96 so as to be carried to safety at the edge of the grid structure. The winch 94 having a winch cable is sufficiently long so that the winch cable can be reeled down a grid opening which can be as high as 21 containers high (e.g. in excess of 3 m). At the end of the winch cable is a hook 100 or other fastener means to latch onto a person that has fallen onto the tracks or down a grid opening. A stretcher (not shown) can be attached to the winch 94 to assist with the safe removal of the injured person from the grid structure. The winch can be manually driven or motorised so giving the operative restrained to the frame more control to safely winch the injured person from the tracks.
[0083] Not only can the winch lift an injured person that has fallen onto the tracks or down a grid opening, the winch can also be used to upright a load handling device that has toppled on the tracks. Occasionally, one or more load handling devices can topple over on the grid structure and cause a section of the grid to be declared non-operational until the toppled load handling device can be made upright or be retrieved to the edge of the grid structure should the load handling device malfunction. This results in an increased downtime of the section of the grid structure. The fall restraint apparatus of the present invention comprising the winch can be used to upright a toppled load handling device since the fall restraint apparatus can be quickly launched on the grid structure and be able to reach the stricken load handling device on the grid structure.
[0084] The top of the load handling device comprises a hoist element that can be used to hoist the load handling device from the tracks. FIG. 13 shows a hoist element 102 used for manual movement of the load handling device 30. The hoist element 102 comprises a cutaway below a bulbous head which gives rise to an underside 104. The hoist element 102 is so designed to permit the attachment of a hoist to lift the load handling device 30 from a grid cell. In certain occasions, the load handling device may malfunction and become stranded on the tracks. Typically in the art, to retrieve the malfunctioned load handling device, the load handling device is winched by a service vehicle so that the wheels of the load handling device are lifted clear of the tracks and the malfunctioned load handling device is placed on a platform in the service vehicle whereupon it is transported to the edge of the grid structure. However, there may not be enough height above the load handling device to lift the load handling device clear of the tracks. This is particularly the case, where the headroom above the load handling device in the distribution centre or fulfilment centre is only sufficient to enable a load handling device to be operative on the tracks but is insufficient to accommodate a tall winch assembly in excess of 2 meters. To overcome this problem, the fall restraint apparatus of the present invention comprises a tow bar that is able to couple onto a stricken load handling device and tow the load handling device to the edge of the grid structure instead of suspending the load handling device clear of the tracks. As shown in FIG. 14, one end 108 of the tow bar 106 is fixed to the frame of the fall restraint apparatus 60 of the present invention and the other end 110 of the tow bar 106 is coupled to or interfaces with the load handling device 30, more particularly, interfaces with the hoist element 102 at the top of the load handling device. One or more operatives restrained to the frame of the fall restraint apparatus 60 can then manually pull or push the stricken load handling device to the edge of the grid structure. The wheels of the load handling device can be dis-engaged so enabling the load handling device to be free wheeled on the tracks and thereby allowing an operative restrained to the frame to either push or pull the load handling device on the tracks. Whilst the particular embodiment in FIG. 14 shows the tow bar attached to the top of the load handling device, other means to attach the tow bar to the load handling device such as at the base of the load handling device provide more stability when towing the load handling device to the edge of the grid structure.
[0085] In use, when requiring access to the grid structure, an operative can lift the fall restraint apparatus simply by lifting the frame and placing it on the tracks so that the rolling assembly mounted to the frame abuts the tracks. The operative can enter the open structure and be restrained to the upper portion of the frame as shown in FIG. 15a. While holding onto the parallel side frame members, the operative restrained to the upper portion of the frame can walk on the grid structure 14b by stepping on the tracks 22a, 22b. The width of the rolling assembly is such that any portion of the rolling assembly is prevented from falling into a grid opening 14c. To manoeuvre or steer on the grid structure, the operative can simply lift the frame so that at least a portion of the rolling assembly is lifted clear of the tracks as shown in FIG. 15b, The operative can then rotate the frame to a desired orientation on the grid structure without the problem of any portion of the rolling assembly falling into a grid opening 14c. Having a frame that is lightweight as discussed above allows the fall restraint apparatus to be easily lifted and rotated on the tracks. The operative restrained to the upper portion of the frame, more specifically within the open structure of the frame, can the walk to the desired location or grid cell of the grid structure.
