A method, system and computer program for controlling an automated storage and retrieval system during reconstruction of the system's physical design

Abstract

A method, system, and computer program for controlling the operation of an automated storage and retrieval system (1) during reconstruction of the system's physical design. The method includes a planning and design phase in which a new design is established and storage columns (105) having track systems (108) affected by the reconstruction are excluded from selection of available routes for container handling vehicles (201) operating on the storage system (1), a relocation phase in which storage containers (201) located in the excluded storage columns (105) are relocated to other storage columns (105), a rerouting phase in which the traffic flow of container handling vehicles (201) is rerouted according to available routes, wherein a master controller (220) is instructed to control the vehicles (201) according to the available routes, a reconstruction phase in which the storage system (1) is rebuilt according to the new physical design, and a final routing phase in which a route planner (200) controls the traffic flow of vehicles (201) according to the available routes on the track system (108) of the rebuilt physical design.

Description

Technical Field

[0001] The present invention relates to an automated storage and retrieval system for storing and retrieving containers handled by container handling vehicles, and more particularly to a method, system, and computer program for controlling the operation of an automated storage and retrieval system during reconstruction of the physical design of the system. Background Art

[0002] FIG. 1 discloses a typical prior art automated storage and retrieval system 1 having a frame structure 100 and a container handling vehicle 201 operating on such system 1 .

[0003] The frame structure 100 comprises upright members 102, horizontal members 103 and a storage volume comprising storage columns 105 arranged in rows between the upright members 102 and the horizontal members 103. In these storage columns 105, storage containers 106, also called boxes, are stacked on top of each other to form stacks 107. The members 102, 103 may typically be made of metal, for example, extruded aluminum profiles.

[0004] The frame structure 100 of the automatic storage and retrieval system 1 includes a rail system 108 arranged across the top of the frame structure 100, and multiple container handling vehicles 201 operate on the rail system 108 to lift storage containers 106 from the storage column 105, lower storage containers 106 into the storage column 105, and also transport storage containers 106 above the storage column 105.

[0005] The rail system 108 includes a first set of parallel rails 110 arranged to guide movement of the container handling vehicle 201 across the top of the frame structure 100 in a first direction X, and a second set of parallel rails 111 arranged perpendicular to the first set of rails 110 to guide movement of the container handling vehicle 201 in a second direction Y perpendicular to the first direction X. Also shown in FIG. 1 are a first rail 110 a in the first direction X, a second rail 110 b in the first direction X, a first rail 111 a in the second direction Y, and a second rail 111 b in the second direction Y.

[0006] The storage containers 106 are stored in columns 105, wherein the columns 105 define a third direction Z that is orthogonal to the first direction X and the second direction Y. The storage containers 106 are accessed by the container handling vehicle 201 through access openings 112 in the rail system 108, i.e., the rail system 108 is arranged on the frame structure 100, which defines each access opening 112 at the top of each storage column 105.

[0007] The container handling vehicle 201 can move laterally above the storage column 105 , ie in a plane parallel to the horizontal XY plane. Storage containers are stored in the storage column 105 .

[0008] Upright members 102 of frame structure 100 may be used to guide storage containers when lifting and lowering containers from and into row 105. Stack 107 of containers 106 is generally self-supporting.

[0009] Z=1 identifies the topmost level of storage containers, i.e., the level immediately below the rail system 108, Z=2 identifies the second level below the rail system 108, Z=3 the third level, and so on. In the exemplary prior art disclosed in FIG. 1 , Z=8 identifies the bottommost level of storage containers. Similarly, x=1…n and y=1…n identify the position of each storage column 105 in the horizontal plane. Thus, as an example, and using the Cartesian coordinate system X, Y, Z shown in FIG. 1 , the storage container designated 106 ′ in FIG. 1 can be said to occupy storage location X=10, Y=2, and Z=3. Container handling vehicle 201 can be said to be traveling in level Z=0, and each storage column 105 can be identified by its X and Y coordinates.

