Vertical part storage system

Abstract

Embodiments of the present disclosure include a component storage and retrieval system that includes a storage stack, an operator access station, and an automated elevator. The storage stack defines discrete tray storage locations. The operator access station includes a surface adapted to support a tray. The automated elevator moves the pallets from the access station surface to a specified one of the discrete pallet storage locations and retrieves the selected pallets from the storage stack and brings the selected pallets to the access station. The access station includes a camera positioned such that a tray supported on the surface is within a field of view of the camera. The camera generates data representing an image of the tray from which the system identifies the component on the tray and determines where the component is located on the tray. The system communicates the identified location to the operator.

Description

Technical Field

[0001] The present disclosure relates generally to storage systems and, more particularly, to electronic component reel storage and inventory management systems. Background Art

[0002] Storing electronic component reels and managing large inventories of reels can be expensive and time consuming. There can be many challenges in storing and retrieving small items in large stacks or piles. In some cases, it can be particularly difficult to find and store a specific reel within a large group of items. Some challenges include finding ways to best utilize dedicated rack space and finding ways to quickly store and retrieve reels using automated equipment. Methods for improving storage systems are sought. Summary of the invention

[0003] Embodiments of the present disclosure include a component storage and retrieval system that includes a storage stack, an operator access station, and an automated lift. The storage stack defines discrete pallet storage locations at different levels. The operator access station includes a surface suitable for supporting a movable pallet. The automated lift moves the pallet from the access station surface to a designated storage location among the discrete pallet storage locations of the storage stack, and retrieves the selected pallet from the storage stack and brings the selected pallet to the access station. The access station includes a fixed camera positioned so that the pallet supported on the surface is within the camera's field of view, wherein the field of view spans multiple discrete component storage locations of the pallet. The camera generates data representing an image of the pallet, based on which the system (a) identifies the components on the pallet, and (b) determines where the components are located on the pallet. The system communicates the identified discrete component storage locations to an operator at the operator access station.

[0004] In some embodiments, the storage stack includes a vertical storage rack including a frame defining a plurality of stacking compartments, each stacking compartment being arranged to receive and store a respective pallet, and each of the discrete pallet storage locations includes a compartment in the plurality of stacking compartments.

[0005] In some embodiments, the operator access station includes a first compartment of the plurality of stacked compartments. The first compartment defines a height greater than heights of remaining compartments of the plurality of stacked compartments.

[0006] In some embodiments, the operator access station includes a top plate spaced from a surface of the operator access station, and a camera is secured to the top plate above the tray, wherein a field of view of the camera is directed toward the tray supported on the surface of the operator access station. In some embodiments, the field of view of the camera spans all discrete component storage locations of the tray. In some embodiments, the system further includes one or more additional cameras secured to the top plate of the operator access station. The fixed camera is arranged such that a field of view of the fixed camera spans a first group of the plurality of discrete component storage locations, and the one or more additional cameras are arranged such that a field of view of the one or more additional cameras spans a second group of the plurality of discrete component storage locations, the second group being different from the first group.

[0007] In some embodiments, the automated lift includes i) a lift drive coupled to a frame of a storage stack, ii) a lift chain engaged with the lift drive and configured to be driven by the lift drive, and iii) an extractor attached to the lift chain. The lift drive includes a rotatable gear engaged with the lift chain such that rotation of the gear moves the extractor vertically to position the extractor adjacent a selected position in a discrete tray storage location to store or retrieve a corresponding tray.

[0008] In some embodiments, the extractor includes i) an extractor drive including an extractor gear, ii) an extractor chain engaged with the extractor drive and configured to be driven by the extractor drive, and iii) one or more tabs secured to the extractor chain and movable along a horizontal plane of the extractor by the extractor chain. The one or more tabs are arranged to engage a corresponding tray when the extractor gear rotates to move the corresponding tray to and away from a supporting surface of the extractor to store or retrieve the corresponding tray.

[0009] In some embodiments, the system further comprises an illumination source attached to or near the operator access station and configured to radiate light. During retrieval of the parts on the pallet, the storage and retrieval system communicates the identified part location to an operator at the operator access station by radiating light on the identified parts on the pallet.

[0010] In some embodiments, each discrete component storage location of the tray includes an identifier that includes at least one of a label or a machine-readable code. The identifier is exposed when no component is in the discrete component storage location, and the identifier is covered when the component is in the discrete component storage location. The system determines which of the discrete component storage locations is empty and which of the discrete component storage locations contains a component based on the presence or absence of the identifier in the image.

[0011] In some embodiments, each component includes a unique component machine-readable code associated with the corresponding component. The system associates the unique component machine-readable code of each component with the tray and the corresponding discrete component storage location within the tray.

[0012] In some embodiments, the component comprises an electrical component reel or a hand tool.

[0013] Embodiments of the present disclosure also include a component storage and retrieval system. The system includes a storage stack, an operator access station, an automatic lift, and a group of pallets. The storage stack is defined as discrete pallet storage locations at different levels. The operator access station includes a surface suitable for supporting a movable pallet. The automatic lift moves the pallet from the access station surface to a specified storage location in the storage location of the storage stack, and retrieves the selected pallet from the storage stack and brings it to the access station. The group of pallets is suitable for being accommodated in at least one storage location in the pallet storage location of the storage stack, and is on the operator access station surface and carried by the automatic lift. Each pallet defines a plurality of discrete reel positioning areas. Each area carries a mark that is visible from above the pallet when there is no reel in the area. The access station includes a fixed camera that is positioned so that the pallets in a group of pallets are within the field of view of the camera when supported on the surface. The field of view spans a plurality of discrete reel positioning areas of the pallet. The camera generates data representing an image of the tray, based on which the system is configured to (a) identify whether a reel is positioned in each reel locating area of ​​the tray; (b) identify a reel positioned on the tray, and (c) associate the identified reel with one of the reel locating areas based on where the identified reel is positioned. The system communicates the identified reel position to an operator at an operator access station.