[0086] Whilst the particular embodiment shown in FIG. 6 shows an open structure closed by the parallel frame members, other types of frames can be used to restrain at least one operative to the upper portion of the frame. In a second embodiment of the fall restraint apparatus 360 of the present invention shown in FIG. 16, the upper frame 364 comprises opposing A-frames 366 or diagonal frame members that meet at an apex close to the top of the frame. The A frames 366 support a suspension frame member or suspension beam 396 disposed between the opposing A frames 366. In comparison to the upper portion of the frame shown in FIG. 6, the at least one operative is suspended from the suspension beam 396 disposed between the opposing A-frames 366. The front 373a and rear 373b wheel assemblies are respectively mounted to the base of the A-frames such that the length of the suspension beam corresponds to the wheel base of the fall restraint apparatus 360, i.e. the distance between the front 373a and rear 373b wheel assemblies. The suspension beam 396 is elongated so as to enable more than one operative to be suspended from the suspension beam, e.g. via an inertia reel (not shown) coupled to the suspension beam. As shown in FIG. 16, one or more hooks 382 are suspended from the suspension beam 396 so as to allow an operative or winch assembly (not shown) to be attached to the suspension beam 396. The fall restraint apparatus 360 can adopt the same or similar rolling assembly 370 of the first embodiment of the present invention described above, in that the rolling assembly comprises a front wheel assembly 373a and a rear wheel assembly 373b. The length, Lw, of each wheel assembly of the front and rear wheel assembly extends across a grid opening 14c so that the wheel assembly contacts different tracks or areas of the grid structure (at least two contact points) when travelling on the grid structure to prevent any portion of the rolling assembly falling into a grid cell opening. In the second embodiment of the fall restraint apparatus 370, each wheel assembly of the front and rear wheel assembly comprises three elongated rollers 380 rotatable about a respective common axis. Like the first embodiment of the fall restraint apparatus, the front and rear wheel assemblies 373a, 373b extend transversely to the longitudinal direction of the suspension beam 396 such that an operative restrained to the suspension beam is able to move the fall restraint apparatus in the longitudinal direction when walking on the grid structure. One or more winch assemblies (not shown) discussed above can be mounted to the suspension beam 396. The elongated suspension beam 396 according to the second embodiment of the present invention provides enough clearance for the fall restraint apparatus to be positioned over a grid cell and the winch assembly (not shown) mounted to the elongated suspension beam can hoist a malfunctioned load handling device clear of the grid structure.
[0087] Different arrangements of the frame members can be used in the upper portion of frame depending on the application of the fall restraint apparatus. In the first embodiment, the frame members are arranged to provide an interior open structure to support an operative restrained to the frame to walk on the tracks. In the second embodiment shown in FIG. 16, the frame members are arranged to provide opposing A-frames and a suspension beam disposed between the A-frames to define a gantry so as to allow the fall restraint apparatus to easily hoist larger objects such as a malfunctioned load handling device. In both embodiments of the present invention, the frame is light enough to be easily moved on the track and the rolling assembly extends outwardly of the upper portion of the frame so as to abut different areas of the grid structure or tracks thereby providing improved stability of the fall restraint apparatus on the grid structure, i.e. the footprint occupied by the rolling assembly is greater than the footprint occupied by the upper portion of the frame. This enables the fall restraint apparatus to be easily moved and steered on the grid structure since the frame is light enough for at least a portion of the rolling assembly to be lifted clear of the tracks. Whilst not shown in FIG. 16, a tow bar can be incorporated onto the fall restraint apparatus of the second embodiment of the fall restraint apparatus 360 in order to push or pull a stricken load handling device coupled to the tow bar to the edge of the grid structure.
[0088] An adaption of the first embodiment of the fall restraint apparatus shown in the fall restraint apparatus 460 in FIG. 6 comprising an interior open structure 466 for restraining an operative 88 to the frame 462 is shown in a third embodiment of the present invention in FIG. 17. As with the first and second embodiment of the present invention shown in FIGS. 6 and 16, the fall restraint apparatus 460 of the third embodiment of the present invention comprises a frame 462 comprising an upper portion 464 for restraining the at least one operative 88 to the frame 462 and a lower portion 468 for mounting the rolling assembly 472. The fall restraint apparatus 460 is adapted with the same or similar rolling assembly 472 as the other embodiments of the present invention in that the stability of the frame 462 on the grid is provided by a rolling assembly mounted to the lower portion extending outwardly of the upper portion across a grid opening. Crucially, the rolling assembly 472 comprises a front wheel assembly 473a and a rear wheel assembly 473b. Each wheel assembly of the front and rear wheel assembly 473a having a length Lw that extends cross a grid opening 14c and running transversely to the longitudinal direction of the upper portion 464 such that the wheel assembly 473a, 473b contacts the grid 14b at two points or two different tracks 22a, 22b as shown in FIG. 17. In the particular embodiment of the present invention, each wheel assembly 473a, 473b of the front and rear wheel assembly comprises elongated rollers, more specifically two elongated rollers 480 that are arranged to rotate about a common axis, F-F and R-R respectively.
