Express bin lift for automated storage system

Abstract

A lift system for an automated storage system of the type where storage containers are stacked in storage columns arranged in a grid, and where automated container handling vehicles retrieve and replace containers from a top level of the grid. The lift system has a platform vertically movable adjacent to a face of the grid, arranged for receiving and transporting one or more containers. A dedicated mechanical device is arranged for grabbing, lifting and moving the storage containers from a staging area at the top of the grid and placing containers on the platform and vice versa.

Claims

1. An automated storage system comprising a plurality of upright members and horizontal members defining a framework structure in a form of a grid of storage columns containing storage containers arranged in stacks, and having automated container handling vehicles operating on a rail system on a top level of the grid, the rail system comprising perpendicular horizontal tracks upon which the vehicles can travel in a first direction and a second direction perpendicular to the first direction, the intersection of the perpendicular tracks further defining cells above grid columns, wherein the system comprises: a platform vertically movable adjacent to a face of the grid, arranged for receiving and transporting one or more containers, a dedicated mechanical lifting device arranged for grabbing, lifting and moving the storage containers from a top of the grid and placing containers on the platform and vice versa, and wherein the storage system comprises a plurality of grids arranged vertically above one another on different vertical levels, each of the grids provided with its own dedicated mechanical lifting device, and each of the plurality of grids having at least one face in essential vertical alignment with each other, and further wherein the platform is movable in a horizontal direction in an amount sufficient to compensate for any horizontal misalignment between the grids, such that containers transported from one level may be retrieved by the dedicated mechanical lifting device on a different level.

2. The storage system according to claim 1, wherein the dedicated mechanical lifting device is a manipulator trolley arranged to travel along two parallel trolley rails, said trolley rails extending from a position above the grid to a position above the platform, wherein an area between the trolley rails defines a staging area comprising a plurality of cells arranged to receive storage bins awaiting retrieval by the manipulator trolley and/or to receive storage bins awaiting retrieval by the handling vehicles.

3. The storage system according to claim 2, wherein the staging area comprises a first number of cells designated for holding containers awaiting transport to the platform and a second number of cells designated for placement of storage containers awaiting retrieval by container handling vehicles, said first number of cells and second number of cells each being at least equal to the number of storage containers that may be placed on the platform.

4. The storage system according to claim 1, wherein the platform comprises a vertically movable frame member arranged to travel along one or more vertical rails arranged outside and functionally adjacent to the face of the grid, a horizontally movable carriage member connected to the vertically movable frame member, the carriage member arranged for receiving containers, the carriage member being connected to the frame member by one or more guide wheels arranged to roll along one or more horizontal guide rails of the frame member.

5. The storage system according to claim 4, wherein the carriage member further comprises one or more alignment wheels connected to the carriage at a position relative to vertical rails whereby the alignment wheels are arranged to, during vertical movement of the frame member, contact and roll up a sloped surface of a protruding alignment bracket mounted on the vertical rail, thereby causing the carriage member to move in the horizontal direction in relation to the frame member.

6. The storage system according to claim 1, wherein the storage system further comprises an on and off loading station at a lower level comprising a manipulator trolley arranged to remove containers from platform and transfer the containers to a container delivery means for transporting the containers to a destination in the system.

7. The storage system according to claim 6, wherein the delivery means is a conveyor system.

8. The storage system according to claim 6, wherein the delivery means is a plurality of autonomous delivery vehicles.

9. A platform for transporting storage containers between a plurality of vertically arranged storage grids in a multi-level storage system, the grids of the storage system being vertically arranged with respect to each other, each grid of the multi-level storage system being of a type comprising a plurality of upright members and horizontal members defining a framework structure in a form of a grid section of storage columns containing storage containers arranged in stacks, and having automated container handling vehicles operating on a rail system on a top level of the grid section, the rail system comprising perpendicular horizontal tracks upon which the vehicles can travel in a first direction and a second direction perpendicular to the first direction, the intersection of the perpendicular tracks further defining cells above grid columns, wherein the platform is vertically movable along one or more vertical rails arranged outside and functionally adjacent to vertically aligned faces of the grid sections, the platform is horizontally adjustable in relation to the one or more vertical rails in an amount sufficient to accommodate a horizontal misalignment between the rail systems of the respective grid sections, and wherein the storage system comprises a plurality of grids arranged vertically above one another on different vertical levels, each of the grids provided with its own dedicated mechanical lifting device, and each of the plurality of grids having at least one face in essential vertical alignment with each other, and further wherein the platform is movable in a horizontal direction in an amount sufficient to compensate for any horizontal misalignment between the grids, such that containers transported from one level may be retrieved by the dedicated mechanical lifting device on a different level.