[0010] The storage volume of the frame structure 100 is generally referred to as a grid 104, wherein the possible storage locations within the storage columns 105 in the grid are referred to as storage cells. Each storage column 105 can be identified by its position in the X and Y directions, while each storage cell can be identified by its container number in the X, Y, and Z directions.

[0011] The track system 108 typically includes a track with grooves in which the wheels of the storage container vehicle 201 can travel. Alternatively, the track may include upwardly protruding elements, wherein the wheels of the vehicle include flanges to prevent derailment. These grooves and upwardly protruding elements are collectively referred to as tracks. Each track may include a single rail, or each track may include two parallel rails.

[0012] WO2018146304, the contents of which are incorporated herein by reference, shows a typical configuration of a track system 108 comprising tracks in the X and Y directions and parallel rails.

[0013] In the frame structure 100, most columns 105 are storage columns 105, i.e., columns 105 in which storage containers 106 are stored in stacks 107. However, some columns 105 may have other purposes. In FIG1 , columns 119 and 120 are dedicated columns used by container handling vehicles 201 to unload and / or load storage containers 106 so that they can be transported to access stations (not shown), where storage containers 106 can be accessed from outside the frame structure 100 or transferred into or out of the frame structure 100. In the prior art, such locations are often referred to as "ports," and the columns in which such ports are located may be referred to as "port columns" 119, 120. Transportation to the access stations can be in any direction, i.e., horizontal, inclined, and / or vertical. For example, storage containers 106 can be placed in a random or dedicated column 105 within the frame structure 100, then loaded and transported to the port columns 119, 120 by any container handling vehicle 201 for further transportation to the access station. Note that the term "inclined" means that the transport of the storage container 106 has a general direction of transport somewhere between horizontal and vertical.

[0014] In Figure 1, the first port column 119 can be, for example, a dedicated unloading port column, where container handling vehicles 201 can unload storage containers 106 to be transported to an access station or a transfer station, and the second port column 120 can be a dedicated loading port column, where container handling vehicles 201 can load storage containers 106 that have been transported from an access station or a transfer station.

[0015] The access station may typically be a picking station or storage station where product items are removed from or placed in the storage container 106. At the picking station or storage station, the storage container 106 is typically not removed from the automated storage and retrieval system 1, but rather, once accessed, is returned to the frame structure 100. The port may also be used to transfer the storage container to another storage facility (e.g., to another frame structure or another automated storage and retrieval system), a transport vehicle (e.g., a train or truck), or a production facility.

[0016] When a storage container 106 stored in one of the columns 105 disclosed in FIG. 1 is to be accessed, one of the container handling vehicles 201 is instructed to retrieve the target storage container 106 from its location and transport the target storage container to the unloading port column 119. This operation includes moving the container handling vehicle 201 to a position above the storage column 105 where the target storage container 106 is located, retrieving the storage container 106 from the storage column 105 using a lifting device (not shown) of the container handling vehicle 201, and transporting the storage container 106 to the unloading port column 119. If the target storage container 106 is located deep within the stack 107, i.e., one or more other storage containers 106 are located above the target storage container 106, the operation also involves temporarily moving the above-located storage containers before lifting the target storage container 106 from the storage column 105. This step, sometimes referred to in the art as "digging," can be performed using the same container handling vehicle 201 that is subsequently used to transport the target storage container to the unloading port column 119, or using one or more other cooperating container handling vehicles 201. Alternatively, or in addition, the automated storage and retrieval system 1 may have a container handling vehicle 201 specifically designed for the task of temporarily removing a storage container from a storage column 105. Once a target storage container 106 has been removed from a storage column 105, the temporarily removed storage container 106 may be relocated to the original storage column 105. Alternatively, however, the removed storage container 106 may be relocated to another storage column 105.

