CONVEYOR SYSTEM

Abstract

An automated storage and retrieval system includes a framework structure and a delivery system. The framework structure includes upright members, horizontal members, and a storage volume comprising storage columns and port columns arranged in rows between the upright members and the horizontal members. A rail system is arranged across the top of framework structure. The rail system includes a first set of parallel rails arranged to guide movement of container handling vehicles in a first direction across the top of the frame structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicles in a second direction which is perpendicular to the first direction, and access openings to the columns, the container handling vehicles being operable to raise a storage container from the storage columns, and transport the storage container above the storage columns to the port column, and lower the storage container into the port column. The delivery system includes at least one conveyor system including a first conveyor and a second conveyor. The first conveyor is located below the rail system and extending from a first end below the port column to a second end below a second column, the first end arranged to receive the storage container through the port column, the first conveyor comprising a first drive device for moving the storage container on the first conveyor between the first and second ends. The second conveyor is aligned with the first conveyor and arranged as an extension of the first conveyor. The second conveyor has a first end positioned adjacent the first end of the first conveyor and a second end positioned outside an outer periphery of the framework structure. The second conveyor includes a second drive device for moving the storage container on the second conveyor between its first and seconds ends. The at least one conveyor system is arranged for returning the storage container through the port column by moving the storage container from the second end of the second conveyor to the first end of the first conveyor via the second end of the first conveyor.

Claims

1. An automated storage and retrieval system comprising a framework structure and a delivery system, wherein the framework structure comprises: upright members, horizontal members and a storage volume comprising storage columns and port columns arranged in rows between the upright members and the horizontal members; a rail system arranged across the top of framework structure, the rail system comprising a first set of parallel rails arranged to guide movement of container handling vehicles in a first direction across the top of the frame structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicles in a second direction which is perpendicular to the first direction, and access openings to the columns, the container handling vehicles being operable to raise a storage container from the storage columns, and transport the storage container above the storage columns to the port column, and lower the storage container into the port column; the delivery system comprises at least one conveyor system comprising: a first conveyor located below the rail system and extending from a first end below the port column to a second end below a second column, the first end arranged to receive the storage container through the port column, the first conveyor comprising a first drive device for moving the storage container on the first conveyor between the first and second ends; a second conveyor aligned with the first conveyor and arranged as an extension of the first conveyor, the second conveyor having a first end positioned adjacent the first end of the first conveyor and a second end positioned outside an outer periphery of the framework structure, the second conveyor comprising a second drive device for moving the storage container on the second conveyor between first and seconds ends of the second conveyor; and wherein the at least one conveyor system is arranged for returning the storage container through the port column by moving the storage container from the second end of the second conveyor to the first end of the first conveyor via the second end of the first conveyor.

2. The automated storage and retrieval system according to claim 1, wherein the first drive device is operated independently of the second drive device.

3. The automated storage and retrieval system according to claim 1, wherein the second end of the first conveyor is located below a storage column.

4. The automated storage and retrieval system according to claim 1, wherein the second end of the first conveyor is located below a port column.

5. The automated storage and retrieval system according to claim 1, wherein the second end of the second conveyor is adapted for handling of the storage container by at least one of a robotic operator and a human operator.

6. The automated storage and retrieval system according to claim 1, further comprising a set of rails for an auto-pick robot, wherein the second conveyor is passing underneath the set of rails for the auto-pick robot.

7. The automated storage and retrieval system according to claim 1, wherein the second conveyor further comprising weighing devices to weigh the storage containers.

8. The automated storage and retrieval system according to claim 7, wherein the weighing devices are positioned between a support structure of the second conveyor and a mounting surface of the support structure.

9. The automated storage and retrieval system according to claim 1, further comprising a plurality of the conveyor systems positioned adjacently one another in a vertical direction.

10. The automated storage and retrieval system according to claim 1, further comprising a plurality of the conveyor systems positioned adjacent one another in a horizontal direction.

11. The automated storage and retrieval system according to claim 1, wherein each of the conveyors is comprising two parallel conveyor-halves, each conveyor half comprising a drive device adapted to move the conveyor half.

12. The automated storage and retrieval system according to claim 11, wherein the drive devices are positioned between the two parallel conveyor-halves.

13. The automated storage and retrieval system according to claim 11, wherein each conveyor half comprises a plurality of rollers and the drive device comprises at least one belt linking adjacent rollers.