10. The platform according to claim 9, wherein the platform comprises a vertically movable frame member to which is connected a horizontally movable carriage member, the carriage member arranged for receiving containers, the carriage member being connected to the frame member by one or more guide wheels arranged to roll along one or more horizontal guide rails of the frame member, the carriage member further comprising one or more alignment wheels connected to the carriage at a position relative to vertical rails, whereby the guide wheels are arranged to, during vertical movement of the frame member, contact and roll up a sloped surface of a protruding alignment bracket mounted on the vertical rail, thereby causing the carriage member to move in the horizontal direction in relation to the frame member.

11. A method for transporting storage containers in an automated storage grid system of a type comprising a plurality of upright members and horizontal members defining a framework structure in a form of a grid of storage columns containing storage containers arranged in stacks, and having automated container handling vehicles operating on a rail system on a top level of the grid, the rail system comprising perpendicular horizontal tracks upon which the vehicles can travel in a first direction and a second direction perpendicular to the first direction, the intersection of the perpendicular tracks further defining cells above grid columns, wherein the method comprises: arranging a vertically moveable platform adjacent to a face of the grid, arranging a dedicated mechanical lifting device for grabbing, lifting and moving the storage containers from a top of the grid and placing containers on the platform and vice versa, designating a first number of a cells for placement of storage containers awaiting movement from the grid to the platform, designating a second number of cells for placement of storage containers awaiting retrieval by container handling vehicles, causing the container handling vehicles to place storage containers on cells, causing the dedicated mechanical lifting device to remove any containers from the platform and place said containers on cells, causing the dedicated mechanical lifting device to lift the storage containers from cells and place the containers on the platform, and causing the platform to lower the containers to a lower level in the grid system, and wherein the storage grid system comprises a plurality of grids arranged vertically above one another on different vertical levels, each of the grids provided with its own dedicated mechanical lifting device, and each of the plurality of grids having at least one face in essential vertical alignment with each other, and further wherein the platform is movable in a horizontal direction in an amount sufficient to compensate for any horizontal misalignment between the grids, such that containers transported from one level may be retrieved by the dedicated mechanical lifting device on a different level.

12. The method according to claim 11, wherein lower level is a vertically arranged lower grid section, and wherein the platform is horizontally adjustable to accommodate any horizontal misalignment between the grid section and the lower grid section.

13. The method according to claim 11, wherein the first number of cells and the second number of cells are arranged in respectively rows.

14. A method for adjusting a horizontal position of a transportation platform of a type in a multi-level storage system where the platform travels vertically along one or more vertical rails, wherein the method comprises arranging the platform to be vertically movable along the vertical rails, wherein the platform comprises a vertically movable frame member to which is connected to a horizontally movable carriage member, wherein the carriage member further comprises one or more alignment guides preferably in the form of wheels connected to the carriage member at a position whereby the alignment wheels travel along a surface of the vertical rails during vertical movement of the platform, arranging, on the vertical rails, one or more alignment brackets, the alignment brackets comprising an upper and lower sloped surface and protruding from a side of the vertical rails a distance corresponding to an intended horizontal adjustment distance for the platform, causing the alignment wheel or wheels to, during vertical movement of the frame member, contact and roll up sloped surface of the protruding alignment bracket mounted on the vertical rail, thereby causing the carriage member to move in a horizontal direction in relation to the frame member, and wherein the storage system comprises a plurality of grids arranged vertically above one another on different vertical levels, each of the grids provided with its own dedicated mechanical lifting device, and each of the plurality of grids having at least one face in essential vertical alignment with each other, and further wherein the platform is movable in a horizontal direction in an amount sufficient to compensate for any horizontal misalignment between the grids, such that containers transported from one level may be retrieved by the dedicated mechanical lifting device on a different level.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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:

(2) FIG. 1 is a perspective view of a grid of a prior art automated storage and retrieval system.

(3) FIGS. 2a and 2b show a perspective view of a prior art container handling vehicle having a centrally arranged cavity for containing storage containers therein.

(4) FIGS. 3a and 3b show a perspective view of a prior art container handling vehicle having a cantilever for containing storage containers underneath.

(5) FIG. 4 is a perspective view of a multi-level automated storage and retrieval system.

(6) FIG. 5 is a side elevational view of a multi-level automated storage and retrieval system.