[0014] In some embodiments, the storage stack includes a vertical storage rack including a frame defining a plurality of stacking compartments, each stacking compartment being arranged to receive and store a respective pallet, and each of the discrete pallet storage locations includes a compartment in the plurality of stacking compartments.

[0015] In some embodiments, the operator access station includes a top plate spaced apart from a surface of the operator access station, and the camera is secured to the top plate above the tray, wherein a field of view of the camera is directed toward the tray supported on the surface of the operator access station.

[0016] In some embodiments, the field of view of the camera spans all of the discrete component storage locations of the tray.

[0017] In some embodiments, the system further comprises one or more additional cameras fixed to a top plate of the operator access station. The fixed camera is arranged such that a field of view of the fixed camera spans a first group of the plurality of discrete component storage locations, and the one or more additional cameras are arranged such that a field of view of the one or more additional cameras spans a second group of the plurality of discrete component storage locations, the second group being different from the first group.

[0018] In some embodiments, each discrete component storage location of the tray includes an identifier that includes at least one of a label or a machine-readable code. The identifier is exposed when no component is in the discrete component storage location, and the identifier is covered when the component is in the discrete component storage location. The system determines which of the discrete component storage locations is empty and which of the discrete component storage locations contains a component based on the presence or absence of the identifier in the image.

[0019] In some embodiments, each component includes a unique component machine-readable code associated with the respective component, and the system can associate the unique component machine-readable code of each component with the pallet and with the respective discrete component storage location within the pallet.

[0020] Embodiments of the present disclosure also include a method comprising receiving, by a processing device, data representing an image of at least a portion of a pallet from a camera of a component storage and retrieval system. The component storage and retrieval system includes i) a storage stack defining discrete pallet storage locations at different levels, ii) an operator access station including a pallet support surface, and iii) an automatic lift configured to move the pallet between the pallet support surface and a designated storage location in the storage stack. The image includes a plurality of discrete component storage locations of the pallet. The method also includes identifying, by the processing device, components on the pallet based on the data received from the camera. The method also includes determining, by the processing device, where the components are located on the pallet based on the data received from the camera. The method also includes transmitting the identified discrete component storage locations to an operator at the operator access station.

[0021] Specific embodiments of the subject matter described in this specification may be implemented to achieve one or more of the following advantages. For example, the vertical reel component storage system of the present disclosure may have a small physical footprint while providing high-density storage. In addition, the vertical reel component storage system of the present disclosure may automatically detect incoming components to be stored and automatically retrieve components from a storage location. In addition, the systems and methods of the present disclosure may be implemented on existing equipment. In addition, the vertical reel component storage system may improve the accuracy of inventory and storage, which may prevent the wrong parts from being used or sent to the production line. In addition, the vertical reel component storage system may improve the turnaround time from work in progress (WIP) to inventory. In addition, the vertical reel component storage system may shorten inventory turnover. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a perspective schematic diagram of a vertical component storage system according to an embodiment of the present disclosure.

[0023] 2-5 are schematic side views of sequential steps for storing components in the vertical component storage system of FIG. 1 .

[0024] 6-7 are schematic side views of sequential steps for retrieving components from the vertical component storage system of FIG. 1 .

[0025] 8-9 are perspective views of sequential steps for loading or unloading a pallet into or from an extractor.

[0026] FIG. 10 is a perspective view of a tray according to the first embodiment of the present disclosure.

[0027] FIG. 11 is a perspective view of a tray according to a second embodiment of the present disclosure.

[0028] 12 is a schematic diagram of an exemplary control system or controller for a vertical component storage system.

[0029] FIG. 13 is a flow chart of a logic algorithm having steps for storing a component. DETAILED DESCRIPTION

[0030] The vertical component storage system of the present disclosure includes a vertical storage rack having a plurality of compartments for storing carriers (e.g., trays or pallets) containing one or more electronic component reels. The vertical storage rack has an operator access station where an operator can access a tray to retrieve or store the tray. The vertical component storage system includes an elevator that moves the tray between the operator access station and the storage compartments of the vertical storage rack to store or retrieve the tray.

[0031] FIG. 1 depicts a vertical component storage system 100 including a storage stack 102 (e.g., a vertical storage rack) for storing a plurality of components 110. The components 110 may be tape reels used in surface mount technology (SMT) systems. Tapes are used in the production of electronic circuits, where electronic components from the tape reels are placed directly on the surface of a printed circuit board. SMT board clusters require many different components, and the specific list of components will change with each board design produced. This requires manufacturers to maintain and manage inventory of hundreds or even thousands of different reels. In addition, when switching from one run to the next, part of the reel typically must be returned to inventory. Managing large reel inventories can be challenging. The vertical component storage system 100 utilizes cameras or image sensors, data query, and vertical lifting technology to provide an efficient storage system. The vertical component storage system 100 is not limited to storing reels. For example, the vertical component storage system 100 can be used to store narrow hand tools or other small electronic components, such as printed circuits.

[0032] An operator 101 may use the vertical component storage system 100 to store and retrieve components to and from the system 100. The storage stack 102 has a housing 103 that defines discrete pallet storage locations (see FIGS. 2-7 ) at different levels or heights of the storage stack 102 within the housing 103. Each discrete pallet storage location may store one or more pallets of components.

