SYSTEM AND METHOD FOR GRAVITATIONAL UNLOADING OF ITEMS FROM A CONTAINER

Abstract

System and method for unloading a container of its content, comprising an automated storage and retrieval system, wherein the system comprises a rail system comprising a first set of parallel rails arranged to guide movement of a container handling vehicle in a first direction across the top of a framework structure, and a second set of parallel rails arranged perpendicular to the first set of rails to guide movement of the container handling vehicle in a second direction which is perpendicular to the first direction, the first and second sets of parallel rails dividing the rail system into a plurality of grid cells, the framework structure comprises upright members and horizontal members, at least one container handling vehicle configured to operate on the rail system, wherein the at least one container handling vehicle is provided with at least one orientation sensor configured to measure at least one orientation parameter of the sensor in a three-dimensional cartesian reference system, a central control unit configured to receive, transmit and process data signals of the container handling vehicle and to receive and process data signals of the sensor, at least one container comprised of four side walls and a bottom creating an open box structure, means for transporting the container to an unloading station where the content of the container is emptied by gravity wherein the unloading station comprises a container tipping device that tips the container around at least one axis, emptying the content.

Claims

1. A method, executed using a storage and retrieval system, of unloading a container of its contents, wherein the container comprises four side walls and a bottom in an open box structure, wherein the storage and retrieval system comprises means for transporting the container to an unloading station to empty the contents of the container by gravity, the method comprising: collecting a container from the storage and retrieval system; transporting the container to the unloading station using a means of transportation; unloading the contents by tipping the container at least partially around at least one axis; turning the container to an upright position; and transporting the container back to the unloading station using the means of transportation.

2. The method of claim 1 wherein the means of transportation comprises a conveyor belt, chains with hooks, rollers, roller balls or a gravity-driven system.

3. The method of claim 1, wherein the container comprises a plurality of compartments of one or more compartment combinations, wherein the unloading station comprises a plurality of lids, each of the lids corresponding to a compartment combination of the container, the method further comprising: registering the compartment combination of a specific container with an identifier of the container; and in response to the container entering the unloading station, opening a particular lid and unloading the contents of a particular compartment corresponding to the particular lid.

4. The method of claim 3, wherein the lids are in a cradle on which the container is placed when the container enters the unloading station.

5. The method of claim 1, further comprising: in response to a container entering the unloading station, a pusher giving the container an initial push to propel the container and every container in front one position forward by every container pushing on another container; and in response to the container passing through the unloading station, transporting the container back into the storage and retrieval system or sending the container for refilling.

6. A method of unloading a container in an automated storage and retrieval system, wherein the automated storage and retrieval system comprises a rail system comprising a first set of parallel rails arranged to guide movement of a container handling vehicle in a first direction across a top of a framework structure, and a second set of parallel rails arranged perpendicular to the first set of parallel rails to guide movement of the container handling vehicle in a second direction which is perpendicular to the first direction, the first set of parallel rails and the second set of parallel rails dividing the rail system into a plurality of grid cells, the framework structure comprising upright members and horizontal members, at least one container handling vehicle being configured to operate on the rail system, wherein the at least one container handling vehicle comprises at least one orientation sensor configured to measure at least one orientation parameter of the at least one orientation sensor in a three-dimensional cartesian reference system, wherein the automated storage and retrieval system comprises a central control unit configured to receive, transmit and process data signals of the container handling vehicle and to receive and process data signals of the at least one orientation sensor, wherein the automated storage and retrieval system comprises at least one container comprised of four side walls and a bottom creating an open box structure, the method comprising: transporting the container to an unloading station; using a container rotating device of the unloading station, rotating the container around at least one axis; emptying a contents of the container by gravity; and guiding the container along a helical path.

7. The method of claim 6, wherein the unloading station has an opening for allowing the contents of the container to empty.

8. The method of claim 6, wherein the container rotating device comprises at least one rail defining a path for the container, the method further comprising, using the at least one rail, guiding the container as it travels through the unloading station and turning the container at least partially around said at least one axis.