(7) FIG. 6 a perspective view of a multi-level automated storage and retrieval system with container handling vehicles depicted.

(8) FIG. 7 is a side elevational view of a multi-level automated storage and retrieval system FIG. 8 is a close up view of a motor and pulley arrangement.

(9) FIG. 9 shows an embodiment of a manipulator trolley for movement of storage containers from a top level grid to a lift platform of the invention.

(10) FIG. 10 shows an embodiment of a manipulator trolley for movement of storage containers from a lower level grid to an exemplary lift platform of the invention.

(11) FIG. 11 is a top view of a staging area showing “put” cells and “get” cells.

(12) FIG. 12 is a close up perspective view showing container handling vehicles placing containers in the staging area.

(13) FIG. 13 is a perspective view of an embodiment of the lift platform.

(14) FIG. 14 is an exploded view of the lift platform of FIG. 13.

(15) FIG. 15 is a perspective view of the lift platform of FIG. 13 and means for adjusting the horizontal position of the platform.

(16) FIG. 16 is a perspective view of an automated storage and retrieval system with an offloading/onloading station at a lower level.

(17) FIG. 17 is a close up view of the offloading/onloading station with a conveyor arrangement.

(18) FIG. 18 is a close up view of the offloading/onloading station of FIG. 17 with the conveyor arrangement.

(19) FIG. 19 is a close up view of the offloading/onloading station in operation with autonomous delivery vehicles.

DETAILED DESCRIPTION OF THE INVENTION

(20) In the following, embodiments of the invention will be discussed in more detail by way of example only and with reference to the appended drawings. It should be understood, however, that the drawings are not intended to limit the invention to the subject-matter depicted in the drawings.

(21) The present invention provides an automated storage and retrieval system 1 constructed in accordance with the prior art as described above in connection with FIGS. 1-3, i.e. a framework 100 having a number of upright members 102 and a number of horizontal members 103, which are supported by the upright members 102 to define a first storage grid 104. The storage grid 104 comprises grid columns 112, a plurality of which are storage columns 105 in which are stacked storage containers 106. Framework 100 comprises a track system 108 of parallel tracks 110,111 extending in an X direction and Y direction arranged across the top of storage grid 104, upon which travel a plurality of container handling vehicles (201/301). The container handling vehicles are preferably autonomous vehicles arranged to lift storage containers 106 from storage columns 105 and transport the storage containers about the grid, as well as placing storage containers back in the storage columns 105.

(22) In FIG. 1 the storage grid 104 is shown with a height of eight cells. It is understood, however, that the storage grid 104 in principle can be of any size. In particular it is understood that storage grid 104 can be considerably wider and/or longer and/or deeper than disclosed in FIG. 1. For example, the storage grid 104 may have a horizontal extent of more than 700×700 grid cells and a depth of more than twelve grid cells.

(23) According to one aspect, automated storage and retrieval system 1 may comprise multiple levels, as shown in FIGS. 4 and 5 which depict two levels of storage grids 104 and 104′. There, first storage grid 104 is arranged vertically above a corresponding second storage grid 104′, for example on an upper floor of a building directly above second storage grid 104′. FIG. 4 depicts first storage grid 104 and second storage grid 104′ as having the same number columns in the X and Y directions. It should be understood that this is not necessarily the case, as the grids on different levels may have different configurations. As can be seen in FIG. 5, grid columns 112 of first storage grid 104 are essentially in alignment with corresponding grid columns 112′ of second storage grid 104 along a front face 400 and 400′ respectively. FIG. 6 shows container handling vehicles 201 and 201′ (alternatively 301/301′) traveling on rail system 108 and 108′ respectively.

(24) According to one aspect, the present invention provides a bin lift arrangement for transporting storage bins between levels in a multi-level automated storage and retrieval system, and for transporting storage bins between the top of a storage grid 104/104′ to the bottom of the storage grid, where the storage bins can for example be further transported to an access station.

(25) The bin lift arrangement comprises a vertically movable platform 402 that is vertically movable, adjacent to a face of the grid, along one or more, preferably two, vertical lift rails 404. As can be seen in FIG. 5, platform 402 has a depth essentially corresponding to the width of a storage container 106, and lift rails 404 are arranged outside a face, for example a front face 400/400′ of storage grid 104/104′ in this embodiment at a distance such that a front edge of platform 402 is functionally adjacent to front face 400/400′.