[0033] The vertical component storage system 100 also includes an operator access station or loading station 104 having a surface 106 that supports a removable tray or pallet 108. The tray 108 contains one or more components 110, such as a reel 112 of electronic components. The vertical component storage system 100 also has an automatic lift 114 that moves the tray 108 from the surface 106 of the operator access station 104 to a designated storage location in the discrete tray storage locations of the storage stack 102. The automatic lift 114 also retrieves the selected tray from the storage stack 102 and brings the tray 108 to the operator access station 104, where the operator 101 can retrieve the tray 108 or the components 112 of the tray 108. When the components 112 have been retrieved, the operator 101 can press a button or otherwise input an instruction to indicate that the operation is complete, so the system can return the tray 108 to its storage location.

[0034] The operator access station 104 has one or more cameras 116 attached or fixed to a wall or ceiling 115 of the operator access station 104. The ceiling 115 can be spaced apart from the surface 106 of the operator access station 104 by, for example, a distance between 600 mm and 1000 mm. The height of the ceiling 115 can depend on a combination of camera and lens characteristics, as well as on considerations of the minimum height required for an operator to easily access the reels on the tray while maximizing storage space above the operator access station 104. The camera 116 can be, for example, a 20 megapixel digital camera. In addition, the camera 116 can be a monochrome (e.g., black and white) camera. A monochrome camera can have a high image resolution in contrast to a color camera, where there is color interpolation (e.g., a Bayer pattern) between pixels.

[0035] Additionally, the camera 116 can be mounted on a motion system to move the camera's field of view. For example, instead of using two different cameras at points A and B in the top plate 115, a single camera can be moved between points A and B. The single camera can be moved between points A and B to perform the same function that two cameras would perform.

[0036] The camera 116 is positioned such that the tray 108 supported on the surface 106 is within the field of view of the camera 116. The field of view spans a plurality of discrete component storage locations 120 of the tray 108. Each location 120 is arranged to receive one component 110.

[0037] The vertical component storage system 100 includes a computer or processing device 122 that is communicatively coupled to the camera 116. The processing device 122 may reside above the operator access station 104 (as shown in FIG. 1 ), or may reside at a different location, such as at the bottom end of the storage stack 102 or outside of the storage stack 102. The camera 116 generates data representing an image of the pallet 108. The processing device 122 may, based on the data received from the camera, (a) identify the component 110 on the pallet 108, and (b) determine where the component 112 is located on the pallet 108 (e.g., in which component storage location 120 of the pallet 108).

[0038] The processing device 122 may also output information to communicate the identified discrete component storage location 120 to the operator 101 at the operator access station 104. For example, the processing device may be communicatively coupled to the electronic user interface 124 to communicate the location information so that the user interface electronic display 124 displays the information. Additionally, the processing device 122 may be communicatively coupled to one or more illumination sources 126 (e.g., lasers or LED lights). The illumination sources 126 may also be attached to a wall or ceiling 115 of the operator access station 104, or may otherwise reside near the operator access station 104. During retrieval of the component, the processing device 122 may communicate information to the illumination sources 126 so that the illumination sources 126 radiate light onto the component to be retrieved from the pallet based on the information received from the processing device 122. For example, the system may include a plurality of illumination sources 126, wherein each illumination source 126 is directed to a respective location of the pallet 108.

[0039] The processing device 122 is communicatively coupled to or includes a controller 123. The controller 123 is operably coupled to the automatic lift 114 to control the vertical and horizontal movement (e.g., up and down movement and loading and unloading movement) of the lift 114 based on information received from the processor. In addition, the controller 123 can control other components of the system 100, such as the camera 116 and the lighting source 126.

[0040] The controller 123 may be coupled to multiple components of the automatic lift 114. The controller 123 may reside above the operator access station 104. In some embodiments, the controller 123 may reside at the automatic lift 114 or at a different location of the vertical component storage system 100. In some embodiments, the controller 123 may be implemented as a distributed computer system that is located partially at the vertical component storage system 100 and partially outside the vertical component storage system 100. The computer system may include one or more processors and a computer-readable medium that stores instructions that can be executed by one or more processors to perform the operations described herein. In some embodiments, the controller 123 may be implemented as a processing circuit, firmware, software, or a combination thereof.

[0041] Referring now to FIG. 2 , the vertical component storage system 100 has a frame 130 (e.g., a frame storing the stack 102 ) defining pallet storage locations 132 (e.g., a plurality of stacking compartments or slots), each of which is arranged to receive and store one or more pallets 108 . The frame 130 may be supported on a floor 134 of a building or room in which the vertical component storage system 100 resides, and may extend to or near a ceiling 136 of the building or room. The frame 130 of the vertical component storage system 100 may have a height of, for example, between 2 meters and 8 meters, depending on the height of the ceiling 136 and the design specifications of the system 100 . In addition, the frame 130 of the vertical component storage system 100 may have a footprint of, for example, 1.5 square meters to 3 square meters (e.g., 2.2 square meters) or more, depending on the size and shape of the pallets 108 and the field of view of the camera. Thus, the vertical component storage system 100 may have a small footprint while providing high density storage. The storage stack 102 may store, for example, 2,000 to 1,000 (eg, 4,500) reels or components.

[0042] The cameras 116 are positioned such that the pallet 108 supported on the surface 106 of the operator access station 104 is within the field of view "F" of the camera 116. The field of view "F" spans across a plurality of discrete component storage locations of the pallet 108. For example, the field of view "F" of the camera 116 may span the entire pallet 108 (e.g., all of the discrete component storage locations of the pallet 108) or a portion of the pallet 108 (e.g., one or a group of discrete component storage locations of the pallet 108). In some embodiments, the field of view "F" of the camera 116 may span the entire support surface 106 of the operator access station 104. The field of view "F" of each camera 116 is directed toward the pallet 108 and the components residing on the pallet 108. For example, one camera 118 may be arranged on a ceiling of the operator access station 104 such that the camera's field of view "F" spans a first group of a plurality of discrete component storage locations on the pallet 108, and a second camera 116 or a second group of cameras 116 is oriented such that the second camera 116 or a second group of cameras 116 has a field of view that spans a second group of a plurality of discrete component storage locations, the second group being different from the first group.