9. The method of claim 6, wherein the container rotating device comprises a tube with a tunnel, the method further comprising, using the tube, guiding the container through the unloading station and turning the container at least partially around said at least one axis.

10. The method of claim 6, wherein the container rotating device comprises a set of wheels pushed up against the container, the method further comprising rotating the set of wheels to turn the container around.

11. The method of claim 6, wherein the means for transporting the container to the unloading station comprises a conveyor belt, chains with hooks, rollers, roller balls or a gravity-driven system or a mechanical arm pushing the container.

12. The method of claim 6, wherein the container comprises several compartments, wherein each compartment of the container has its own lid.

13. The method of claim 12, further comprising covering a particular compartment of the container using a lid connected to the opening in the unloading station.

14. The method of claim 12, further comprising covering a particular compartment of the container using a lid in a cradle of the unloading station.

15. The method of claim 14, wherein each lid can be individually unlocked allowing only the contents of a particular compartment with an unlocked lid to be emptied.

16. The method of claim 14, wherein the unloading station comprises a measuring device allowing it to control a shutter device in the lid to control an amount of the contents to be unloaded from the container.

17. A method of unloading a container using an unloading system of an automated storage and retrieval system, the unloading system comprising a central control unit configured to receive, transmit and process data signals of a container handling vehicle and to receive and/or process data signals of an orientation sensor configured to measure at least one orientation parameter of the orientation sensor in a three-dimensional cartesian reference system, and an unloading station comprising a container rotating device, the method comprising: using the container rotating device, rotating the container around at least one axis; and emptying a required amount of contents of the container; wherein the container rotating device comprises a guide surface which guides the container along a helical path.

18. The method of claim 17, wherein the container rotating device further comprises at least one rail defining a path for the container, the method further comprising, using the at least one rail, guiding a container as it travels through the unloading station and turning the container at least partially around said at least one axis.

19. The method of claim 17, wherein the container rotating device comprises a tube with a tunnel, the method further comprising, using the tube, guiding the container through the unloading station and turning the container at least partially around said at least one axis.

20. The method of claim 17, further comprising turning the container around using, in the container rotating device, a set of wheels pushed up against the container by said set of wheels rotating to turn the container around.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] 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:

[0042] FIG. 1 is a perspective view of a framework structure of a prior art automated storage and retrieval system.

[0043] FIG. 2 is a perspective view of a prior art container handling vehicle having an internally arranged cavity for carrying storage containers therein.

[0044] FIG. 3 is a perspective view of a prior art container handling vehicle having a cantilever for carrying storage containers underneath.

[0045] FIG. 4 is a perspective view from underneath of a central cavity container handling vehicle where a lifting platform for handling containers is visible.

[0046] FIG. 5A and FIG. 5B is a perspective view of an embodiment of the present invention wherein a helix screw is enclosed in a box shape wherein one of the containers enters one side and is turned around by the helix screw allowing the contents to be poured from the container into a collecting station.

[0047] FIG. 6 is an alternative embodiment of the present invention where a framework of rails guides the container and allows it to be turned around and the content of the container to be emptied into a collecting station.

[0048] FIG. 7 is yet another embodiment of the present invention wherein a set of biased wheels press against the sides of the container spinning the container around allowing the items in the container to empty into a collecting station.

DETAILED DESCRIPTION

[0049] In the following, embodiments of the invention will be discussed in more detail with reference to the appended drawings. It should be understood, however, that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0050] 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.

[0051] 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.

[0052] 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 700700 columns and a storage depth of more than twelve containers.

[0053] FIG. 4 is a perspective view from underneath of a central cavity container handling vehicle where a lifting platform for handling containers are visible.

[0054] FIGS. 5A and 5B are a perspective view of an embodiment of the present invention wherein a helix screw enclosed in a box shape wherein one of the containers enters one side and are turned around by the helix screw allowing the contents to be poured from the container into a collecting station.

[0055] The box shape has an opening in either end in the form of a tunnel running through the box for guiding the container. The tunnel has a shape that is similar to the shape of a container. The container can be propelled through the tunnel by gravity working on the box. In this scenario the box is at an incline falling controlled through the tunnel in the box. Alternatively, the box can be propelled through the tunnel by a propelling mechanism This propelling mechanism can be either rollers, roller balls, conveyor belts, chains and hooks, or any other type of propelling solution that will allow a container to move through a tunnel.