14. A method for transporting storage containers in an automated storage and retrieval system comprising a framework structure and a delivery system, wherein the framework structure comprises: upright members, horizontal members, and a storage volume comprising storage columns and port columns arranged in rows between the upright members and the horizontal members; a rail system arranged across the top of framework structure, the rail system comprising a first set of parallel rails arranged to guide movement of container handling vehicles in a first direction across the top of the frame structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicles in a second direction which is perpendicular to the first direction, and access openings to the columns, the container handling vehicles being operable to raise a storage container from the storage columns, and transport the storage container above the storage columns to the port column, and lower the storage container into the port column; the delivery system comprises at least one conveyor system comprising: a first conveyor located below the rail system and extending from a first end below the port column to a second end below a second column, the first end arranged to receive the storage container through the port column, the first conveyor comprising a first drive device for moving the storage container on the first conveyor between the first and second ends; a second conveyor aligned with the first conveyor and arranged as an extension of the first conveyor, the second conveyor having a first end positioned adjacent the first end of the first conveyor and a second end positioned outside an outer periphery of the framework structure, the second conveyor comprising a second drive device for moving the storage container on the second conveyor between first and seconds ends of the second conveyor; wherein the at least one conveyor system is arranged for returning the storage container through the port column by moving the storage container from the second end of the second conveyor to the first end of the first conveyor via the second end of the first conveyor, wherein the method comprises: raising, using a first container handling vehicle, a first storage container from a storage column; transporting, using the first container handling vehicle, the first storage container, on the rail system to the port column; lowering, using the first container handling vehicle, the first storage container through the port column onto the first end of the first conveyor; moving, using the first drive device and the second drive device, the first storage container from the first end of the first conveyor to the second end of the second conveyor; moving, using the first drive device and the second drive device, the first storage container from the second end of the second conveyor to the first end of the first conveyor via the second end of the first conveyor; and returning the first storage container to the framework structure by lifting, using a second container handling vehicle, the first storage container through the port column.

15. The method according to claim 14, wherein the method further comprises lowering, using the second container handling vehicle, a second storage container through the port column onto the first end of the first conveyor, when the first storage container is on the second end of the first conveyor.

16. The method according to claim 15, wherein the method further comprises leaving the second container handling vehicle in position above the port column after lowering the second storage container onto the first end of the first conveyor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Following drawings are appended to facilitate the understanding of the invention. The drawings show embodiments of the invention, which will now be described by way of example only, where:

[0050] FIG. 1 is a perspective view of a framework structure of a prior art automated storage and retrieval system.

[0051] FIG. 2 is a perspective view of a prior art container handling vehicle having a centrally arranged cavity for carrying storage containers therein.

[0052] FIG. 3 is a perspective view of a prior art container handling vehicle having a cantilever for carrying storage containers underneath.

[0053] FIG. 4a is a schematic top view of a prior art conveyor port.

[0054] FIG. 4b is a schematic illustration of the prior art conveyor port of FIG. 4a.

[0055] FIG. 5 is a perspective view of an exemplary automated storage and retrieval system according to the present invention.

[0056] FIG. 6 is a schematic top view of exemplary conveyor systems according to the present invention.

[0057] FIG. 7 is a schematic illustration of an an exemplary automated storage and retrieval system according to the present invention.

[0058] FIG. 8 is a perspective view of an exemplary automated storage and retrieval system according to the present invention.

[0059] FIG. 9 is a perspective view of an exemplary automated storage and retrieval system according to the present invention.

[0060] FIG. 10 is a top view of an exemplary automated storage and retrieval system according to the present invention.

[0061] FIG. 11 is a perspective view of an exemplary roller conveyor according to the present invention.

[0062] FIG. 12 is a side view of the exemplary roller conveyor of FIG. 11.

DETAILED DESCRIPTION OF THE INVENTION

[0063] In the following different alternatives 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 features are described in relation to the system only, it is apparent that they are valid for the methods as well, and vice versa.

[0064] The framework structure 100 of the automated storage and retrieval system 1 is constructed in accordance with the prior art framework structure 100 described above in connection with FIGS. 1-3, i.e. a number of upright members 102 and a number of horizontal members 103, which are supported by the upright members 102, and further that the framework structure 100 comprises a first, upper rail system 108 in the X direction and Y direction.

[0065] The framework structure 100 further comprises storage compartments in the form of storage columns 105 provided between the members 102, 103, where storage containers 106 are stackable in stacks 107 within the storage columns 105.