[0017] When a storage container 106 is to be stored in one of the columns 105, one of the container handling vehicles 201 is instructed to load the storage container 106 from the load port column 120 and transport it to a position above the storage column 105 where it will be stored. After removing any storage containers located at or above the target location within the storage column stack 107, the container handling vehicle 201 positions the storage container 106 at the desired location. The removed storage container 106 can then be placed back into the storage column 105 or relocated to another storage column.

[0018] For monitoring and controlling the automated storage and retrieval system 1, for example, monitoring and controlling the position of each storage container 106 within the frame structure 100, the contents of each storage container 106, and the movement of the container handling vehicles 201, so as to deliver the required storage containers 106 to the required location at the required time without causing the container handling vehicles 201 to collide with each other, the automated storage and retrieval system 1 includes a control system 500, which is typically computerized and typically includes a database for tracking the storage containers 106.

[0019] If the automated storage and retrieval system 1 described above is modified by a rebuild, the rail system 108 is typically affected when adding and / or removing storage columns 105 and / or port columns 119, 120. For example, when a storage column 105 having a rail system 108 is added, the existing rail system on the adjacent storage column to which it is connected will be affected and unusable during the rebuild. Similarly, if a storage column 105 having a rail system 108 is removed, the rail system on the adjacent storage column to which it is connected will be affected and unusable.

[0020] This means that some previously available routes for container handling vehicles 201 operating on the rail system will be unavailable, requiring downtime by temporarily shutting down the automated storage and retrieval system 1 until the rebuilding of the system 1 is complete.

[0021] However, system 1 downtime is undesirable as it can be costly to the operator. The present invention addresses this problem by providing a method and system for controlling an automated storage and retrieval system 1 so that it operates normally during reconstruction of the system 1, at least in unaffected areas of the system. Summary of the Invention

[0022] The present invention is defined by a method for controlling an automated storage and retrieval system during the physical design reconstruction of the system. The storage and retrieval system includes a frame structure that forms a three-dimensional storage grid structure for storing storage containers, wherein the grid structure forms vertical storage columns, each vertical storage column having a uniform horizontal area defined by the size of an access opening of the vertical storage column, and a rail system disposed on the frame structure, the frame structure defining each access opening at the top of each storage column. The rail system provides available routes for container handling vehicles to transport and transfer to and from the storage columns, each vehicle including a vehicle controller that communicates with a master controller. The master controller assigns tasks for handling and transferring storage containers to each vehicle and controls the traffic flow of the vehicles according to a route planner. The master controller and / or the route planner are connected to a database that includes layout information of the rail system and location information of vehicles and storage containers. The route planner determines an optimal route on the rail system for each vehicle based on the available routes, based on the layout information of the rail system and the location information of each vehicle and storage container. The method includes the following steps:

[0023] - after a design step of designing a new physical design of the frame and the corresponding track system, a step of designating a portion of the track system that will be a buffer zone and a portion of the track system that will be removed from the automated storage and retrieval system, in which buffer zone the track system will be affected by the reconstruction, the step comprising updating a database with information having the new physical design and layout of the track system affected by the reconstruction;

[0024] - a repositioning step, wherein the storage container (106) is repositioned in a storage position in a column below the portion of the rail system in the buffer zone and the portion of the rail system to be removed;

[0025] - a temporary routing step, wherein the database updates layout information of the rail system to exclude portions of the rail system located in a buffer zone and portions of the rail system to be removed from available routes, the route planner reroutes traffic flows of container handling vehicles according to available routes not affected by the reconstruction, and the route planner instructs the main controller to control the vehicles according to the available routes;

[0026] a final routing step after the reconstruction step of rebuilding the automated storage and retrieval system according to the new physical design by adding and / or removing portions of the frame and the track system, wherein layout information of the track system in the database is updated to include the portions of the track system in the buffer zone and the new portions of the constructed track system within the available routes, and a route planner uses the updated layout information to route traffic flow of vehicles on the track system after the physical design of the automated storage and retrieval system has been rebuilt.

