Method and system and computer program for controlling the operation of a container handling vehicle and remotely operating a dedicated container handling vehicle

Abstract

The present application discloses a method and system and computer program for controlling the operation of a container handling vehicle and a remotely operated dedicated container handling vehicle, the dedicated vehicle and the container handling vehicle respectively operating below and above an automated storage and retrieval system. The purpose is to ensure that the dedicated vehicle and the container handling vehicle have the minimum or most cost-effective waiting time when transferring storage containers between the dedicated vehicle and the container handling vehicle. The different steps are performed by an operation controller, which communicates with a first type of controller in each container handling vehicle and a second type of controller in each dedicated vehicle, and wherein timing information is a key factor.

Description

[0001] This application is a divisional application of the Chinese patent invention application "Method and system for controlling the operation of container handling vehicles and special vehicles serving automatic storage and retrieval systems" with an application date of June 11, 2019 and application number 201980053876.3. Technical Field

[0002] The present invention relates to an automated storage and retrieval system having a grid structure, and a conveying system, the conveying system comprising a port at a first position located below the automated storage and retrieval system. A plurality of dedicated vehicles (drones) are used to transport storage containers from a second position to the port and from the port to a second position, the second position being typically a pick-up station. More specifically, the present invention relates to a method, system and computer program for controlling and coordinating the interaction between dedicated vehicles and container handling vehicles, the dedicated vehicles and the container handling vehicles operating below and above the automated storage and retrieval system, respectively. Background Art

[0003] Figure 1 A typical prior art automated storage and retrieval system 10 is disclosed having a frame structure 100 and wherein the automated storage and retrieval system 10 is operated when a container handling vehicle 200 (also referred to as a robot) runs on a track system 108 on top of the frame structure 100 .

[0004] The frame structure 100 includes a plurality of upright members 102 and optionally a plurality of horizontal members 103 supporting the upright members 102. The members 102, 103 may typically be made of metal, such as extruded aluminum.

[0005] The frame structure 100 defines a storage grid 104 comprising storage columns 105 arranged in rows in which storage containers 106, also referred to as boxes, are stacked one on top of another to form stacks 107. Each storage container 106 can typically hold a plurality of product items (not shown).

[0006] The automated storage and retrieval system 10 includes a track system 108 for container handling vehicles 200. The track system 108 is arranged in a grid pattern across the top of the storage grid 104. The container handling vehicles 200 run on the track system 108 and are operated to lower and raise storage containers 106 into and from the storage columns 105, as well as transport storage containers 106 on the track system 108. Figure 1 , the horizontal extent of one of the grid cells 122 constituting the grid pattern is marked by a bold line.

[0007] The track system 108 includes a first set of parallel tracks 110 arranged to guide the container handling vehicles 200 to move on top of the frame structure 100 in a first direction X, and a second set of parallel tracks 111 arranged perpendicular to the first set of tracks 110 to guide the container handling vehicles 200 to move in a second direction Y, which is perpendicular to the first direction X. In this way, the track system 108 defines a grid column over which the container handling vehicles 200 can move laterally over the storage columns 105, i.e., in a plane parallel to the horizontal XY plane.

[0008] Each container handling vehicle 200 comprises a body and a wheel arrangement of eight wheels 201, wherein a first set of four wheels enables the container handling vehicle 200 to move laterally in the X direction, and the remaining second set of four wheels enables the container handling vehicle to move laterally in the Y direction. One or both sets of wheels in the wheel arrangement may be raised and lowered so that the first set of wheels and / or the second set of wheels may engage with a corresponding set of tracks 110, 111, wherein this is defined by a controller that controls the movement and direction of the container handling vehicle 200.

[0009] Each container handling vehicle 200 includes a lifting device (not shown) for vertically transporting storage containers 106, such as lifting storage containers 106 from storage rows 105 and lowering storage containers 106 into storage rows. The lifting device includes one or more clamping / engaging devices (not shown) adapted to engage storage containers 106. The clamping / engaging device can be lowered from the vehicle 200 by the lifting device to adjust the position of the clamping / engaging device in a third direction Z orthogonal to the first direction X and the second direction Y.