[0089] In contrast to the first embodiment of the present invention shown in FIG. 6, the upper portion 464 of the frame additionally comprises upwardly extending frame members that are braced or connected together to form a hoisting or lifting frame 465 for supporting a winch 482. In the particular embodiment of the present invention shown in FIG. 17, the hoisting frame 465 comprises upwardly extending tubular frame members that are connected to the lower portion 468 of the frame and the parallel frame members in the upper portion of the frame. The hoisting frame 465 can double up as a roll cage for protecting the operative within the upper portion 468 of the frame should the fall restraint apparatus 460 topple on the grid structure 14b. A winch 482 is mounted to the hoist frame 465 such that the winch 482 is suspended from the uppermost portion of the hoisting frame. As with the other embodiments of the present invention, in operation the operative restrained to the frame is able to walk on the tracks 22a, 22b whilst holding onto the parallel frame members. To steer the fall restraint apparatus on the grid, the operative simply lifts the frame such that at least a portion of the rolling assembly 472 is lifted clear of the tracks allowing the operative to rotate the frame in a desired orientation. The key of the present invention is to be able to have a lightweight fall restraint apparatus in order to lift at least a portion of the rolling assembly off the tracks so as to enable to steer the fall restraint apparatus on the grid. Preferably, the fall restraint apparatus has a weight less than 100 kg, preferably, less than 60 kg, more preferably, less than 30 kg. The provision of a lightweight frame comprising an assembly of tubular frame members to form an open structure allows for a lightweight fall restraint apparatus.
[0090] In yet a further embodiment of the present invention, two or more of the fall restraints apparatus of the first and/or the third embodiments of the present invention shown in FIGS. 6 and 17 can be joined together by a linkage 594 to form an assembly 500 as shown in FIG. 18. By allowing two or more fall restraint apparatus 560a, 560b to be joined together by a linkage 594 to form an assembly 500 increases the load carrying capability of the assembly since two or more operators can drive the assembly on the tracks. Each of the two or more fall restraint systems can be operated independently relative to each other such that a person restraint in each of the two or more fall restraint apparatus are able to independently manoeuvre their respective fall restraint apparatus by lifting at least a portion of its rolling assembly. In the particular embodiment shown in FIG. 18, a first 560a and second 560b fall restraint apparatus are shown spaced apart and separated by the linkage 594 to define a work area between the first 560a and second 560b fall restraint apparatus. The linkage 594 extending between the first 560a and second 560b fall restraint apparatus can be a suspension or horizontal beam or suspension frame member for suspending a malfunctioned robotic load handling device above the tracks and/or an operative working on the tracks.
[0091] The suspension beam or suspension frame member 594 can be mounted to the upper portion 564a, 564b of the frame structure of the first and second fall restraint apparatus. The mounting of the ends of the suspension beam or the suspension frame member 594 to the upper portion of the frame structure at each of the first and second fall restraint apparatus resembles the hoisting frame shown in FIG. 17 comprising upwardly extending tubular frame members either side of the frame structure of the fall restraint apparatus and braced together by a frame member extending across the frame structure in a direction substantially perpendicular to the longitudinal direction the suspension frame member. The hoisting frame 565 helps to elevate the suspension frame member 594 above the tracks sufficient to suspend a load handling device from the suspension frame member or optionally, a person to be tethered to the suspension frame member whilst standing on the tracks.
[0092] One or more operators restrained in each of the first 560a and second 560b fall restraint apparatus are able to move their respective first and second fall restraint apparatus on the tracks such that the first and second fall restraint apparatus behaves as a tandem on the tracks, i.e. the movement of the assembly on the tracks is dependent on the operators restrained in the first and second fall restraint apparatus moving their respective fall restraint apparatus. One or both ends 502 of the suspension beam or the suspension frame member 594 is/are mounted to the first 560a and/or second 560b fall restraint apparatus by a pivotable joint such that the first fall restraint apparatus 560a can move independently of the second fall restraint apparatus 560b on the tracks. This allows the first fall restraint apparatus to swing around relative to the second fall restraint apparatus whilst still being linked together on the tracks.
[0093] In the particular embodiment shown in FIG. 18, the linkage joining the first and second fall restraint apparatus is a suspension frame member 594 comprising parallel beams 595 braced by one or more tie rods 504 in a ladder-type arrangement to provide more support to the suspension frame member from buckling when suspending a robotic load handling device. As discussed above with reference to FIG. 12, a winch (not shown) can be mounted to the suspension beam or suspension frame member 594 for winching a malfunctioned robotic load handling device from the tracks and/or up righting a toppled robotic load handling device on the tracks. As discussed above, a hook (not shown) or other suitable fastener can be attached to the free end of a winch cable for engaging with the hoist element of the load handling device. A stretcher (not shown) can be attached to the winch to assist with the safe removal of the injured person from the grid structure. The winch can be manually driven or motorised so giving the operative restrained to the frame more control to safely winch the injured person from the tracks. The spacing between the first and second fall restraint apparatus can be an area for an operator to work on the tracks or the load handling device whilst being tethered to the suspension frame member, e.g. by an inertia reel.
[0094] In operation, one or more operators restrained to each of the first 560a and second 560b fall restraint apparatus are able to manoeuvre the assembly 500 by virtue of the rolling assembly 572a, 572b of the first and second fall restraint apparatus on the tracks. The weight of each of the first and second fall restraint apparatus is sufficient for an operator restraint to the respective first and second fall restraint apparatus to manoeuvre the assembly 500 on the tracks by lifting at least a portion of its wheel assembly clear of the tracks. Whilst the combined weight of the assembly is greater than 100 kg, the weight of each of the first and second fall restraint apparatus is less than 60 kg allowing the assembly to be manoeuvred easily on the tracks.