[0027] According to one embodiment, a buffer zone is defined as the memory ranks and corresponding track systems adjacent to the memory ranks that will be removed or added during the reconstruction. The buffer zone acts as a boundary between the portion of the track system that can be used and the portion of the track system that cannot be used during the reconstruction process.

[0028] According to one embodiment, the storage container is repositioned by moving it to a storage column not affected by the reconstruction and / or to a location outside the storage and retrieval system. Like this, after the buffer zone is established, the storage container in the storage column affected by the reconstruction will be accessible.

[0029] According to one embodiment, the location information in the database is updated with the new storage location of the relocated storage container.

[0030] According to one embodiment, after rerouting the traffic flow, access to the buffer zone is physically blocked by placing an obstruction on a portion of the track system within the buffer zone. The obstruction is removed before the final routing step. By placing an obstruction within the buffer zone, errant container-handling vehicles are prevented from traversing the buffer zone.

[0031] According to one embodiment, the database is updated with the addresses of the storage columns according to the new physical design. Each storage column typically has a unique address in a Cartesian coordinate system. When the storage and retrieval system is expanded in the x and / or y direction, the new storage columns can be addressed with coordinates having increasing coordinate values that are continuous from the coordinates of the existing adjacent storage columns. If the storage and retrieval system is expanded in the negative x direction, for example, relative to an existing storage column addressed as (1, 1), the coordinates addressing all storage columns can be shifted in the x direction. When a storage column 105 is deleted, the addresses of each storage column can be similarly renumbered.

[0032] According to one embodiment, a new storage column of a rebuilt storage and retrieval system is filled with storage containers, typically increasing the storage capacity of the storage and retrieval system. Storage containers already stored in existing columns in unaffected areas of the storage and retrieval system can be relocated and / or stored in the new storage column once imported into the storage and retrieval system.

[0033] The present invention is further defined by an automated storage and retrieval system having a control system for controlling the operation of the system during the physical design of the automated storage and retrieval system according to the above-described method. The storage and retrieval system includes a frame structure forming a three-dimensional storage grid structure for storing storage containers, wherein the grid structure forms vertical storage columns, each vertical storage column having a uniform horizontal area defined by the size of an access opening of the vertical storage column, and a rail system disposed on the frame structure, the frame structure defining each access opening around the top of each storage column, the rail system providing a usable route for container handling vehicles to transport and transfer containers. The control system includes a main controller connected to a route planner and vehicle controllers of the container handling vehicles to control the traffic flow of the vehicles according to the route planner. A database is connected to the main controller and / or the route planner. The database includes layout information of the rail system and location information of the vehicles and storage containers, and the layout information of the rail system is updated in the database from time to time during the design step, the provisional routing step, and the final routing step of the above-described method. The route planner is configured to determine an optimal route for each vehicle on the rail system based on available routes according to layout information of the rail system and position information of each vehicle relative to the storage container stored on the database at that time, the available routes available for selection by the route planner during the design step, the provisional routing step and the final routing step being different in each case.

[0034] The present invention further provides a computer program that, when executed by a processor in a control system of an automated storage and retrieval system, performs a method for controlling an automated storage and retrieval system during reconstruction of a physical design of the automated storage and retrieval system. The control system may include a route planner connected to a database including layout information of the track system and position information of vehicles and storage containers, the route planner determining an optimal route for each vehicle of the automated storage and retrieval system on the track system based on the position information of each vehicle and storage container and the layout information, based on available routes, as described above. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] To facilitate understanding of the present invention, the following drawings are attached. The drawings illustrate embodiments of the present invention, which will now be described by way of example only, in which:

[0036] FIG1 is a perspective view of a frame structure of a prior art automated storage and retrieval system;

[0037] FIG2 shows the components of a control system for controlling an automated storage and retrieval system;

[0038] Figure 3 is a top view of an exemplary prior art design for a storage and retrieval system;

[0039] Figure 4 is a top view of an exemplary reconstructed design of a storage and retrieval system;

[0040] Figure 5 is a top view of the storage and retrieval system, with the excluded track system in the buffer zone marked;

[0041] Figure 6 is a top view of the storage and retrieval system and available track systems during reconstruction, and

[0042] Figure 7 is a flow chart illustrating the different steps of a method of controlling a storage and retrieval system during reconstruction according to the new design.