[0010] Each container handling vehicle 200 includes a storage compartment or space (not shown) for receiving and loading storage containers 106 when transporting the storage containers 106 across the track system 108. The storage space may include a centrally disposed cavity within the vehicle body, such as described in WO 2014 / 090684 A1, the contents of which are incorporated herein by reference.

[0011] Alternatively, the container handling vehicle 200 may have a cantilever structure, as described in NO 317366, the contents of which are also incorporated herein by reference.

[0012] In the storage grid 104, most of the grid columns are storage columns 105, i.e., grid columns 105 in which storage containers 106 are stored in stacks 107. However, the storage grid 104 usually has at least one such grid column, which is not used for storing storage containers 106, but is used by a container handling vehicle 200 to unload and / or pick up storage containers 106 so that the storage containers can be transported to a second location (not shown) where the storage containers 106 can be accessed from the outside of the storage grid 104, or the storage containers can be transferred out of or into the storage grid 104. In the art, such a location is usually referred to as a "port", and the grid column where the port is located can be referred to as a "transfer column" 119. The unloading port and the pick-up port of the container handling vehicle 200 are referred to as the "upper port of the transfer column 119". And the opposite end of the transfer column is referred to as the "lower port of the transfer column".

[0013] Figure 1 The storage grid 104 in FIG. 1 includes two conveyor lanes 119 and 120. The first conveyor lane 119 may, for example, include a dedicated unloading port where a container handling vehicle 200 can unload a storage container 106 for transport through the conveyor lane 119 and further transport to an access station or transfer station (not shown), and the second conveyor lane 120 may include a dedicated pick-up port where a container handling vehicle 200 can pick up a storage container 106 that has been transported from the access station or transfer station (not shown) through the conveyor lane 120. Each port of the first conveyor lane 119 and the second conveyor lane 120 may include a port suitable for picking up and unloading a storage container 106.

[0014] The second location may typically be a pick-up station or deposit station where product items are removed from or positioned into storage containers 106. In the pick-up station or deposit station, storage containers 106 are typically not removed from the automated storage and retrieval system 10, but are returned to the storage grid 104 once accessed. In order to transfer storage containers out of or into the storage grid 104, a plurality of lower ports are also provided in the transport train. These lower ports are used, for example, to transfer storage containers 106 to another storage facility (e.g., to another storage grid), directly to a transport vehicle (e.g., a train or truck), or to a production facility.

[0015] To monitor and control the automated storage and retrieval system 10, the system includes a control system (not shown), which is typically computerized and includes a database for tracking the storage containers 106 and which boxes are being handled, i.e., retrieved or stored, at any time. The control system can monitor and control the location of the respective storage containers 106 within the storage grid 104; the contents of each storage container 106; and the location and movement of the container handling vehicles 200, so that the desired storage container 106 can be delivered to the desired location at the desired time without the container handling vehicles 200 colliding with each other.

[0016] When approaching the storage Figure 1 104, the control system instructs one of the container handling vehicles 200 to retrieve the storage container 106 from the current position of the storage container in the storage grid 104 and transport the storage container to or through the first conveying column 119. This operation includes moving the container handling vehicle 200 to a grid 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, and transporting the storage container 106 to the first conveying column 119. If the target storage container 106 is located deep within the stack 107, that is, one or more other storage containers are positioned above the target storage container 106, the operation will include temporarily moving the storage container 106 positioned above 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 200 that is subsequently used to transport the target storage container 106 to the delivery train, or using other cooperating container handling vehicles 200. Alternatively or additionally, the automated storage and retrieval system 10 can have a container handling vehicle 200 that is dedicated to the task of temporarily removing a storage container 106 from a storage train 105. Once the target storage container 106 has been removed from the storage train 105, the temporarily removed storage container 106 can be relocated to the original storage train 105. Alternatively, however, the removed storage container can be relocated to another storage train 105.

[0017] When a storage container 106 is to be stored in the storage grid 104, one of the container handling vehicles 200 is instructed to pick up a storage container 106 from the second conveyor row 120 and transport the storage container to a grid position above the storage row 105 where it is to be stored. The container handling vehicle 200 positions the storage container 106 at the desired location after any storage containers at or above the target location within the storage row stack 107 have been removed. The removed storage container can then be lowered back into the storage row 105 or repositioned to another storage row 105.