(26) The term “functionally adjacent” as used herein means that the platform can move up and down in the vicinity of grids 104/104′ without interference. Platform 402 is arranged to receive and transport one or more storage bins 106 in a vertical direction. Platform 402 may be movable by a motor and pulley arrangement 406, e.g., as shown in FIG. 8 or by other lifting means known in the art.

(27) Storage containers 106 are movable from storage grid 104/104′ to and from platform 402 by a dedicated mechanical device for grabbing, lifting and moving the storage containers. The term “dedicated mechanical device” as used herein refers to a device separate from the container handling vehicles 201/201′/01/301′, the function of which is primarily reserved for the movement of containers between the grid and the platform and vice versa. In one embodiment such a device is in the form of a manipulator trolley 408/408′ as shown in FIGS. 9 and 10. FIG. 9 shows a manipulator trolley 408 arranged in connection with a top level grid 104, while FIG. 10 shows a manipulator trolley 408 arranged in connection with lower level grid 104′. Manipulator trolleys 408/408′ have one or more grabbing/lifting mechanisms 410 arranged to grab a storage container 106 from a position at the top of the storage grid and lift the container upward, whereupon the manipulator trolley 408/408′ transports the storage container to a position above platform 402, whereupon the grabbing/lifting mechanism 410 lowers the storage container onto the platform. When platform 402 returns with storage containers 106, the manipulator trolleys 408/408′ perform this sequence in reverse to remove a container from the platform 402 and place it on the top of the storage grid 104/104′.

(28) Manipulator trolleys 408/408′ are movable from the position over the storage grid 104/104′ to the position over platform 402 by travelling by a motorized mechanism along horizontal trolley rails 412. In one embodiment, shown in FIG. 5, trolley rails 412 are arranged immediately above rail system 108/108′ on which the container handling vehicles 201,301 travel. In another embodiment, shown in FIG. 6, trolley rails 412 may be suspended above rail system 108/108′ at distance greater than the height of the vehicles such that the vehicles can travel underneath the trolley rails 412.

(29) According to one aspect of the invention, as shown in FIG. 11, the area of the grid arranged between trolley rails 412 denotes a staging area 414. Staging area 414 comprises cells at the top level of the grid where containers 106 may be placed by vehicles 201/301 where they wait to be retrieved and moved by manipulator trolley 408, as well as cells where manipulator trolley may place cells where they wait to be retrieved by vehicles. These cells may be referred to as “put” cells and “get” cells respectively, represented by the letters P and G in FIG. 11. Here there is shown four put cells along the far edge of the grid surface, and four get cells arranged along the next inner most row, corresponding to a platform 402 with a capacity of four containers 106. It should be understood that platform 402 may have a different capacity, and that staging area 414 and the put cells P and get cells G may be arranged in any manner and may be dynamically redesignated as necessary, for example according to routing considerations determined by the automated storage system.

(30) In operation, as illustrated in FIG. 12, container handling vehicles 201,301 place containers 106 in the put cells P, thus freeing the vehicles to attend to other tasks. Manipulator trolley 408/408′ will then grab the containers 106 in the put cells P, preferably grabbing and lifting the containers 106 in unison, and place the containers 106 on platform 402. In the event that the platform 402 is transporting containers 106 for replacement in the storage columns 112,112′, the manipulator trolley 408 will first place the returning containers in the get cells G, move over to the put cells P and lift the containers 106 arranged there, and thereafter place those containers on platform 402. Vehicles may then arrive to retrieve the containers 106 from the get cells G, and replace them in the storage columns 112,112′.

(31) According to one embodiment of the invention, platform 402 is movable in a horizontal direction, transverse to its vertical direction of travel. This horizontal movement is provided to account for any potential horizontal misalignment between columns 112 of different grid levels. FIGS. 13-15 illustrate one embodiment of platform 402 that provides for such horizontal displacement. It should be understood that other arrangements for horizontal adjustment of platform 402 are possible within the scope of the invention.

(32) FIG. 13 shows an assembled platform 402, while FIG. 14 shows an exploded view of platform 402. Platform 402 comprises a rectangular lifting frame 416. Lifting frame 416 has connection points 418 along a top edge, for example a shackle, for attachment to one or more pulley lines 420 operated by motor/pulley arrangement 406. Lifting frame 416 further comprises a plurality of rail wheels 422 arranged to engage and travel along lift rails 404.