[0043] Reference Numbers

[0044] 100-frame structure

[0045] 102-Upright members of frame structure

[0046] 103-Horizontal members of frame structures

[0047] 104-Storage Grid Structure

[0048] 105-Storage Column

[0049] 106-Storage Container

[0050] 106'-Special location for storage containers

[0051] 107-Stack

[0052] 108-Track System

[0053] 110-parallel tracks in the first direction (X)

[0054] 110a - first guide rail in first direction (X)

[0055] 110b - second guide rail in the first direction (X)

[0056] 111-parallel tracks in the second direction (Y)

[0057] 111a-first guide rail in the second direction (Y)

[0058] 111b - second guide rail in the second direction (Y)

[0059] 112-Access opening

[0060] 119-First port column

[0061] 120-Second port column

[0062] 200-Route Planner

[0063] 201-Container handling vehicle

[0064] 210-Database (DB)

[0065] 220-Main Controller

[0066] 230-Vehicle Controller

[0067] X-first direction

[0068] Y-second direction

[0069] Z-third direction

[0070] 500-Control System DETAILED DESCRIPTION

[0071] In the following description, the invention will be explained in more detail with reference to the accompanying drawings. It should be understood, however, that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0072] The frame structure 100 of the automated storage and retrieval system 1 is constructed according to the prior art frame structure 100 described above in conjunction with FIG1 , i.e., a plurality of upright members 102 and a plurality of horizontal members 103 supported by the upright members 102, and the frame structure 100 further includes a first top rail system 108 in the X and Y directions. The frame structure 100 provides storage compartments in the form of storage columns 105 disposed between the members 102, 103, wherein storage containers 106 are stackable in stacks 107 within the storage columns 105.

[0073] The frame structure 100 can be of any size, and it will be appreciated that it can be wider and / or longer and / or deeper than the frame structure disclosed in Figure 1. For example, the frame structure 100 can have a horizontal extent of more than 700x700 columns and a storage depth of more than 12 containers.

[0074] As will be appreciated from the description, rebuilding the design of the storage system 1 will affect the rail system 108 so that some routes currently used by container handling vehicles 201 will be inaccessible during the rebuild process. Previously, the storage and retrieval system had to be shut down during the rebuild.

[0075] The present invention provides a method, system and computer program that enable a storage and retrieval system to be rebuilt while it is running. This means that the system does not need to be shut down when rebuilding the system.

[0076] 2 illustrates components included in a control system 500 for controlling an automated storage and retrieval system. A master controller 220 is connected to the route planner 200 and the vehicle controller 230 in each container handling vehicle 201. A database is connected to the route planner 200 and / or the master controller 220. The database 210 includes layout information of the grid structure 104 and location information of the vehicles 201 and storage containers 106.

[0077] The layout of the storage system 1 is typically described in terms of Cartesian x, y coordinates defining each storage column 105, such as Figure 3 The coordinates of each storage column 105 will also reflect the layout of the rail system 108, as each storage column 105 includes a portion of the rail system 108 on top of it.

[0078] The route planner 200 includes a processor running a computer program that determines the optimal route on the rail system 108 for each task assigned to a vehicle 201. For example, a task might be to retrieve a specific storage container from a specific storage column 201 and deliver it to a specific port column for further handling. The optimal route will be based on the layout information of the rail system 108 and the currently available routes. The route planner 200 will instruct the main controller 220 to control each vehicle 201 based on the available and optimal routes for the assigned task. The optimal route is generally the shortest and / or fastest route for the task that does not conflict with the routes of other vehicles. The main controller will then send a control instruction to each container handling vehicle 201, which includes information about the task to be performed and the route to be taken for that task.