[0018] One problem associated with known automated storage and retrieval systems 10 is that the area around the pick-up ports and unloading ports may block some container handling vehicles 200 that are instructed to unload or pick up storage containers 106. This may seriously hinder the operation of the automated storage and retrieval system 10. In small systems, this situation may be alleviated by adding conveyor columns to the grid, because this will allow the container handling vehicles 200 to be distributed among a large number of ports of the conveyor columns, thereby avoiding blockage. However, if ports and columns are added, the conveyor system infrastructure must usually be increased. This requires space, which may not necessarily be available. Moreover, adding and maintaining the conveyor system infrastructure is expensive.

[0019] Another problem with the prior art automated storage and retrieval system 10 is that the separate unloading ports and pick-up ports of the conveyor trains 119, 120 require the container handling vehicles 200 to move to the storage trains 105 after unloading to retrieve new storage containers 106. Also, the container handling vehicles 200 must be unloaded, i.e., the container handling vehicles must be free of storage containers 106 when they are delivered to the pick-up ports 120 to pick up storage containers 106. This results in inefficiencies and increased congestion around the ports because the container handling vehicles 200 are moving around the storage grid 104 without the storage containers 106 as payload. Additionally, the conveyor trains 119, 120 may occupy space on the storage grid 104 that could be used for other purposes, such as support for the container handling vehicles 200 passing through the trains 119, 120.

[0020] The present invention provides a new method of avoiding the problems described when handling storage containers 106 and transferring storage containers to and from an automated storage and retrieval system. Summary of the invention

[0021] The present invention is defined by a method for controlling the operation of a plurality of container handling vehicles and a plurality of remotely operated special purpose vehicles so that the total elapsed time or waiting time cost for transferring storage containers between the container handling vehicles and the special purpose vehicles is minimized or optimized based on a weighted function, wherein the special purpose vehicles operate at a height below an automated storage and retrieval system having a frame structure defining a storage grid for storing storage containers in grid cells, and wherein the storage containers are stored and retrieved by container handling vehicles operating on top of the storage grid.

[0022] The following steps are performed by at least one operations controller in communication with a first type of controller in each container handling vehicle and a second type of controller in each dedicated vehicle:

[0023] -When a specific storage container is to be transferred from a storage column and its corresponding grid cell to a dedicated vehicle:

[0024] o assigning and instructing a container handling vehicle to pick up a storage container from the grid cell and lower the storage container to a selected port located at a lower end of the identified free conveyor lane by sending instructions to a controller of a first type of the assigned container handling vehicle;

[0025] o causing a container handling vehicle to move to a grid unit, pick up a storage container and transport the storage container to a grid unit of a conveying column where a port is located;

[0026] o sending a signal to the dedicated vehicles, the signal including information of the selected port at the first location and when the storage container will be available at the port;

[0027] o allocating and instructing a dedicated vehicle to retrieve the designated storage container based on responses from the dedicated vehicles;

[0028] o moving the specialized vehicle to a port at a first location, picking up a storage container and bringing the storage container to a second location,

[0029] - and / or when a designated storage container is transferred to a grid unit by a dedicated vehicle for storage in the storage column corresponding to the grid unit:

[0030] o determining which port at the first location to use;

[0031] o sending instructions to a controller of a second type of dedicated vehicle to transport the storage container from its current position representing the second position to the port at the first position;

[0032] o moving the specialized vehicle from the second location to the port at the first location;

[0033] o sending a signal to these container handling vehicles, the signal including information of the port from which the storage container is to be retrieved;

[0034] o allocating and directing a container handling vehicle to lift and retrieve a designated storage container from the port at the first location based on responses from the container handling vehicles;

[0035] o Lifting the storage container from the port via the conveyor train and moving the container handling vehicle to transport the storage container to the grid cell corresponding to the storage train to which the designated storage container is to be transferred.

[0036] Depending on the size of the storage grid, the number of ports for transferring storage containers between the container handling vehicle and the special vehicle may vary. For smaller systems, only two ports may be allocated for this purpose, such as one for lowering a storage container for retrieval and one for raising a storage container to be stored. Different configurations are possible and can be tailored to the size of the storage grid and the available area for the special vehicle to operate below the storage grid.