[0066] The framework structure 100 can be of any size. In particular it is understood that the framework structure can be considerably wider and/or longer and/or deeper than disclosed in FIG. 1. For example, the framework structure 100 may have a horizontal extent of more than 700×700 columns and a storage depth of more than twelve containers.

[0067] One embodiment of the automated storage and retrieval system according to the invention will now be discussed in more detail with reference to FIG. 5 and FIG. 6a.

[0068] FIG. 5 is a perspective view of a part of the automated storage and retrieval system 1 comprising a framework structure 100 and a delivery system 140. The delivery system 140 comprises a conveyor system 500, comprising a first conveyor 501 located below the rail system 108 and extending from a first end 503 below the port column 119 to a second end 502 below a second column. The first end 503 is arranged to receive a storage container 106 through the port column 119. The first conveyor 501 comprises a first drive device for moving the storage container 106 on the first conveyor 501 between the first and second ends. The first conveyor 501 has space for at least two storage containers. The delivery system 140 also comprises a second conveyor 505 aligned with the first conveyor 501 and arranged as an extension of the first conveyor 501. The second conveyor 505 has a first end 506 positioned adjacent the first end 503 of the first conveyor 501 and a second end 504 positioned outside an outer periphery 507 of the framework structure. The outer periphery 507 may in one embodiment be provided by a cover 800. The second conveyor 505 comprises a second drive device for moving the storage container on the second conveyor 505 between its first and second ends, 506, 504.

[0069] The second end 504 of the second conveyor 505 is located outside the storage grid 104, the outer periphery of the framework structure 100 is illustrated with a solid line 507. The second end 504 may be referred to as an access station, or the handling position of the conveyor port 500. The handling position may be a picking and/or supply station allowing an operator to pick or supply items from/to the storage grid 104. In the illustrated embodiment, the second end 502 of the first conveyor 501 is located below a storage column 105. In an alternative embodiment, the second end 502 of the first conveyor 501 may be located below a port column.

[0070] The second conveyor 505 may be provided with weighing devices 508 adapted to weigh the storage bin containers. In the embodiment illustrated in FIG. 5, the weighing devices 508 are positioned between a support structure 509 of the second conveyor 505 and a mounting surface, such as a floor, of the support structure 509. In an alternative embodiment, the weighing devices 508 are positioned between the support structure 509 and the second conveyor 505.

[0071] FIG. 7 schematically illustrates the functionality of the conveyor port 500. i-ii) Once a storage container A has been presented to an operator at the handling position 504, the second drive device of the second conveyor 505 moves the storage container A from the handling position 504 to the first end 506, then to the first end 503 of the first conveyor 501, that, using the first drive device of the first conveyor 501, moves the storage container to the second end 502 of the first conveyor 501. The second end 502 of the first conveyor is also referred to as the wait position 502. While the storage container A was presented to the operator, another storage container B was lowered through the port column 119 to a position above the first end 503 of the first conveyor 501. The first end 503 of the first end of the first conveyor is also referred to as the get/put position 503. Storage container B may be held in position by the lifting device of a container handling vehicle 201, 301. iii) While the storage container A is in the wait position 502, the storage container B is lowered and released on the first conveyor 501 in the get/put position 503, e.g. by the lifting device of the container handling vehicle. iv-v) Once the storage container B has been released on the first conveyor 501, the first conveyor 501 moves both the storage container A and the storage container B simultaneously, such that storage container A is moved to the get/put position 503, and storage container B is moved onto the first end 506 of the second conveyor 505. The first conveyor 501 stops moving when storage container A is in the get/put position 503. vi) The second conveyor 505, moving independently of the first conveyor 501, continues to move the storage container B towards the handling position 504. vii) While the storage container B moves towards the handling position 504, or is in the handling position 504, storage container A is lifted through the port column 119, e.g. by the lifting device of the container handling vehicle, for storage in a storage column 105.

[0072] In this way, the at least one conveyor system 500 is arranged for returning the storage container 106 through the port column 119 by moving the storage container 106 from the second end 504 of the second conveyor 505 to the first end 503 of the first conveyor 501 via the second end 502 of the first conveyor 501.

[0073] Once storage container A has been removed from the port column 119, another storage container may be lowered through the port column 119 to the position above the get/put position 503. For a quick removal of a storage container from the conveyor belt 501, the lifting device of the handling vehicle may be kept in a ready position immediately above the get/put position 503 after releasing the storage container on the conveyor belt 501.