[0079] Now refer to Figures 3 to 7 The method performed for controlling the automated storage and retrieval system 1 during reconfiguration of its physical design is described.

[0080] Figure 3 A top view of an exemplary prior art design of a storage and retrieval system 1 is shown. For simplicity, the figure illustrates an example of a smaller storage system containing a total of 60 storage columns. Each storage column is uniquely identified by its address / coordinates, e.g., the upper left storage column in the figure is identified by its x, y coordinates (1, 1), and the lower right storage column is identified by (10, 7).

[0081] A rail system 108 is arranged on top of the frame structure 100, defining the perimeter of each access opening 112 at the top of each storage column 105. The resulting grid pattern of the rail system 108 provides a different route for each container handling vehicle 201.

[0082] When the storage and retrieval system 1 is rebuilt according to a new design, the first step in the method is to design a new frame and corresponding track system 108.

[0083] Figure 4 Shown Figure 3 An example of a modified and exemplary rebuild design of a storage system 1 is shown. In this new design, storage columns 105 addressed at (6, 7) through (10, 7) are removed, and new storage columns 105 addressed at (11, 1) through (11, 6) are added. When storage columns 105 with corresponding rail systems 108 are added to or removed from an existing storage and retrieval system 1, a portion of the rail system 108 on an existing adjacent storage column 108 is affected by the rebuild and cannot be used by container handling vehicles 201.

[0084] When the storage and retrieval system 1 is expanded in the x and / or y direction, new storage columns may be addressed with coordinates having increasing coordinate values that continue from the coordinates of existing adjacent storage columns 105, e.g. Figure 3 Increments the integer value when moving in the positive x and / or y directions represented by the east (E) and south (S) directions. Figure 4 The new columns marked in reflect this.

[0085] On the other hand, if the storage and retrieval system 1 is Figure 3 If the negative X and / or Y directions represented by West (W) and North (N) are expanded, the coordinates of all memory columns addressed can be shifted so that the Figure 3 The memory column 105 in the upper left corner (N / W) starts with (1, 1) as its coordinates. When a memory column 105 is deleted, the addresses of each memory column may be similarly renumbered.

[0086] Figure 5 Shows that in addition to the storage column being removed or rebuilt, when the Figure 4 The new design shown will affect the memory column 105 when the memory system is rebuilt. Figure 5 Indicated by shading in FIG, the portion of the track system 108 at the top of the storage rank 105 that will be affected by removing or adding an adjacent storage rank 105 is included. The portion of the track system 108 in the buffer and the portion of the track system 108 on the storage rank to be removed cannot be used during reconstruction.

[0087] During the rebuild of the storage system 1, to ensure that container handling vehicles 201 avoid using the affected portion of the track system 108 within the buffer zone and the removed area, the storage columns 105 in the affected portion of the track system 108 are temporarily excluded from the available routes. In the example shown, the excluded storage columns 105 in the buffer zone are (10, 1) to (10, 6) and (6, 6) to (6, 9). These are in addition to the storage columns being removed or rebuilt, namely (6, 7) to (10, 7) and (11, 1) to (11, 6) in the example shown.

[0088] Figure 6 An unaffected area of storage columns 105 is shown. These storage columns 105 provide the route planner with available routes during the reconstruction phase. During the reconstruction phase, the storage and retrieval system will operate normally in this unaffected area. In the example used here, the available routes will be located at the top of the 45 storage columns 105 addressed from (1, 1) to (9, 5) on the track system 108.

[0089] Figure 7is a flow chart illustrating the different steps performed according to a method 400 for controlling an automated storage and retrieval system 1 during reconstruction of the physical design of the system.

[0090] The steps of the method illustrate the different phases, namely planning and design phase, relocation phase, rerouting phase, reconstruction phase and final routing phase.