[0037] If there are several available ports for transferring storage containers, a decision can be made as to the most suitable port to be used.Multiple ports can be grouped together under the delivery column in the distribution area under the storage grid, or the ports can be dispersed at different locations under the storage grid.

[0038] In one embodiment, when a given storage container is transferred to or from a grid cell by a dedicated vehicle and a container handling vehicle, selection of a port from a set of ports available for transferring the storage container is based on a compromise between the best match travel time of the container handling vehicle between the nearest available port and the grid cell to which the storage container is to be transferred or from and the location of the port accessible by the nearest idle dedicated vehicle.

[0039] The travel time of available container handling vehicles will be calculated. This will be based on the current location of these container handling vehicles and the routes they can take to reach the grid cell, and the time it will take for the cell to have an available port where the specified storage container is stored in or retrieved from the grid cell.

[0040] Travel times for available dedicated vehicles will also be calculated based on their current location and the routes they can take to reach the port and the time it will take for the unit at the available port to transfer the designated storage container to or from the container handling vehicle.

[0041] The port selected for transferring the storage container is then a compromise based on the container handling vehicles and the special purpose vehicles having the best matching travel time to the port. The goal is to select the port so that the time taken by the special purpose vehicles and the container handling vehicles to transfer the designated storage container to and from the storage grid is minimized. In addition to this, the best timing is achieved when there is minimal waiting at the port when transferring the storage container.

[0042] This means that storage containers are transferred via the port without container handling vehicles or special vehicles having to wait for each other.

[0043] When retrieving a designated storage container, aspects that contribute to the time it takes for the storage container to be ready for a dedicated vehicle to be transferred to the port are: the time it takes to move the storage container from its current location to the grid unit where the storage container is stored, the time it takes to pick up the storage container, the time it takes to move the storage container to the grid unit where the port is located, and the time it takes to lower the storage container to the port.

[0044] Retrieving the storage container may include digging it out, i.e., first removing other containers on top of the storage container before accessing the storage container. This operation may be performed by a container handling vehicle other than the container handling vehicle selected to transfer the storage container to the port, so that when the selected container handling vehicle arrives at the unit where the storage container is located, the designated storage container is available.

[0045] In one embodiment, wherein a designated storage container is transferred to a grid unit by a dedicated vehicle and a container handling vehicle, the container handling vehicle assigned to retrieve the designated storage container from the port at the first location is a container handling vehicle that is currently available and has a travel time that best matches from its current location to the port when taking into account the dedicated vehicle.

[0046] In another embodiment, when a designated storage container is retrieved from a grid unit by a container handling vehicle and a dedicated vehicle, the dedicated vehicle assigned to retrieve the designated storage container from the port at the first location is a dedicated vehicle that is currently available and has a travel time that best matches the container handling vehicle from its current location to the port.

[0047] The present invention also includes a system that enables control of the operation of container handling vehicles operating on top of the storage grid and remotely operated special vehicles operating at a height below the automated storage and retrieval system so that the total transit time or waiting time cost for transferring storage containers between the container handling vehicles and the special vehicles is minimized or optimized based on a weighted function.

[0048] The system comprises an operations controller which is signal-connected to the controllers in all robots and all special vehicles. In this way, the operations controller will always have an overview and control of the location and availability of the robots and special vehicles. The interaction of these controllers enables the execution of the above-described method.

[0049] The present invention also includes a computer program which, when executed by a computer, performs the above-described method to control the operation of a remotely operated special purpose vehicle so that the total elapsed time or waiting time cost for transferring storage containers between a container handling vehicle and a special purpose vehicle is minimized or optimized based on a weighted function, wherein the special purpose vehicle operates at a height below an automatic storage and retrieval system having a frame structure defining a storage grid for storing storage containers in grid cells, and wherein the storage containers are stored and retrieved by container handling vehicles operating on top of the storage grid.

[0050] The advantage of the present invention is that it provides optimal control of a new automatic storage and retrieval system including both container handling vehicles and special vehicles. This means improved efficiency when storing and retrieving items in storage containers. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] The following drawings depict exemplary embodiments of the present invention and are attached to facilitate understanding of the present invention.