[0043] The camera may be fixed to the ceiling of the access station 104 or may be movable. For example, a camera or a group of cameras may be mounted on a motion system (e.g., a mobile platform) above or near the surface 106 to allow the camera to move its field of view relative to the pallet 108 to cover the entire area of ​​one or more pallets 108. The processor may determine the position of each camera and determine the position of the parts in the pallet based on the position of the camera.

[0044] The vertical component storage system 100 can have two columns 140 of compartments 132. The columns 140 can be separated by an elevator volume or housing 142 in which the automatic elevator 114 resides. Each compartment 132 has a floor or support surface and a top plate. For example, each compartment 132 has a volume defined between a corresponding floor and a top plate, wherein the top plate is the bottom surface of the floor of the next compartment. Each compartment 132 can have an open end facing the elevator housing 142 to receive a pallet from the automatic elevator 114. Each compartment 132 has side walls and a rear wall defined by the housing 103 of the vertical component storage system 100.

[0045] Each compartment 132 can have a height defined between its corresponding bottom plate and top plate that is slightly greater than the thickness "t" of the tray 108. For example, if the tray 108 has a thickness "t" of approximately 16 mm, each compartment 132 can have a height (e.g., pitch) of, for example, 20 mm to 30 mm (e.g., 27 mm) or more. The pitch can be the same on each slot. However, some slots can "skip" the pitch so that the spacing between trays is twice the spacing of one slot (e.g., 54 mm). The system 100 can determine where each tray will be stored based on the thickness of the rolls on the tray.

[0046] Each compartment 132 may have a different height and width. The width of each compartment 132 may be defined by the side walls of the housing 103 or the inner walls of the interior of the housing 103. In some embodiments, the vertical component storage system 100 may be arranged without the housing 103 so that the compartments 132 are exposed to the external environment where the operator resides.

[0047] The operator access station 104 may be arranged as a compartment 133 of stacked compartments 132. For example, the height of compartment 133 is greater than the height of the remaining compartments 132, but its width may be equal to or similar to the width of the stacked storage compartments 132. The operator access station 104 is open on the end facing the operator and is open on the opposite end facing the intermediate elevator housing 142.

[0048] The automated lift 114 includes an extractor 144 that includes a car or platform that moves vertically along the lift housing 142 of the vertical parts storage system 100 to store and retrieve pallets 108. For example, the extractor 144 moves up and down the height of the parts storage system 100 to move pallets 108 between the operator access station 104 and the selected storage compartment 132. In some embodiments, the extractor 144 can pick up a top pallet 108 of a stack of pallets that is supported on the surface 106 of the operator access station 104.

[0049] As described in further detail below with respect to FIGS. 10 and 11 , once the operator places the pallet 108 on the support surface 106 of the operator access station 104, the vertical component storage system 100 may automatically detect at least one of: i) which pallet storage location of the pallet 108 is empty and which pallet storage location has a component, ii) which component is in which pallet storage location, iii) whether the component is placed upside down in its corresponding pallet storage location, and iv) an identifier (e.g., an ID number) of the pallet 108. Once the vertical component storage system 100 identifies the components in the pallet 108 and associates each component with its corresponding pallet storage location of the pallet 108, the vertical component storage system 100 determines in which compartment 132 the pallet 108 is to be stored. For example, each compartment 132 may be associated with a pallet identifier such that the vertical component storage system 100 stores each pallet 108 in its designated compartment 132.

[0050] 2 and 3, once the vertical component storage system 100 associates the component with the pallet 108 and the pallet with the designated compartment 132 of the pallet, the extractor 144 moves the pallet 108 from the support surface 106 of the operator access station 104 to the top surface of the extractor 144. The automatic lift 114 can then move the extractor 144 up or down to the selected or designated compartment. As shown in FIG3, the extractor 144 can be placed with its top surface generally aligned with or adjacent to the support surface 106 of the operator access station 104, and then engage the end of the pallet 108 to move the pallet 108 to the top surface of the extractor 144.

[0051] 4 and 5, with the pallet 108 loaded on the extractor 144, the automated lift 114 moves the extractor 144 vertically along the lift housing 142 to the designated storage compartment 132 where the pallet 108 is to be stored. As shown in FIG5, once the pallet 108 is aligned with the open end of the designated compartment 132, the extractor 144 moves the pallet 108 from the top surface of the extractor 144 to the interior volume of the compartment 132. In some embodiments, to align the pallet 108 with the open end of the compartment 132, the top surface of the extractor 144 may be aligned with the floor of the designated compartment 132 (e.g., the top surface is disposed along a common plane).

[0052] 6 and 7 , the vertical component storage system 100 retrieves a pallet 108 from its designated storage compartment 132 to place the pallet 108 on the operator access station 104. For example, to retrieve a component, an operator may input information indicating which component to retrieve (e.g., by using the electronic user interface 124 shown in FIG. 1 ) into the vertical component storage system 100. Based on the input information, the vertical component storage system 100 determines in which compartment 132 the pallet 108 containing the component to be retrieved is located.