[0074] The first drive device may be operated independently of the second drive device, and vice versa. The use of two independently operable conveyors 501, 505 instead of the single belt conveyor 401, allows for making a longer conveyor than possible for the conveyor port 400 while maintaining the same functionality.

[0075] In one exemplary embodiment, the second conveyor 505 is made sufficiently long to avoid an operator reaching the get/put position 503 where the container handling vehicles operates, thus making the operation of a manual access station safer. One such embodiment is illustrated in FIG. 8, where a cover 800 is positioned between the outer periphery 507 of the framework structure 100 and the handling position 504.

[0076] The present invention is not limited by the length of the second conveyor 505. As such, the first conveyor 501, and hence the get/put position 503 and the corresponding port column 119 is not required to be positioned close to the periphery of the framework structure 100. The port column 119 may be put anywhere inside the framework structure 100.

[0077] The framework structure 100 may be provided with a plurality of delivery system 140. In one exemplary embodiment, a second delivery system may be positioned below the second port column 120.

[0078] In one exemplary embodiment, as illustrated in FIGS. 6a, 6b, FIG. 9 and FIG. 10, the delivery system 140 further comprises a plurality of conveyor systems 500, 600 positioned adjacent one another in a vertical direction. A second conveyor system 600 is positioned below the first conveyor system 500. The second conveyor system 600 is longer than the first conveyor system 500 and extends further into rail system 108 as well as further out of the framework structure 100. FIGS. 6a and 6b illustrates the alignment of the first 500 and second 600 conveyor system. The outer periphery of the framework structure 100 is illustrated by the solid line 507 for both systems.

[0079] The second conveyor system 600 comprises a third conveyor 601 located below the rail system 108 and extending from a first end 603 to a second end 602 at a second location. The first end 603 of the third conveyor 601 is positioned below a third port column 121 further into the container rail system 108 than the first port column 119. The third port column 121 is typically positioned adjacent the second end 502 of the first conveyor 501. The third conveyor 601 comprises a third drive device for moving a storage container on the third conveyor 601 between the first and second ends. The third conveyor 601 has space for at least two storage containers. The second conveyor system 600 also comprises a fourth conveyor 605 aligned with the third conveyor 601 and arranged as an extension of the third conveyor 601. The fourth conveyor 605 has a first end 606 positioned adjacent the first end 603 of the third conveyor 601 and a second end 604 positioned outside the outer periphery 507 of the framework structure 100. The second end 604 is typically positioned adjacent the second end 504 of the second conveyor 505. This configuration, as illustrated in FIG. 9 allows for easy access to two storage bins at the same time. The fourth conveyor 605 comprises a fourth drive device for moving the storage container on the fourth conveyor 605 between its first 606 and second 604 end. The exemplary fourth conveyor 605 has a size corresponding to approximately five storage containers.

[0080] With reference to FIG. 10, in an exemplary embodiment of the present invention, the automated storage and retrieval system may further comprise a plurality of the conveyor ports positioned adjacent one another in a horizontal direction. The illustrated automated storage and retrieval system 1 has four conveyor systems 140, each comprising two conveyor systems 500, 600. In the illustrated embodiment, the first end 503 of the first conveyor 501 is located below port column 119, and the first end 603 of the first conveyor 601 is located below port column 121.

[0081] Also illustrated in FIG. 10, the automated storage and retrieval system may further comprise a set of rails 1001 for an auto-pick robot 1002, where the second conveyor 505, 605 passes underneath the set of rails 1001 for the auto-pick robot 1002. This configuration may use auto-pick robots having a smaller range of movement than on grid auto-pick robots, thus operational speed may be increased. Furthermore, that the auto-pick robots are positioned outside a periphery of the of the framework structure 100 allows for manual pick by an operator if the auto-pick robot is out of service.

[0082] In one exemplary embodiment, the conveyor systems 140 are positioned adjacent an external conveyor system. The auto-pick robot may then pick from the storage containers and deliver to containers on an external conveyor system. The containers on the external conveyor may be cardboard boxes or other bags or boxes made for shipment directly to consumers.

[0083] In the illustrated exemplary embodiments, the first conveyor 501 and the second conveyor 505 are arranged horizontally, however, in one alternative embodiment the second conveyor 505 is arranged in a declining or inclining angle relative to the first conveyor 501, such that the storage container may be moved to a picking station at a different vertical level.