[0056] In an alternative solution the container can be pushed through the unloading system by the containers entering after it. When a container enters the unloading system a pusher gives the container an initial push. The push propels the container and every container in front one position forward by every container pushing on the container in front. When the container has passed through the unloading system the container is transported back into the grid or it can be sent for refilling.

[0057] The tunnel is twisted in the form of a helix screw. This allows the container to turn as the tunnel turns. The box is enclosed and ensures that the content of the items does not spill out of the container as it moves through the helix screw in the box. However, in order to be able to collect the items in the container, it is essential that the items leave the container at the right time. The box therefore has at least one opening in the side that allows the items in the container to be emptied. The opening in the side of the box is at least smaller than the container itself. The opening can be so large that it allows all the content of the container to be emptied into a collecting station.

[0058] Alternatively, the hole in the side of the box can be long allowing the content of the container to be emptied over a longer area. Further there can be more than one hole. If there are more than one hole the at intervals of the holes allow can be spaced apart in such a way that the content of the container can be emptied into several collecting stations.

[0059] The helix screw in the box can turn the container around 360 degrees. Alternatively, the screwing motion can turn the box any degree and back again. This would e.g., allow the container to tilt around one axis a certain number of degrees and then back again allowing the container to e.g., not empty its entire content in one go.

[0060] Alternatively, the container can be divided into compartments. In this scenario each compartment has one lid. This lid can be closed and opened at the instructions from the central computer system. this would allow the content of only one or more specified compartments to be emptied at a time.

[0061] In yet another solution each opening in the side of the box can have a shutter solution that allows a specified amount of the content to be emptied, this shutter solution can be controlled by the central computer system that keeps track of which container is at the collecting station at any one time and also know what items to collect at the collecting station at any one time and what amount of the item to be collected.

[0062] When the items that it in the compartments are powders or liquids, or any type of material that cannot be counted, like e.g., powders or liquids, thy can be weighed or measured at the collecting station. The shutter device can ensure that the right amount of powders and liquids are pored from the container.

[0063] When unloading bigger items that are not weighed or measured, but are counted, the shutter system can open and close allowing only one item to exit the container at a time. Alternatively, sensors can be placed around the opening of the unloading station counting the number of items that falls out of the container. The sensors in question can be e.g., cameras

[0064] The collecting station can be in the form of a container that the items drops into or it can be in the form of a plastic bag or any other form of solution that allows for collecting items.

[0065] The collecting station can be boxes on a conveyor belt transporting collected items to a pick-up point.

[0066] In FIG. 5A, the arrow B indicates the traveling direction of the container into the tunnel in the box. The arrow A indicated the shape of the tunnel forming a helix screw through the box.

[0067] FIG. 6 is an alternative embodiment of the present invention where a framework of rails guides the container and allows it to be turned around and the content of the container being emptied into a collecting station.

[0068] The rails guide the container through the system. There can be two or more rails for guiding the container through the system. The container is held in place by the rails and is moved forward through the system by a propelling mechanism. This propelling mechanism can be either rollers, roller balls, conveyor belts, chains and hooks, or any other type of propelling solution that will allow a container to move through the rails.

[0069] Alternatively, the container can be inverted by a mechanism that grabs hold of the container and turns the container around poring the content out. The container can have different compartments containing different content. The mechanism can therefore have lids that are capable of closing of certain compartments and only pour out the content of specific compartments.

[0070] This mechanism can be a robotic arm. The robotic arm can be controlled by the central computer system.

[0071] In a two-rail solution, the container can be placed in a cradle that is propelled using rollers, roller balls, conveyor belts, chains and hooks or any similar solution. The rails follow a similar helix screw shape. The helix shape of the two rails inverts the container. By inverting the container, the items in the container are emptied out into a collection station.