[0095] The second fall restraint apparatus 560b can trail behind the first fall restraint apparatus 560a when moving the assembly 500 on the tracks such that they move in tandem on the tracks. To steer the assembly on the tracks so as to position the suspension beam or the suspension frame member over a malfunctioned load handling device or an injured person on the tracks, an operator in one or both the first and second fall restraint apparatus can steer their respective fall restraint apparatus on the tracks. Having a pivotable joint connecting the suspension beam or suspension frame member to the first and second fall restraint apparatus allows the first and second fall restraint apparatus to move independently with respect to each other and thereby, providing an improved steering ability of the assembly on the tracks.
[0096] The fall restraint apparatuses 560a, 560b shown in FIG. 18 additionally comprise anti-topple mechanisms 506a, 506b in the form of tensioned cables or wires. These comprise a continuous stabilising surface which prevents the fall restraint apparatuses from falling into a grid opening. The first restraint apparatus 560a comprises two tensioned tethers 506a, and each tension tether is located at the lower portion 568a of the frame extending between the front wheel assembly 573a and the rear wheel assembly 573b. One end of each tension tether is attached to one end of the front wheel assembly 573a, and the other end of the tension tether is attached to an opposing end of the rear wheel assembly 573b. The second restraint apparatus 560b comprises two tensioned tethers 506b, and each tension tether is positioned in an identical way to the first restraint apparatus 560a. The tensioned tethers are positioned on the fall restraint apparatus, so that if the fall restraint apparatus becomes unbalanced, the tensioned tethers touches or rests on the grid members and avoid the fall restraint apparatus falling into a grid opening. In effect, the anti-topple mechanisms increase the footprint of the fall restraint apparatus, thereby making it more stable on the grid structure.
[0097] The tensioned tethers may be made of any material which is strong and can remain taut for long periods of time, for example, the tensioned tethers may comprise steel. Further, the tensioned tethers do not contribute significantly to the weight of the fall restraint apparatus, and so offer a further stability measure whilst still allowing an operative to physically lift the fall restraint apparatus into its desired position on the grid structure. Anti-topple mechanisms, such as the tensioned tethers shown in FIG. 18 may be used on any embodiment of the fall restraint apparatus.
[0098] In another embodiment shown in FIG. 19, the fall restraint apparatus 660 comprises a gantry 662 comprising a pair of horizontal beams 664 arranged in parallel and supported by one or more legs or vertical members 666 at the front and the rear of the gantry 662. The pair of horizontal beams 664 are spaced apart and held apart by a spacer 668 connected to the distal ends of the pair of horizontal beams 664. The spaced apart relationship between the pair of horizontal beams 664 supported by one or more legs 666 at the front and rear of the gantry 662 provides an open interior space or workspace 669 extending between the one or more legs 666 at the front and rear of the gantry. In comparison to other service vehicles operative on the grid structure known in the art, the workspace 669 defined by the pair of horizontal beams 664 and the one or more legs 666 at the front and rear of the gantry 662 provides an area for one or more operatives 671 restrained in the workspace 669 to have clear visibility of a malfunctioned robotic load handling device on the grid structure without the need to move the robotic load handling device to a position on the service vehicle in order to gain access to the malfunctioned robotic load handling device as found in prior art solutions. This allows the one or more operatives 671 restrained in the workspace 669 to carry out the necessary repairs to a malfunctioned robotic load handling device whilst on the grid structure without the need to carry the malfunctioned robotic load handling device to the edge or periphery of the grid structure. In comparison to the embodiments of the fall restraint apparatus shown in FIGS. 6, 16 and 17, the fall restraint apparatus shown in the embodiment shown in FIGS. 19 to 23 does not necessarily need to be lightweight in the sense of weighing less than 100 kg, preferably less than 60 kg. As the workspace 669 in the embodiment shown in FIG. 19 is able to accommodate more than one operative, the weight of the fall restraint apparatus is not necessarily a determining factor when manoeuvring the fall restraint apparatus on the grid structure. However, to reduce the weight of the fall restraint apparatus, the components of the gantry and plurality of legs can be formed from tubular members, e.g. lightweight aluminium tubular members.
[0099] Having the space within the fall restraint apparatus to work on a malfunctioned robotic load handling device allows the operative to work on the malfunctioned robotic load handling device at the point of breakdown. In a majority of cases, the repair of the malfunctioned robotic load handling device is generally a simple fix and having the ability to work on the malfunctioned robotic load handling device at the point of breakdown reduces the downtime the robotic load handling device is inoperable on the grid structure.