[0052] Figure 1 is a perspective view of a prior art automated storage and retrieval system with an operable prior art container handling vehicle;

[0053] Figure 2 is a perspective view of an exemplary embodiment of an automated storage and retrieval grid and delivery system including a dedicated vehicle according to the present invention;

[0054] Figure 3 shows the steps performed to retrieve the box;

[0055] Figure 4 shows the steps performed to store the box, and

[0056] Figure 5 The communication paths between the operation controller, the dedicated vehicle and the container handling vehicle (robot) are shown. DETAILED DESCRIPTION

[0057] In the following, the invention will be discussed 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 depicted subject matter.

[0058] A typical prior art automated storage and retrieval system 10 having a frame structure 100 is described in the Background section above.

[0059] The container handling vehicle track system 108 allows the container handling vehicle 200 to move horizontally between different grid locations, where each grid location is associated with a grid cell 122 .

[0060] exist Figure 1In the embodiment, the storage grid 104 is shown as having a height of eight grid cells 122. However, it should be understood that the storage grid 104 can be any size in principle. The storage grid 104 can be larger than Figure 1 For example, the storage grid 104 may have a horizontal extent of greater than 700×700 storage columns 105. Furthermore, the storage grid 104 may be greater than Figure 1 For example, the storage grid 104 is much deeper in depth (i.e., in Figure 1 There may be more than 12 grid cells 122 (in the Z direction as shown).

[0061] The container vehicle 200 may be of any type known in the art, for example any of the automated container handling vehicles disclosed in WO 2014 / 090684 A1, in NO 317366 or in WO 2015 / 193278 A1. Methods and control systems for controlling such prior art systems are known.

[0062] The applicant has developed a new solution for operating an automated storage and retrieval system which solves or at least alleviates one or more problems associated with the use of prior art storage and retrieval systems.

[0063] exist Figure 2 In the system shown, a dedicated container handling vehicle, referred to as a dedicated vehicle 30, operates in the area below the automated storage and retrieval system 10. In order to efficiently handle storage containers 106, the dedicated vehicle 30 must cooperate with the container handling vehicle 106 operating on top of the automated storage and retrieval system 10.

[0064] The special vehicle 30 differs from the container handling vehicle 200 in structural features and the manner in which the special vehicle handles the storage container 106. The container handling vehicle 200 handles the storage container 106 by lifting and lowering the storage container under the lower portion of the container handling vehicle, while the special vehicle 30 delivers and receives the container 106 over its upper portion.

[0065] Figure 2 A perspective view of a novel automated storage and retrieval system 10 is shown. In addition to a container handling vehicle 200 configured to move on a rail system 108 above a storage column 105, the novel system also includes a conveying system 140 that includes one or more specialized vehicles 30. The specialized vehicles 30 are configured to receive and support one or more storage containers 106 for transport between one or more conveying columns 119, 120 and one or more predetermined locations outside the storage grid 104. The predetermined location may be, for example, a second location or a conveyor line or a transport vehicle such as a truck.

[0066] exist Figure 2In the embodiment shown, the special vehicle 30 has a container carrier device on its top side. In this way, the special vehicle 30 can receive and transport the container 106 when it is directly positioned below the conveying column 119, 120. Figure 2 The specialized vehicle shown also includes wheels suitable for running on tracks as well as a propulsion device, a controller, a communication device and a power source.

[0067] The new system includes a storage grid 104 and a conveying system 140 located below the storage grid 104 . Figure 2 1 shows a conveyor rail system 50 by way of example. In order to obtain maximum storage space for storage containers in the storage and retrieval grid, it may be advantageous to arrange the conveyor rail system 50 so that it extends as little as possible into the storage grid 104. This means that the storage and retrieval grid may comprise a plurality of storage columns 105 extending from the upper height of the storage grid 104 to the base, thereby allowing the maximum possible storage capacity, since the entire storage column 105 may be used for storage.

[0068] The conveying track system may include a first track system located within the frame structure of the storage grid 104, and a second track system located outside the frame structure of the storage grid 104, and wherein the first track system and the second track system are connected so that the special vehicle 30 can operate between these track systems.