[0053] In the event that the extractor 144 is empty (e.g., no pallet 108 is loaded on the extractor), the automatic lift 114 moves the extractor 144 vertically along the lift housing 142 to the storage compartment 132, and the pallet 108 will be removed from the storage compartment 132. As shown in FIG6, the extractor 144 can be placed with its top surface generally aligned with or adjacent to the floor of the compartment 132 containing the pallet 108 to be retrieved. Once the extractor 144 is adjacent to the pallet 108, the extractor 144 engages the end of the pallet 108 to move the pallet 108 from the compartment 132 to the top surface of the extractor 144. As shown in FIG7, in the event that the pallet 108 is loaded on the extractor 144, the automatic lift 114 moves the extractor 144 vertically along the lift housing 142 to the operator access station 104. Once the pallet 108 is aligned with the surface 106 of the operator access station 104 , the extractor 144 moves the pallet 108 from the top surface of the extractor 144 to the support surface 106 of the operator access station 104 .

[0054] 7 , with the pallet 108 positioned on the support surface 106 of the operator access station 104, the vertical component storage system 100 detects the pallet 108 and indicates the pallet storage location of the component to be retrieved to an operator standing near the operator access station 104. For example, the illumination source 126 of the vertical component storage system 100 may radiate light onto one or more components to be retrieved from the pallet 108.

[0055] 8 and 9 illustrate the automatic lift 114 and the pallet 108 during loading or unloading of the pallet 108. As shown in FIG8, the extractor 144 of the lift 114 has a car or platform 145 having a top surface 158 that supports the pallet 108 when the pallet 108 is located on the extractor 144. For example, the extractor 144 may have two side frames 172 (only one frame 172 is shown in FIG8) and two arms 160 extending vertically relative to the two side frames 172 and extending between the two side frames 172. The two arms 160 are spaced apart from each other and may define the top surface 158 that supports the pallet 108. In some embodiments, the extractor 144 may have a continuous support surface without the two arms 160. The arm 160 may have a groove 161 that receives a ridge or raised feature of the bottom surface of the tray 108 to securely receive the tray 108 and prevent the tray 108 from moving during vertical movement of the extractor 144 .

[0056] The automatic lift 114 also includes one or more lift drives 152 (e.g., motors), one or more lift chains or belts 150, one or more guide rails or shafts 154, end gears 156 engaged with each lift chain 140, and shafts 157 connected to the opposite lift chain or belt. The drive 152 can be attached to a frame (e.g., a wall, a floor, or a ceiling) of the vertical component storage system 100. Each chain 150 is engaged to two end gears 156 (only the top gear is shown in FIG. 8). The extractor 144 is attached to the chain 150. For example, each side frame 172 is attached to the corresponding one or more lift chains 150 and is movable by the corresponding one or more lift chains 150. The chain 150 can extend through the side frame 172. The top gear 156 can be driven by the lift drive 152 to drive the chain 150 in a clockwise direction and a counterclockwise direction, thereby lifting or lowering the extractor. The driver 152 may also rotate a shaft 157 having a gear opposite the top gear 156 to engage and rotate a chain (not shown) that engages the opposite side of the extractor 144. The elevator driver 152 may be operably coupled to a controller (see FIG. 1 ) such that the controller controls the direction and speed of rotation of the elevator driver 152. For example, the processor may determine the location (e.g., height) of a designated compartment, and the controller may move the driver 152 based on the location of the compartment to position the extractor 144 at a predetermined location next to the designated compartment.

[0057] Each side frame 172 has a drive assembly that includes a chain 162, an engagement tab or pawl 170, a drive gear 164, an end gear 174, and a chain drive 166 (e.g., a motor). The chain drive 166 is attached to the side frame 172 at or near the midpoint of the side frame 172. The drive gear 164 is attached to the drive 166 and rotated by the drive 166. The chain 1562 is engaged to the two end gears 174 and the drive gear 164. In some embodiments, one of the end gears can be the drive gear. The drive gear 164 can be driven by the chain drive 166 to drive the chain 162 in a clockwise and counterclockwise direction to load or unload the tray 108 to or from the extractor 144. The drive assembly can have two tabs 170 that are spaced a distance from each other that corresponds to the distance separating the two holes 182 of the tray. The tabs 170 engage the tray 108 through the holes 182 to move the tray 108 in the horizontal direction “H” to load or unload the tray 108 into or from the extractor 144 .

[0058] As shown in FIG8 , the tray 108 includes a plurality of components 112. The tray 108 may have a support surface 184 and a frame 180 defining an aperture 182. To load the tray 108 onto the extractor 144, the elevator 114 places the chain 162 of the extractor 144 along the level of the aperture 182. The end gear 174 near the first aperture 182 to be engaged is sized and spaced a distance from the aperture so that the tab 170 enters the aperture 182 as the tab 170 rotates along the end gear 174. Similarly, the gear 174 is arranged so that when the tray 108 is loaded onto the extractor 144, the next tab 170 enters the last aperture 182. As shown in FIG9 , once the chain 162 is aligned with the aperture 182, the chain drive 162 drives the chain in a clockwise direction (in a top view) so that the tab engages the aperture to move the tray 108 and place the tray on top of the extractor 144. The tabs 170 seat within the apertures 182 of the tray 108 when the tray is positioned on the extractor 144 .

[0059] To unload the pallet 108 , the chain drive 162 drives the chain in a counterclockwise direction so that the tabs engaging the holes 182 move the pallet 108 and place the pallet on top of a horizontal surface adjacent to the extractor 144 (eg, the floor of a compartment or a support surface of an operator access station).