[0072] By using a cradle, it is also possible to use a monorail system. The cradle is attached to the monorail, and the container is placed in the cradle. The monorail system transports the cradle with the container through the unloading system, and the container is picked up and transported back into the grid when the system is

[0073] In a four-rail solution, the container can be held in place by the rails and propelled through the unloading system by e.g., a conveyor belt, rollers, roller balls or similar attached to either rail pushing on the container while at the same time propelling the container forward. The helix shape of the four rails allows the container to be inverted as it travels through the rails. The inverting of the container empties the content of the container into a collection station.

[0074] The two and four rail solution can be either with or without a cradle. Further there can be two cradles handling the container. There can be one cradle at the top and one cradle at the bottom. The cradle covering the top of the container can have lid(s) that cover the compartments in the container. The lid(s) can be unlocked, uncovering the compartments of interest.

[0075] In either of these two solutions the tracks and rails can either rotate the container all the way around or it can rotate the container any number of degrees and then back again. By rotating the container a predetermined degrees and then back again it allows for a better control of the emptying of the container.

[0076] Depending on the material inside the container, by rotating the container a predetermined number of degrees this allows for the possibility of controlling the speed of the unloading.

[0077] In an alternative embodiment, the container can be divided into compartments. In this scenario each compartment can have one lid. This lid can be closed and opened at the instructions from the central computer system. this would allow the content of only one or more specified compartments to be emptied at a time.

[0078] The collecting station can be boxes on a conveyor belt transporting collected items to a pick-up point.

[0079] The arrow C indicates how the shape of the rails is capable of rotating the container making it possible to empty the content into a collecting station.

[0080] FIG. 7 presents an alternative embodiment of the present invention. In this embodiment there are a set of wheels that are biased pressing against the container. When the wheels turn around the same way the container is turned around. By rotating the container around the items stored therein can be emptied from the container.

[0081] In this solution the container can be turned any number of degrees depending on how much of the items that needs to be emptied from the container. By inverting the container, all the contents of the container are emptied. However, by rotating the container a predetermined number of degrees it is possible to control the amount of content that is emptied from the container.

[0082] The spring function of the biased wheels allows the wheels to follow the contours of the container as it rotates.

[0083] The collecting station can be in the form of a container that the items drops into or it can be in the form of a plastic bag or any other form of solution that allows for collecting items.

[0084] In an embodiment there is also possible to turn the container by using a robotic arm. The robotic arm can be used to turn the container around in order to empty the content of the container in a collecting station.

[0085] The collecting station can be boxes on a conveyor belt transporting collected items to a pick-up point.

[0086] 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

Prior Art (FIG. 1-4)

[0087] 1 Prior art automated storage and retrieval system [0088] 100 Framework structure [0089] 102 Upright members of framework structure [0090] 103 Horizontal members of framework structure [0091] 104 Storage grid [0092] 105 Storage column [0093] 106 Storage container [0094] 106 Particular position of storage container [0095] 107 Stack [0096] 108 Rail system [0097] 110 Parallel rails in first direction (X) [0098] 110a First rail in first direction (X) [0099] 110b Second rail in first direction (X) [0100] 111 Parallel rail in second direction (Y) [0101] 111a First rail of second direction (Y) [0102] 111b Second rail of second direction (Y) [0103] 112 Access opening [0104] 119 First port column [0105] 120 Second port column [0106] 201 Prior art container handling vehicle [0107] 201a Vehicle body of the container handling vehicle 201 [0108] 201b Drive means/wheel arrangement, first direction (X) [0109] 201c Drive means/wheel arrangement, second direction (Y) [0110] 301 Prior art cantilever container handling vehicle [0111] 301a Vehicle body of the container handling vehicle 301 [0112] 301b Drive means in first direction (X) [0113] 301c Drive means in second direction (Y) [0114] 401 Prior art container handling vehicle [0115] 401a Vehicle body of the container handling vehicle 401 [0116] 401b Drive means in first direction (X) [0117] 401c Drive means in second direction (Y) [0118] Y Second direction [0119] Z Third direction [0120] 1 Container [0121] 2 Box with a tunnel in a helix screw [0122] 3 Spring biased wheels. [0123] 4 Rails [0124] 5 Opening for unloading the items from the container