[0100] A pair of legs 666 at the front and the rear of the gantry 662 support the parallel horizontal beams 664 and are spaced apart having the same spacing as the pair of horizontal beams above. The legs 666 are braced at one or both sides of the gantry so as to enclose the workspace 669. One of the pair of legs at the front and rear of the gantry are braced together by one or more bracing members 674, 676. In the particular embodiment of the present invention shown in FIG. 19, diagonal bracing members 674, 676 connect one of the pair of legs 666 at the front and rear of the gantry to one of the pair of horizontal beams 664 at one side of the gantry in a K-brace but other patterns of the bracing members are applicable in the present invention including but is not limited to a cross brace. The spacing between the pair of legs at the front and rear of the gantry is sized to accommodate one or more pockets 678 to allow an operative restrained within the workspace to store tools and/or replacement parts in the one or more pockets 678. Alternatively, the spacing between the pair of legs at the front and rear of the gantry may accommodate one or more panniers to store tools and/or replacement parts. One or more handles or bars 680 (see FIG. 20) extend across the pair of legs 666 at the front and/or rear of the gantry so as to enable an operative restrained within the workspace to hold onto the handle whilst walking on the grid structure (see FIG. 19).
[0101] Also shown in FIG. 19 is one or more bridging members 682 extending across the workspace and supported by the pair of horizontal beams 664. As with the other embodiments of the present invention discussed above, a winch (not shown) can be mounted to the bridging member 682 for winching a load from the grid structure. For example, the winch mounted to the bridging member can be used to upright an overturned robotic load handling device or lift a malfunctioned robotic load handling device clear of the tracks so as enable the robotic load handling device to be carried to the edge or periphery of the grid structure. In the particular embodiment shown in FIG. 20, the bridging member 682 is mounted on a pair of rails or tracks 684 supported by the pair of horizontal beams 664. The pair of rails 684 can be fixed to the pair of horizontal rails or integrally formed with the pair of horizontal beams 664. This permits the bridging member 682 to be moveable along the length of the pair of horizontal beams 664 and allows the bridging member 682 to be accurately positioned over a malfunctioned robotic load handling device rather than the need to move the fall restraint apparatus when trying to position the winch over the malfunctioned robotic load handling device.
[0102] To manoeuvre the fall restraint apparatus 660 on the grid structure, the gantry 662 is mounted on a rolling assembly 670 as discussed above with reference to FIGS. 8 and 9. As discussed above, the rolling assembly can be a freewheeling rolling assembly so as to enable an operative restrained with the workspace to manually move the fall restraint apparatus on the grid structure. The rolling assembly comprises a front wheel assembly and a rear wheel assembly, each wheel assembly of the front and rear wheel assembly extends laterally and outwardly either side of the gantry such that each wheel assembly of the front wheel assembly and the rear wheel assembly contacts different tracks of the grid structure. Here, the length, Lw, of each wheel assembly 672a, 672b of the front and rear wheel assembly extends across a grid opening 14c so that the wheel assembly contacts different tracks or areas of the grid structure (at least two contact points) when travelling on the grid structure to prevent any portion of the rolling assembly falling into a grid cell opening. In the particular embodiment shown in FIG. 19, each wheel assembly 672a, 672b of the front and rear wheel assembly comprises three sets of wheels rotatable about a respective common axis. Like the first embodiment of the fall restraint apparatus, the front and rear wheel assembly 672a, 672b extends transversely to the longitudinal direction of the pair of horizontal beams 664 such that each wheel assembly 672a, 672b of the front and rear wheel assembly extends laterally and outwardly either side of the gantry 662. The outwardly extending wheel assembly provides increased stability of the fall restraint apparatus 660 so that an operative 671 restrained within the workspace 669 is able to move the fall restraint apparatus in the longitudinal direction when walking on the grid structure. Similarly to the other embodiments, the wheel assembly at the front and rear of the gantry is freewheeling in the sense that they are freely rotating.
[0103] As the front and rear wheel assembly 672a, 672b extends outwardly either side of the gantry across multiple grid cells, at least a portion 673a, 673b of the front and rear wheel assembly are collapsible in the sense that they can be stowed away so reducing the footprint of the fall restraint apparatus for the purpose of storage of the fall restraint apparatus or freeing up grid cells occupied by anyone of the front and rear wheel assembly 672a, 672b. In the particular embodiment shown in FIG. 20, one or more sets of wheels of the front and rear wheel assembly 673a, 673b are pivotally mounted to one of the legs supporting the pair of parallel horizontal beams 664 at the front and rear of the gantry 662. The one or more sets of wheels of the front and rear wheel assembly 673a, 673b are mounted on a carrier that is engageable with one of the legs 666 supporting the pair of parallel horizontal beams 664 at the front and rear of the gantry 662. In the stowed configuration, two 673a, 673b out of the three sets of wheels at the front and rear of the gantry extending laterally either side of the gantry are rotated so as to be lifted clear of the ground (in this case tracks) and secured to one of the legs supporting the pair of parallel horizontal beams at the front and rear of the gantry. When deploying the stowed wheels, the two sets of wheels 673a, 673b at the front and rear of the gantry are disengaged from the legs of the gantry and are rotated so that they contact the tracks. FIG. 20 shows the wheel assembly at the front and rear of the gantry in a stowed configuration and FIG. 19 shows the wheel assembly at the front and rear of the gantry in a deployed configuration having wheels extending laterally either side of the gantry.