[0060] FIG. 10 shows a loaded pallet 208 according to a first embodiment of the present disclosure. The pallet 208 includes a plurality of discrete pallet storage locations or spaces 204. Each space 204 may be arranged to contain a component 212, such as a reel or a hand tool. Because the camera of the operator access station is fixed in place, based on the image captured by the camera, the processor may determine the location of each space 204 by the location of each space 204 in the image. For example, the processor may determine the location of each space 204 based on processing the image by dividing the image or the pallet 208 into a symmetrical or asymmetrical grid corresponding to the pallet 208. For example, each pallet 208 may have an associated grid (e.g., four, six, or eight square grids), and after identifying the pallet 208 from the image, the processor may determine what type of grid corresponds to the pallet 208. Upon determining the type of grid corresponding to the pallet 208, the processor may divide the image into the corresponding grid to determine which component 212 is in which location or which space 204 of the pallet.

[0061] In some cases, tray 208 may include visual lines 209 or shapes that form a grid or otherwise delimit each space 204 so that the image shows spaces 204. Marking tray 208 with delimited boundaries may simplify the process or reduce the steps required to determine the location of each component 212.

[0062] In some embodiments, each space or location 204 may have an identifier 202 on the tray 208. The identifier 202 may be used to determine the location of each space 204 and also to determine whether the component 212 is placed upright or inverted. The identifier 202 may be a simple binary mark 202a (e.g., a black dot) or a machine-readable code 202b (e.g., a barcode) that contains information such as the identity and location of the empty space 204. Additionally, the processor may determine the boundaries of each space 204 based on the distance from the identifier 202 or based on information contained in the identifier 202. For example, the machine-readable code 202b may contain information about the location of its corresponding space 204 (the space containing the code 202b) and information demarcating the boundaries of its corresponding space 204. The processor may decode the machine-readable code 202b and determine the location of the space 204 within the tray 208 and determine the boundaries of the space 204.

[0063] In addition, each component 212 may have a machine-readable code 200 on one side of the component. The processor uses the code 200 to identify the component (e.g., what type of electronic component the reel has) and associate the component 212 with its corresponding space 204. The space identifier 202 is exposed when there is no component 212 in the corresponding component storage location 204, and the space identifier 202 is covered when the component 212 is in the component storage location 204. Because the identifier 202 is covered when the component 212 is loaded on the space 204, if the space 204 does not show the position identifier 202 or the component identifier 200, the processor can determine that the component 212 in the space 204 is inverted, or there is another problem so that there is no visible identifier. For example, the component 212 in the location may not have a component identifier, or the component identifier may be covered by another component. In turn, the system can notify the operator by displaying an error message and illuminating the location on the tray. For example, if the system determines that the component 212 is inverted, the system can prompt the operator to flip the component 212. Thus, the processor determines which of the discrete component storage locations 204 is empty and which of the discrete component storage locations 204 contains a component 212 based on the presence or absence of the identifiers 200 , 202 in the image captured by the camera.

[0064] Additionally, each component 212 may have two or more machine-readable codes. For example, one code may be associated with the electronic portion of the reel, and another code may be associated with the reel for inventory purposes.

[0065] As shown in FIG10 , some of the components 212 are facing upward, and one component 212 b is facing downward, with its machine-readable code facing the support surface of the tray 208. The processor can determine that the component 212 b is inverted based on the identification not shown in the determined position 204, and can notify the operator to turn the component 212 and prevent the component 212 from being stored inverted. Thus, the processor associates the component identifier 200 with its corresponding position 204, and once the component 212 is to be retrieved, the system can indicate to the operator exactly where the component 212 to be retrieved is located on the tray 208.

[0066] In some implementations, the processor may determine the location of each space 204 by using an auxiliary space identifier 206. For example, each space 204 may have a binary mark 206 (or machine-readable code) that is visible regardless of whether the space 204 contains a part 212. For example, the mark 206 may be a plurality of black dots 206b associated with the space 204. For example, if the tray 208 has eight spaces 204 as shown in FIG. 10, the first space may have one dot, the second space may have two dots, and so on, until the eighth space has eight dots. The processor may associate each identifier 206 with a specific location of the space 204 in the tray 208. In some cases, the tray 204 may not have a grid or location identifier 206, and the camera may identify a simulated location (X, Y) of the part 212, or locate each part 212 by quadrants.

[0067] Still referring to Figure 10, each component 212 can have a different orientation. Therefore, the positioning of each identifier 200 can vary within the space 204. Because the system determines the boundaries of each space 204, and each identifier 200 is within its boundaries, the system associates each identifier 200 with its correct space 204.

[0068] Additionally, the pallet 208 may have a visible pallet identifier 210. The identifier 210 may be a machine-readable code containing information about the pallet and about the spaces 204 in the pallet 208. For example, each pallet 208 may have a grid or arrangement of associated spaces 204, and the processor may determine the number, location, size, and other parameters of the spaces 104 in the pallet 208 after identifying the pallet 208 using its identifier 210. Additionally, the system may associate each part 212 with its space 204, and may associate a pallet 208 with the parts 212 in the pallet 208.

[0069] The position information of each component 212 within its tray 208 can be used later when retrieving the component from the tray. For example, the vertical component storage system 100 can radiate light onto the component or tool associated with the position on the tray 208. Thus, the vertical component storage system 100 can automatically detect incoming components to be stored and automatically retrieve the components from the stack in the storage location.

[0070] FIG. 11 shows a pallet 308 similar to the pallet 208 in FIG. 19 . The pallet 308 includes a plurality of discrete pallet storage locations 204 , some of which are of different sizes. Each location 204 can be defined by a grid similar to the grid of the pallet 208 in FIG. 10 , but with spaces 204 of different sizes. For example, a large component 212 c can be placed on a large pallet storage location 204 a, and a small component 412 (e.g., a hand tool) can be placed on a small pallet storage location 204 b. If the system detects a component identifier 200 and a space identifier 202 in the same space, the system can determine that the small component is placed in the large space 204 a.