[0084] Each conveyor 501, 505, 601, 605 may be of any suitable conveyor technology, such as one or more belts, or a plurality of rollers.

[0085] Conventional roller conveyors are problematic when the storage containers 106 do not have a flat bottom surface, which is the case for most stackable storage containers, thus when the conveyor is a roller conveyor a storage container on the conveyor will only be in contact with the outer portions of the rolls. The small amount of contact between the rolls and the storage container may lead to slippage of the storage container on the rollers. The drive belt for the rolls is located on the outer end of the rolls where the storage container is in contact with the rolls. When the width of the conveyor is approximately the same width as the storage container, the storage container will also contact the drive belt. As the diameter is smaller where the drive belt is positioned the storage bin will twist and may get stuck on the conveyor. When the roller is wider, such that the drive belt is outside where the storage container is in contact with the rolls, the twisting would not occur, however, the conveyor would then be too wide to put the conveyor ports side-by-side.

[0086] In one exemplary embodiment that may be combined with any of the embodiments disclosed above, with reference to FIGS. 11 and 12, each of the conveyors 501, 505 may comprise pairs of conveyors side by side, or parallel conveyor halves 1101a, 1101b, 1102a, 1102b (not shown). Each of the conveyor halves further comprising a drive device (not shown) adapted to move the conveyor half. In the illustrated exemplary embodiment, the drive devices are positioned between the two parallel conveyor-halves 1101a, 1101b, 1102a, 1102b. In the illustrated exemplary embodiment each conveyor-half 1101a, 1101b, 1102a, 1102b comprises a plurality of rollers, and the drive devices comprise at least one belt linking adjacent rollers.

[0087] In the preceding description, various aspects of the delivery vehicle and the automated storage and retrieval system according to the invention have been described with reference to the illustrative embodiment. For purposes of explanation, specific numbers, systems and configurations were set forth in order to provide a thorough understanding of the system and its workings. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiment, as well as other embodiments of the system, which are apparent to persons skilled in the art to which the disclosed subject matter pertains, are deemed to lie within the scope of the present invention.

LIST OF REFERENCE NUMBERS

[0088] 1 Prior art automated storage and retrieval system [0089] 100 Framework structure [0090] 102 Upright members of framework structure [0091] 103 Horizontal members of framework structure [0092] 104 Storage grid [0093] 105 Storage column [0094] 106 Storage container [0095] 106′ Particular position of storage container [0096] 107 Stack [0097] 108 Rail system [0098] 110 Parallel rails in first direction (X) [0099] 110a First rail in first direction (X) [0100] 110b Second rail in first direction (X) [0101] 111 Parallel rail in second direction (Y) [0102] 111a First rail of second direction (Y) [0103] 111b Second rail of second direction (Y) [0104] 112 Access opening [0105] 119 First port column [0106] 120 Second port column [0107] 121 Third port column [0108] 140 Delivery system [0109] 150 Control system [0110] 201a Vehicle body of the storage container vehicle 201 [0111] 201b Drive means/wheel arrangement, first direction (X) [0112] 201c Drive means/wheel arrangement, second direction (Y) [0113] 301 Prior art cantilever storage container vehicle [0114] 301a Vehicle body of the storage container vehicle 301 [0115] 301b Drive means in first direction (X) [0116] 301c Drive means in second direction (Y) [0117] 304 Gripping device [0118] X First direction [0119] Y Second direction [0120] Z Third direction [0121] 500 First conveyor system [0122] 501 First conveyor [0123] 502 Second end of first conveyor (501)/Wait position [0124] 503 First end of first conveyor (501)/Get/put position [0125] 504 Second end of second conveyor (505)/Handling position [0126] 505 Second conveyor [0127] 506 First end of second conveyor (505) [0128] 507 Outer periphery of framework structure (100) [0129] 508 Weighing device [0130] 509 Support structure [0131] 600 Second conveyor system [0132] 601 Third conveyor [0133] 602 Second end of third conveyor (601)/Wait position [0134] 603 First end of third conveyor (601)/Get/put position [0135] 604 Second end of fourth conveyor (605)/Handling position [0136] 605 Fourth conveyor [0137] 606 First end of fourth conveyor (605) [0138] 800 Cover [0139] 1101a, 1102a Parallel conveyor halves of first conveyor (501) [0140] 1101b, 1102b Parallel conveyor halves of second conveyor (505)