(33) Platform 402 further comprises a horizontally movable carriage member 424 with a receiving surface 426 on which storage bins 106 may be placed. Carriage member 424 has rearward extending guide wheels 428 mounted on a bracket 430. As seen in FIG. 13, guide wheels 428 engage an inner surface of horizontal guide rails 432 of lifting frame 416. Guide wheels 428 thus allow carriage member 424 to move horizontally in relation to lifting frame 416.

(34) As shown in FIG. 15, lifting frame 416 has essentially the same width as the space between lift rails 404, with carriage member 424 being wider than and extending beyond lift rails 404 to both sides. Carriage member 424 is equipped with one or more alignment wheels 434. Alignment wheels 434 are mounted in a position on the back portion of carriage member 424 such that alignment wheels 434 are arranged to the outsides of lift rails 404.

(35) In the event the columns of a second grid level are out of alignment in the horizontal direction with a first level by a known distance, an alignment bracket 436 may attached to lift rail 404 at the vertical position where platform 402 will stop to retrieve or unload containers. Alignment bracket 436 has sloped portions 438 and an intermediate straight portion 440. Sloped portions 438 are arranged to extend the straight portion 440 a distance from the lift rails 402 a distance corresponding to the degree of misalignment between columns of the two levels. As can be appreciated from FIG. 15, as platform 402 is lowered along lift rails 404, alignment wheels 434 will ride up along sloped portion 438, thereby causing carriage member 424 to move horizontally, via guide wheels 428 in relation to lifting frame 416. According to one embodiment, the storage and retrieval system may comprise an inventory of alignment brackets 436 with various offset distances. In the event that grid levels become out of alignment, the operator of the system can simply select the bracket with appropriate offset.

(36) According to yet another embodiment of the invention, an offloading/onloading station 442 may be arranged at a lower level of the automated storage system, at the bottom of lift rails 404. At offloading/onloading station 442, storage bins are moved by a manipulator trolley 408 arranged in connection with station 442 for offloading storage bins from the lifting arrangement for transport to a different location, for example to an access station (not shown) where the bins can be accessed by an operator. Conversely, bins may be loaded onto the lift arrangement at station 442 for transporting to an upper level of the grid. FIG. 16 shows station 442, with platform 402 at an upper level of the grid for retrieving bins 106, FIG. 17 shows platform 402 in transit to station 442, while FIG. 18 shows platform 402 arrived at station 442. In FIG. 18, it can be seen that manipulator trolley 408 travels along trolley rails 412 to onload/offload bins 106 from platform 402.

(37) FIGS. 16-18 show a first embodiment where manipulator trolley 408 moves bins 106 onto, and retrieves bins 106 from a convey system comprising a delivery line 444 and a return line 446. Lines 444 and 446 transport bins 106 to a different location, for example an access station (not shown). In an alternative embodiment, manipulator trolley 408 at offloading/onloading station 442 may place bins 106 directly into, or retrieve bins 106 directly from, one or more autonomous delivery vehicles. Delivery vehicles 408 are more fully described in applications NO20180813 filed 12 Jun. 2018 and NO20181005 filed 19 Jul. 2018, the entire contents of which are hereby incorporated by reference as if fully reproduced herein. Delivery vehicles 448 have a bin receiving portion where bins 106 may be placed by manipulator trolley 408. Delivery vehicles 448 are then free to travel along their own dedicated rail system 450 to a different location, such as the access station. The combination of the lifting arrangement of the present invention with the autonomous delivery vehicles may dramatically increase the flexibility and throughput of the automated storage system. The dedicated rail system may comprise a first rail system located within the framework structure of the storage grid, and a second rail system located outside the framework structure of the storage grid, and wherein the first and second rail system are connected such that the delivery vehicle may operate between said rail systems.

(38) The second location may be connected to the second rail system.

LIST OF REFERENCE NUMBERS

(39) 100 framework 102 upright members 103 horizontal members 104 storage grid 105 storage columns 106 storage containers 107 stacks 108 track system 110/111 tracks 112 grid columns 119,120 port column’ 201,301 container handling vehicles 202 gripping/lifting mechanism 303 cantilever construction 400 front face of grid 402 platform 404 lift rails 406 motor/pulley arrangement 408 manipulator trolley 410 grabbing/lifting mechanism 412 trolley rails 414 staging area 416 lifting frame 418 connection points 420 pulley line 422 rail wheels 424 carriage member 426 receiving surface 428 guide wheels 430 bracket 432 guide rails 434 alignment wheels 436 alignment bracket 438 sloped portion 440 straight portion 442 On/off loading station 444 delivery line 446 return line 448 autonomous delivery vehicle