[0071] FIG12 is a schematic diagram of an exemplary control system or controller for a vertical component storage system according to the present disclosure. For example, the controller 1200 may include the controller 123 shown in FIG1 or be a part of the controller 123. The controller 1200 is intended to include various forms of digital computers, such as printed circuit boards (PCBs), processors, digital circuits, etc. In addition, the system may include portable storage media, such as a universal serial bus (USB) flash drive. For example, a USB flash drive may store an operating system and other applications. The USB flash drive may include input / output components, such as a wireless transmitter or a USB connector that can be inserted into a USB port of another computing device.

[0072] The controller 1200 includes a processor 1210, a memory 1220, a storage device 1230, and an input / output device 1240. Each of the components 1210, 1220, 1230, and 1240 are interconnected using a system bus 1250. The processor 1210 is capable of processing instructions for operation within the controller 1200. The processor can be designed using any of a variety of architectures. For example, the processor 1210 can be a CISC (Complex Instruction Set Computer) processor, a RISC (Reduced Instruction Set Computer) processor, or a MISC (Minimum Instruction Set Computer) processor.

[0073] In one embodiment, the processor 1210 is a single-threaded processor. In another embodiment, the processor 1210 is a multi-threaded processor. The processor 1210 is capable of processing instructions stored in the memory 1220 or on the storage device 1230 to display graphical information of a user interface on the input / output device 1240.

[0074] The memory 1220 stores information within the controller 1200. In one embodiment, the memory 1220 is a computer readable medium. In one embodiment, the memory 1220 is a volatile memory unit. In another embodiment, the memory 1220 is a non-volatile memory unit.

[0075] The storage device 1230 can provide mass storage for the controller 1200. In one embodiment, the storage device 1230 is a computer readable medium. In various embodiments, the storage device 1230 can be a floppy disk device, a hard disk device, an optical disk device, or a tape device. In various embodiments, the storage device 1230 can be a database that allows the system to manage multiple storage stacks.

[0076] The input / output device 1240 provides input / output operations for the controller 1200. In one embodiment, the input / output device 1240 includes a keyboard and / or a pointing device. In another embodiment, the input / output device 1240 includes a display unit for displaying a graphical user interface.

[0077] FIG. 13 shows a flow chart of a logic algorithm with steps that a system (e.g., a processor) may take when storing a part. With a pallet at an operator access station, at block 1300, the system may acquire an image of the pallet. Then, at block 1302, the system may loop through all locations on the pallet. Then, at block 1304, the system may determine whether a mark or ID at a location or position has been found. If not, the system may display an error (e.g., indicating that the reel may be inverted), or at block 1305, the location or position in the memory or database may be set to no part. If yes, at block 1306, the system may determine whether a part ID at the location or position has been found. If no, at block 1307, the system may display an error. If yes, at block 1308, the system may associate a part ID with a location in the pallet and save the association in the memory or database. Then, at block 1310, the system may determine whether all locations in the pallet have been completed or evaluated. If no, the system can loop to the next location on the pallet at box 1311 and then return to box 1302. If yes, at box 1312, the system can send the pallet to an empty slot in storage. Then, at box 1314, the system can determine whether an error has been detected. If yes, at box 1315, the system can wait or prompt the operator to perform corrective action. For example, the system can prompt the operator to recalibrate their system (e.g., elevator assembly). If no, at box 1316, the system can store the pallet storage slot location where the pallet has been stored. Finally, at box 1318, the system can process the next pallet.

[0078] Although several examples have been described for purposes of illustration, the foregoing description is not intended to limit the scope of the invention, which is defined by the scope of the appended claims. There are and will be other examples and modifications within the scope of the appended claims.

Claims

1. A parts storage and retrieval system comprising: a storage stack defining discrete pallet storage locations at different levels; an operator access station including a surface adapted to support a movable tray; as well as an automated lift configured to move a pallet from a storage station surface to a designated one of the discrete pallet storage locations of the storage stack and to retrieve a selected pallet from the storage stack and bring the selected pallet to the storage station, wherein the access station includes a fixed camera positioned such that a tray supported on the surface is within a field of view of the camera, the field of view spanning a plurality of discrete component storage locations of the tray, and wherein the camera is configured to generate data representing an image of the pallet, and based on the data, the system is configured to (a) identify a component on the pallet, and (b) determine where the component is located on the pallet; and Wherein the system is configured to communicate the identified discrete component storage location to an operator at the operator access station.

2. The component storage and retrieval system of claim 1, wherein: The storage stack includes a vertical storage rack including a frame defining a plurality of stacking compartments, each stacking compartment being arranged to receive and store a respective pallet, and each of the discrete pallet storage locations includes a compartment of the plurality of stacking compartments.

3. The component storage and retrieval system of claim 1, wherein: The operator access station includes a first compartment of the plurality of stacked compartments, the first compartment defining a height greater than heights of remaining compartments of the plurality of stacked compartments.

4. The parts storage and retrieval system of claim 1, wherein: The operator access station includes a top plate spaced apart from the surface of the operator access station, and the camera is secured to the top plate above the tray, wherein the field of view of the camera is directed toward the tray supported on the surface of the operator access station.

5. The component storage and retrieval system of claim 4, wherein: The field of view of the camera spans all discrete component storage locations of the tray.

6. The parts storage and retrieval system of claim 4, further comprising one or more additional cameras secured to a ceiling of the operator access station, and wherein: The fixed camera is arranged so that the field of view of the fixed camera spans a first group of the plurality of discrete component storage locations, and the one or more additional cameras are arranged so that the field of view of the one or more additional cameras spans a second group of the plurality of discrete component storage locations, the second group being different from the first group.