[0104] The height of the pair of horizontal beams 664 above the rolling assembly 670 can be varied by mounting the pair of horizontal beams 664 to different lengths of legs. In the particular embodiment shown in FIG. 21, the height of the gantry 662 is increased by mounting the pair of parallel horizontal beams 664 to longer legs 666. Alternatively, one or more legs at the front and rear of the gantry can be telescopic so as to enable the height of the gantry to be varied. The advantage of increasing the height of the gantry is that it allows the height of the workspace to be increased providing sufficient headroom for an operative 671 restrained within the workspace 669 as demonstrated in FIG. 22. Restraining an operative within the workspace of the gantry can involve an operative wearing a suitable harness attached to any portion of the gantry, e.g. horizontal beams or legs, via one or more fasteners (not shown) as discussed above with respect to the other embodiments of the present invention. The one or more fasteners can comprise an inertia reel.
[0105] In operation, when referring to FIG. 22, an operative 671 restrained within the workspace 669 of the gantry 662 is able to push the fall restraint apparatus 660 on the tracks in the direction of a malfunctioned robotic load handling device and manoeuvre the fall restraint apparatus such that the malfunctioned robotic load handling device is within the workspace of the gantry. Once in the workspace, the operative can move the bridging member 682 along the rails 684 so as to position it directly above the robotic load handling device 30 so as to enable a winch mounted to the bridging member 682 to engage with the robotic load handling device, more specifically to the hoist element of the robotic load handling device (see FIG. 13). The winch can be used to upright an overturned robotic load handling device on the tracks or carry a malfunctioned robotic load handling device to a place of safety away from the live grid structure so as to prevent operational robotic load handling devices from crashing into the malfunctioned robotic load handling devicethis is usually at the edge of the grid structure.
[0106] FIG. 23 shows a slight modification of the fall restraint apparatus shown in FIGS. 19 to 22, wherein the fall restraint apparatus 760 comprises a single suspension beam or horizontal beam 764 extends between the one or more legs 766 at the front and rear of the gantry 762 and a moveable trolley 782 carrying a winch is mounted to the single suspension beam 764. In contrast to the bridging member shown in FIGS. 19 to 22 where the load is distributed over the pair of parallel horizontal beams, the load in the embodiment shown in FIG. 23 is borne by the single suspension beam 764. The other features of the fall restraint apparatus shown in FIG. 23 are the same as in the embodiment shown in FIGS. 19 to 22.
[0107] In another embodiment, shown in FIG. 24, the fall restraint apparatus 860 comprises a wedge-shaped frame structure. Specifically, the frame 862 comprises a front end 870 and an opposing rear end 880, and the rear end 880 is wider than the front end 870. The rear end 880 of the frame is also taller than the front end 870. Further, the rear end 880 provides an opening 882 into the open interior space 866. The opening 882 allows an operative, positioned in the open interior structure 866, to take longer, more natural strides when moving around the grid structure and the rear end 880 is positioned in front of the operative. Further, the opening 882 allows an operative to more easily access a part of the grid structure and carry out repair work. The opening 882 also is configured to receive a further fall restraint apparatus. Multiple fall restraint apparatuses can be nested together by pushing the front end of a second fall restraint apparatus into the opening at the rear end of the first fall restraint apparatus. This allows multiple fall restraint apparatuses to be stored in a small area.
[0108] FIG. 25 shows four fall restraint apparatuses, each having the wedge-shaped frame of FIG. 24, nested within each other. The first fall restraint apparatus 860 is at the front of the nest, and a front end 915 of a second fall restraint apparatus 910 is pushed into the opening in the rear end 880 of the first fall restraint apparatus 860 so that the front end 915 of the second fall restraint apparatus 910 is positioned in the interior open space 866 close to the front end 870 of the first fall restraint apparatus 860. The wedge-shaped frame means that the frame converges towards the front end. Thus, the front ends 870 of the frames 886 are both narrower and shorter than the rear end 880 of the frames. The third 920 and fourth fall restraint apparatus 930 have identical shaped frames to the first 860 and second fall restraint apparatus 910 such that the third fall restraint apparatus 920 can be pushed into the opening in the rear end 918 of the second fall restraint apparatus 910 and the fourth fall restraint apparatus 930 can be pushed into the opening in the rear end 928 of the third fall restraint apparatus. In this way, the first 860, second 910, third 920, and fourth fall restraint apparatus 930 can be manoeuvred as a set of fall restraint apparatuses. Further fall restraint apparatuses can be added to the set of fall restraint apparatuses shown in FIG. 25. Other shapes of frame having a rear end that is wider than the front end may also be used, for example, the frame may be L-shaped.