[0091] During the planning and design phase, a new design is established by designing 410 a new or revised grid layout and rail system 108 for the storage system 1. This will typically be performed on a computer running a CAD program, where the new design can be visualized and verified before implementation. The computer program can be operated by a person designing the new layout, or the program can automatically suggest a new grid design based on information from a revised floor plan of the facility in which the storage system 1 will be installed. The suggested grid design can then be accepted or rejected by the operator.

[0092] As mentioned above, a central part of the storage system 1 is the database 210 which includes updated data having layout information of the framework storing the grid structure 104 and the rail system 108 as well as position information of the container handling vehicles 201 and the storage containers / bins 106 .

[0093] When the new grid design and corresponding track system 108 have been determined, the database 210 is updated 420 with this information. The track system 108 affected by the reconstruction is then defined 430 by comparing the existing design with the new reconstruction design, i.e., the portion of the track system 108 on the storage column in the buffer zone adjacent to the portion of the track system 108 on the added or removed storage column.

[0094] The database 210 tracks the different storage containers 106 and which storage columns 105 they are currently stored in. The next step is to identify and relocate 440 the storage containers 106 that are stored in storage columns 105 beneath the rail systems 108 that are to be excluded from the available routes, for example, in a buffer zone and beneath a portion of the rail system that is to be removed. The identified storage containers 106 are then relocated to storage columns 105 beneath rail systems 108 that will not be affected by the reconstruction, for example. Storage containers 106 stored in storage columns 105 that will be removed in the new design will also be relocated prior to the reconstruction process.

[0095] When the associated storage containers 106 have been repositioned, the portions of the rail system affected by the reconstruction (e.g., the portions in the buffer zone and the portions taken off the storage column) are excluded from the selection of available routes, the database 210 is updated 420 with this information, and during the reconstruction process 460, the traffic flow of the container handling vehicles 201 is temporarily rerouted 450 according to the identified available routes.

[0096] During the reconstruction process, rerouting is performed by the route planner 200 according to the updated information of the available routes, and the route planner 200 instructs the main controller 230 in each vehicle 201 assigned the task of transferring the storage container 106 to control and route the vehicle 201 according to the temporarily available routes.

[0097] When the temporary rerouting step has been implemented, the automated storage and retrieval system 1 can be rebuilt according to the new physical design by adding and / or removing portions of the frame and track system 108.

[0098] When the reconstruction is complete, the portions of the rail system 108 in the buffer zone that were previously excluded from the selection of available routes and the new portions of the rail system 108 that have been built are now included as available routes, and the route planner 200 implements a final routing step 470 in which the traffic flow of vehicles 201 is controlled according to the available routes on the rail system 108 after the physical design of the automated storage and retrieval system 1 has been reconstructed.

[0099] According to one embodiment, the new storage columns 105 of the rebuilt storage and retrieval system 1 are populated with new storage containers 106. This situation typically occurs when the storage and retrieval system 1 is expanded with additional storage columns 105.

[0100] In one embodiment, after the rerouting traffic flow step 450, a physical blockage of the excluded portion of the track system 108 is performed. The physical blockage may, for example, include an object, such as a barrier, that is suitable for installation in or on the track system 108 and is stationary when placed on the portion of the track system 108 to be excluded. The physical blockage will improve safety during the rerouting process. The physical blockage is removed before the final routing step 470.

[0101] The routing steps of the above method are performed by a computer program executed by a processor in the route planner 200 connected to the database 210 and the controller 220 of the vehicle 230. These devices are described above with reference to FIG.

[0102] The foregoing description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiments, 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 fall within the scope of the invention.