7. A component storage and retrieval system according to claim 1, wherein the automatic elevator includes i) an elevator drive, the elevator drive is coupled to the frame of the storage stack, ii) an elevator chain, the elevator chain is engaged with the elevator drive and is configured to be driven by the elevator drive, and iii) and an extractor, the extractor is attached to the elevator chain, the elevator drive includes a rotatable gear engaged with the elevator chain, so that rotation of the gear causes the extractor to move vertically to position the extractor adjacent to a selected position in the discrete pallet storage location to store or retrieve the corresponding pallet.

8. The component storage and retrieval system of claim 7, wherein: The extractor comprises: i) an extractor drive comprising an extractor gear, ii) an extractor chain engaged with the extractor drive and configured to be driven by the extractor drive, and iii) one or more tabs secured to the extractor chain and movable along a horizontal plane of the extractor via the extractor chain, the one or more tabs being arranged to engage a corresponding pallet upon rotation of the extractor gear to move the corresponding pallet to and away from a support surface of the extractor to store or retrieve the corresponding pallet.

9. The parts storage and retrieval system of claim 1 , further comprising an illumination source attached to or near the operator access station and configured to radiate light, wherein: The storage and retrieval system is configured to communicate the identified component location to the operator at the operator access station during retrieval of components on a pallet by radiating the light onto the identified components on the pallet.

10. The parts storage and retrieval system of claim 1, wherein: Each discrete component storage location of the tray includes an identifier, the identifier including at least one of a marking or a machine-readable code, the identifier being exposed when no component is in the discrete component storage location and the identifier being covered when a component is in the discrete component storage location, and wherein the system is configured to determine which of the discrete component storage locations is empty and which of the discrete component storage locations contains a component based on the presence or absence of the identifier in the image.

11. The parts storage and retrieval system of claim 1 , wherein: Each component includes a unique component machine-readable code associated with the respective component, and wherein the system is configured to associate the unique component machine-readable code of each component with the pallet and with a respective discrete component storage location within the pallet.

12. The parts storage and retrieval system of claim 1, wherein: The components include electrical component reels or hand tools.

13. A parts storage and retrieval system comprising: a storage stack defining discrete pallet storage locations at different levels; an operator access station including a surface adapted to support a movable tray; an automated lift configured to move a pallet from a storage station surface to a designated one of the storage locations of the storage stack and to retrieve a selected pallet from the storage stack and bring it to the storage station; as well as a plurality of pallets, each pallet adapted to be received in at least one of said pallet storage locations of said storage stack and on an operator access station surface and carried by said automated lift; wherein each tray defines a plurality of discrete reel location areas, each area carrying an indicia that is visible from above the tray when no reel is present in the area; wherein the access station includes a fixed camera positioned such that a tray of the set of trays is within a field of view of the camera when supported on the surface, the field of view spanning the plurality of discrete reel positioning areas of the tray, and wherein the camera is configured to generate data representing an image of the tray, and based on the data, the system is configured to (a) identify whether a reel is positioned in each of the reel positioning areas of the tray; (b) identify a reel positioned on the tray, and (c) associate the identified reel with one of the reel positioning areas based on where the identified reel is positioned; and Wherein the system is configured to communicate the identified reel position to an operator at the operator access station.

14. The component storage and retrieval system of claim 13, wherein: The storage stack includes a vertical storage rack including a frame defining a plurality of stacking compartments, each stacking compartment being arranged to receive and store a respective pallet, and each of the discrete pallet storage locations includes a compartment of the plurality of stacking compartments.

15. The component storage and retrieval system of claim 13, wherein: The operator access station includes a top plate spaced apart from the surface of the operator access station, and the camera is secured to the top plate above the tray, wherein the field of view of the camera is directed toward the tray supported on the surface of the operator access station.

16. The component storage and retrieval system of claim 15, wherein: The field of view of the camera spans all discrete component storage locations of the tray.

17. The parts storage and retrieval system of claim 15, further comprising one or more additional cameras secured to the top plate of the operator access station, and wherein: The fixed camera is arranged so that the field of view of the fixed camera spans a first group of the plurality of discrete component storage locations, and the one or more additional cameras are arranged so that the field of view of the one or more additional cameras spans a second group of the plurality of discrete component storage locations, the second group being different from the first group.

18. The parts storage and retrieval system of claim 13, wherein: Each discrete component storage location of the tray includes an identifier, the identifier including at least one of a marking or a machine-readable code, the identifier being exposed when no component is in the discrete component storage location and the identifier being covered when a component is in the discrete component storage location, and wherein the system is configured to determine which of the discrete component storage locations is empty and which of the discrete component storage locations contains a component based on the presence or absence of the identifier in the image.

19. The parts storage and retrieval system of claim 13, wherein: Each component includes a unique component machine-readable code associated with the respective component, and wherein the system is configured to associate the unique component machine-readable code of each component with the pallet and with a respective discrete component storage location within the pallet.

20. A method comprising: receiving, by a processing device, data representing an image of at least a portion of a pallet from a camera of a component storage and retrieval system, the component storage and retrieval system comprising i) a storage stack, the storage stack defining discrete pallet storage locations at different levels, ii) an operator access station, the operator access station comprising a pallet support surface, and iii) an automated lift configured to move a pallet between the pallet support surface and a designated one of the storage locations of the storage stack, wherein the image includes a plurality of discrete component storage locations of the pallet; identifying, by the processing device, parts on the pallet based on the data received from the camera; determining, by the processing device, where the component is located on the pallet based on the data received from the camera; and The identified discrete component storage location is communicated to an operator at the operator access station.

Images