[0109] As shown in FIG. 24, the opening 882 at the rear end 880 of the frame is defined by a pair of vertical members 888 spaced apart and held apart by a spacer 886 connected to the distal ends of the pair of vertical members 888. The spacer 886 defines the top of the opening 882, whilst the pair of vertical members 888 define the sides of the opening 882. The bottom of the opening 882 is defined by the grid structure, when located on the grid, or the ground if located off the grid. Thus, the fall restraint apparatus 860 does not comprise a rear wheel assembly as present in other embodiments. The dimensions of the opening 882 are such that the front end of the frame of another fall restraint apparatus can fit into the opening 882 and nest within the open interior structure 866 of the fall restraint apparatus.
[0110] Like the other embodiments of the present invention, the frame 862 comprises an upper portion 864 for restraining the at least one operative to the frame 862 and a lower portion 878 for mounting the rolling assembly 872. The frame is configured such that the operative is positioned within the open interior structure 866. The upper portion 864 has a triangular shape when viewed side-on such that parallel side frame members define a handle that slopes downwardly. The lower portion 878 is rectangular in shape when viewed side-on. The front end 870 is narrower and shorter than the rear end 880. In FIG. 24, the front end 870 is approximately two-thirds the height and width of the rear end 880. Other ratios between the height and width of the front end to the rear end are also possible. The operative may move across the grid structure with the rear end 880 of the frame in front of them. Alternatively, the operative may move across the grid structure with the front end 870 in front of them to avoid having their sight blocked by the spacer 886 at the rear end 880 of the frame.
[0111] The fall restraint apparatus 860 is moveable by a rolling assembly 872 at the front end 870 of the frame. The rolling assembly 872 is mounted to the lower portion 878 of the frame. To steer the fall restraint apparatus, the operative pivots or tilts the frame around the rolling assembly 872. For example, to manoeuvre the fall restraint apparatus on the grid structure, an operative lifts the rear end 880 of the frame and pivots the fall restraint apparatus about a vertical axis extending through the rolling assembly 872. Thus, an operative moves the fall restraint apparatus in a similar way to moving a wheelbarrow. The width of the front rolling assembly is such that the operative is able to tilt the fall restraint apparatus on its rolling assembly, for example the rolling assembly may be wider than twice the diagonal length across a grid opening. FIG. 24 illustrates that the rolling assembly 872 comprises two rollers. However, the rolling assembly 872 may comprise any number of rollers, for example one roller, three rollers, or four rollers. Using more rollers makes it easier to steer the fall restraint apparatus. Alternatively, the rolling assembly 872 comprises wheels. The rolling assembly 872 is freewheeling in the sense that the rollers or wheels are freely rotating. Alternatively, the fall restraint apparatus does not comprise any rollers and instead comprises a skate at the front end 870 of the frame, similar to and in addition to a pair of skates 892 extending longitudinally along the length of the frame, as shown in FIG. 24 and now discussed.
[0112] The fall restraint apparatus of FIG. 24 comprises a sliding assembly 892, in the form of a pair of skates, which is arranged to slide over the grid structure with minimal friction. The sliding assembly also increases contact with the grid thereby increasing the stability of the fall restraint apparatus on the grid structure. The pair of skates are attached to the underside of horizontal beams 894 in the lower portion 878 of the fall restraint apparatus. Each skate at each side of the frame diverges outwardly from the front end 870 towards the rear end 880 by an acute angle ? so as to provide increased stability of the fall restraint apparatus 860 on the grid structure. The pair of skates 892 are wider than the width of the horizontal beams 894, thereby increasing contact with the grid members and thereby increasing the stability of the fall restraint apparatus. Additionally, but not shown, the pair of skates have rounded edges on all four sides to allow the frame to be moved in all directions. The skates may be attached directly to the underside of the horizontal beams 894, or as shown in FIG. 24, the pair of skates 892 may be attached to the underside of the horizontal beams 894 by connector beams 896. Overall, the operative can move and steer the fall restraint apparatus using a combination of both the rolling assembly 872 (or alternatively a skate at the front end 870 of the frame) and the pair of skates 892 extending longitudinally along the length of the frame.
[0113] Whilst not shown in FIG. 24, the fall restraint apparatus 860 may comprise an additional beam positioned laterally parallel to the spacer 886 but at a lower height than the spacer in the upper portion 864 of the frame onto which a hoist or hook may be attached. The hoist or hook can be used for lifting a toppled load handling device 30 on the grid structure. In this configuration, the load handling device can be lifted from the grid structure into the interior open structure 866 without destabilising the fall restraint apparatus 866. Alternatively, two fall restraint apparatuses of the present embodiment may be linked together by a suspension beam 594 or suspension frame member, such as the one shown in FIG. 18, for suspending a malfunctioned robotic load handling device above the tracks.
[0114] Various modifications of the illustrative embodiments which are apparent to the person skilled in the art within the scope of the present invention as defined in the claims are deemed to fall within the scope of the present invention. For example, different rolling assemblies can be used without departing from the scope of the present invention as defined in the claims. For example, different combinations of wheels and/or rollers can be used for the rolling assembly. These include but is not limited to an elongated rollers to a plurality of wheels rotatable about a common rotation axis.