Claims

1. A method for controlling an automated storage and retrieval system during reconstruction of a physical design of the system, the storage and retrieval system comprising a frame structure forming a three-dimensional storage grid structure for storing storage containers, wherein: The grid structure forms vertical storage columns, each of the vertical storage columns having the same horizontal area defined by the size of the access openings of the vertical storage columns, and wherein a rail system is arranged on the frame structure and defines the periphery of each access opening at the top of each storage column, the rail system providing container handling vehicles with available routes for carrying and transferring the storage containers to and from the storage columns, each vehicle including a vehicle controller communicating with a main controller, the main controller assigning tasks for carrying and transferring the storage containers to each vehicle and controlling the traffic flow of the vehicles according to a route planner, a database connected to the main controller and / or the route planner, the database including layout information of the rail system and position information of the vehicles and storage containers, the route planner determining an optimal route on the rail system for each vehicle based on the available routes according to the layout information of the rail system and the position information of each vehicle and storage container, wherein reconstructing the physical design of the automated storage and retrieval system is characterized by performing the following steps: After the step of designing a new physical design for a frame and corresponding track system, designating a portion of the track system as a buffer zone, the buffer zone being a portion of the track system to be removed from the automated storage and retrieval system and a portion of the track system adjacent to storage columns to be removed or added during the rebuild, including updating the database with the new physical design and layout information for the track system affected by the rebuild; - a repositioning step, wherein a storage container having a storage location in a storage column below the portion of the rail system in the buffer zone and the portion of the rail system to be removed is relocated to a storage column not affected by the reconstruction and / or to a location outside the storage and retrieval system, and the location information in the database is updated with the new storage location of the relocated storage container; - a temporary routing step, wherein the database updates the layout information of the rail system to exclude portions of the rail system located in the buffer zone and portions of the rail system to be removed from the available routes, the route planner reroutes the traffic flow of the container handling vehicles according to the available routes not affected by the reconstruction, and the route planner instructs the main controller to control the vehicles according to the available routes; - physically preventing access to the buffer zone by placing a barrier on the portion of the track system in the buffer zone after rerouting the traffic flow; -After a reconstruction step of rebuilding the automated storage and retrieval system according to the new physical design by adding and / or removing portions of a frame and track system, the obstacles are removed before a final routing step, in which the layout information of the track system in the database is updated to include, within the available routes, the portions of the track system in the buffer zone and the new portions of the track system that have been constructed, and after rebuilding the physical design of the automated storage and retrieval system, the route planner uses the updated layout information to route the traffic flow of the vehicles on the track system. 2 . The method of claim 1 , further comprising updating the layout information in the database with addresses of memory columns according to the new physical design.

3. The method of claim 1 or 2, wherein the storage containers are used to populate new storage columns of the reconstructed storage and retrieval system.

4. An automated storage and retrieval system having a control system for controlling the operation of the system during reconstruction of the physical design of the automated storage and retrieval system according to the method of claim 1, the storage and retrieval system comprising a frame structure forming a three-dimensional storage grid structure for storing storage containers, wherein: The grid structure forms vertical storage columns, each of the vertical storage columns having the same horizontal area defined by the size of the access openings of the vertical storage columns, and wherein a rail system is arranged on the frame structure, defining the periphery of each access opening at the top of each storage column, the rail system providing a usable route for container handling vehicles to carry and transfer the storage containers to and from the storage columns, the control system comprising a main controller connected to a route planner and vehicle controllers of the container handling vehicles so as to control the traffic flow of the vehicles according to the route planner, a database connected to the main controller and / or the route planner, the database comprising layout information of the rail system and the locations of the vehicles and storage containers wherein the layout information of the track system is updated in the database from time to time during the designing step, the provisional routing step, and the final routing step in the method according to claim 1, wherein the route planner is configured to determine an optimal route for each vehicle on the track system based on available routes according to the layout information of the track system and the position information of each vehicle and the storage container stored in the database at that time, the available routes for selection by the route planner during the designing step, the provisional routing step, and the final routing step being different in each case, and wherein obstacles are placed on the track system affected by the reconstruction to physically block access to the track system.

5. A computer-readable storage medium storing a computer program that, when executed by a processor in a control system of an automatic storage and retrieval system, performs the method for controlling the automatic storage and retrieval system during reconstruction of a physical design of the automatic storage and retrieval system according to claim 1.

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