[0115] Further Features of the embodiment shown in FIGS. 19 to 23 include:
[0116] 1. A fall restraint apparatus for manually moving on a grid structure comprising a first set of parallel tracks and a second set of parallel tracks running transversely to the first set in a substantially horizontal plane and arranged in a grid pattern comprising a plurality of grid cells, each grid cell having a length in the range 600-800 mm and a width in the range 400-600 mm so defining a grid opening defined by a pair of adjacent tracks of the first set of parallel tracks and a pair of adjacent tracks of the second set of parallel tracks; the fall restraint apparatus comprising: [0117] a gantry comprising at least one horizontal beam supported at each end by a plurality of legs to define a workspace for one or more operatives to be restrained within the workspace; [0118] the gantry is mounted on a rolling assembly so as to enable the user restrained in the workspace to manually move the fall restrain apparatus in any direction on the grid structure, the rolling assembly comprises a front wheel assembly and a rear wheel assembly, each wheel assembly of the front and rear wheel assembly extends laterally and outwardly either side of the at least one horizontal beam such that each wheel assembly of the front wheel assembly and the rear wheel assembly contacts different tracks of the grid structure.
[0119] 2. The fall restraint apparatus of feature 1, wherein the plurality of legs at each end of the at least one horizontal beam is provided with the front and rear wheel assembly respectively.
[0120] 3. The fall restraint apparatus of feature 1 or 2, wherein the plurality of legs at each end of the at least one horizontal beam comprises a pair of legs.
[0121] 4. The fall restraint apparatus of feature 3, wherein the pair of legs at each end of the at least one horizontal beam are parallel or upwardly converging.
[0122] 5. The fall restraint apparatus of feature 3 or 4, further comprising a pocket secured between the pair of legs at one or both ends of the at least one horizontal beam.
[0123] 6. The fall restraint apparatus of any of the features 3 to 5, further comprising at least one handle within the workspace, said at least one handle extending between the pair of legs at the front and/or rear of the gantry.
[0124] 7. The fall restraint apparatus of any of the preceding features, wherein at least a portion of the front and rear wheel assembly are pivotally mounted to at least one leg of the plurality of legs at each end of the at least one horizontal beam such that the at least portion of the front and rear wheel assembly are rotatable from a stowed configuration where the at least portion of the front and rear wheel assembly is lifted clear of the tracks to a deployed configuration where the at least portion of the front and wheel assembly engages with the tracks.
[0125] 8. The fall restraint apparatus of feature 7, wherein the at least portion of each of the front and rear wheel assembly are mounted on a carrier that is engageable with the at least one leg of the plurality of legs at each end of the at least one horizontal beam so as to be secured to the at least one leg of the plurality of legs in the stowed configuration.
[0126] 9. The fall restraint apparatus of any of the preceding features, wherein the at least portion of the front and rear wheel assembly comprises a pair of sets of wheels laterally disposed either side of the at least one horizontal beam such that the length of the front and rear wheel assembly is greater than the length corresponding to the diagonal length across a grid opening.
[0127] 10. The fall restraint apparatus of feature 9, wherein each of the front and rear wheel assembly comprises three set of wheels.
[0128] 11. The fall restraint apparatus of feature 10, wherein each of the three sets of wheels comprises a plurality of wheels arranged to be rotatable about a common axis.
[0129] 12. The fall restraint apparatus of any of the preceding features, wherein the front wheel assembly is separated from the rear wheel assembly by a wheelbase having a length greater than the length across at least one grid cell.
[0130] 13. The fall restraint apparatus of any of the preceding features, further comprising a winch moveably mounted to the at least one horizontal beam.
[0131] 14. The fall restraint apparatus of the preceding features, wherein the at least one horizontal beam comprises a pair of horizontal parallel beams such that the pair of horizontal beams is supported at each end by the plurality of legs.
[0132] 15. The fall restraint apparatus of feature 14, further comprising at least one bridging member supported by the pair of horizontal parallel beams such that the bridging member extends across the workspace.
[0133] 16. The fall restraint apparatus of feature 15, wherein the at least one bridging member is moveable along the longitudinal length of the pair of horizontal parallel beams.
[0134] 17. The fall restraint apparatus of feature 16, wherein the at least one bridging member is mounted on a pair of rails or track so as to be moveable along the longitudinal length of the pair of horizontal parallel beams.
[0135] 18. The fall restraint apparatus of any of the preceding features, wherein each of the plurality of legs at each end of the at least one horizontal beam is extendible so as to raise the at least one horizontal beam relative to the rolling assembly.
[0136] 19. The fall restraint apparatus of any of the preceding features, further comprising one or more bracing members extending between one of the one or more of the legs at the front and rear of the gantry so as to enclose the workspace from at least one side of the gantry.
[0137] 20. The fall restraint apparatus of feature 19, wherein the one or more bracing members comprises first and second bracing members, the first and second bracing members are arranged to connect one of the parallel support beams to one of the one or more legs at the front and rear of the gantry in a K-brace.