[0069] Tracks are not necessary for full functionality of the new system. The dedicated vehicle 30 may, for example, run directly on the floor or hover above the floor.

[0070] The storage grid 104 in the new solution is the same as or similar to the storage grid 104 of the above-mentioned prior art, that is, the storage grid 104 includes a rail system 108, multiple stacks 107 of storage containers 106, multiple container handling vehicles 200 for lifting and moving the storage containers 106 stacked in the stacks 107, and conveying columns 119, 120 configured to transfer storage containers 106 between upper ports and lower ports in each conveying column via container handling vehicles 200.

[0071] like Figure 2 As illustrated in FIG. 1 , the conveyor system 140 may also include a conveyor track system 50 located below a conveyor port 150 of one or more conveyor trains 119 , 120 . The conveyor track system 50 may be constructed in the same or similar manner as the track system 108 for the container handling vehicle 200 .

[0072] The conveyor system 140 may also include an interface that can be connected to a third-party storage, production, and distribution system. The conveyor system 140 may also be integrated with a third-party storage, production, and distribution system so that the storage container 106 is transported between the conveyor system 140 and the third-party storage, production, and distribution system. The conveyor system 140 may also be connected to a third-party storage, production, and distribution system, such as a production facility, a storage grid, an assembly facility, a receiving or shipping location, etc. The connection may be achieved by a connectable track system or a conveyor system comprising a plurality of conveyors that are used to transport the storage container 106 between the conveyor system 140 and the third-party storage, production, and distribution system.

[0073] The conveyor track system 50 may be fully or partially integrated into the storage grid 104. However, to ensure efficient operation, it is considered advantageous for the conveyor track system 50 to have a horizontal extent that covers the conveyor ports 150 at the bottom of at least one of the conveyor columns 119,120.

[0074] Figure 2 1 is a perspective view of an automated storage and retrieval system having a conveyor track system 50 extending from a location within the storage grid 104 to a location outside the storage grid 104. One or more second locations (i.e., structures for picking up and placing items in storage containers 106) may be arranged somewhere around the perimeter of the portion of the conveyor track system 50 that is outside the storage grid 104. Alternatively or additionally, conveyors may be arranged at or near the same perimeter of the conveyor track system 50.

[0075] The new system provides challenges related to optimal coordination when transferring storage containers 106 between the container handling vehicle 200 and the specialized vehicle 30 operating at different heights in the automated storage and retrieval system 10 .

[0076] One object of the present invention is to provide a method for controlling a new automated storage and retrieval system 10 to increase the availability of conveyor trains 119, 120 for container handling vehicles 200 operating on a rail system. This is achieved by a method for controlling and coordinating the interaction between the specialized vehicles 30 and the container handling vehicles 200 operating below and above the automated storage and retrieval system, respectively.

[0077] When using and controlling a container handling vehicle 200 and a special vehicle 30 for transferring storage containers 106, the present invention provides an automatic storage and retrieval system that is controlled in a more efficient manner than prior art systems, thereby avoiding or at least reducing congestion of storage containers 106 around conveyor trains 119, 120.

[0078] According to the novel method, storage containers 106 are transferred between a container handling vehicle (robot) 200 and a dedicated vehicle in a manner that saves as much time and / or cost as possible.

[0079] The most time-efficient approach is to minimize the total transit time of transferring storage containers 106 between the container handling vehicle 200 and the dedicated vehicle 30, i.e., where each has a minimal waiting time. This can be achieved when the container handling vehicle 200 and the dedicated vehicle 30 each have an optimal batch travel time when transferring storage containers 106 between the container handling vehicle and the dedicated vehicle. Ideally, this means that each arrives at the port 150 at the same time.

[0080] However, the waiting time cost of the container handling vehicle 200 is generally higher than the waiting time cost of the dedicated vehicle 30. The most cost-effective approach is to ensure that the container handling vehicle 200 is always used to handle the storage container 106. This may mean that the dedicated vehicle 30 selected to transfer the storage container 106 to or from the container handling vehicle 299 must wait for a period of time at the port before the container handling vehicle 200 is ready to transfer the storage container 106 at the port 150.

[0081] The minimum or optimal waiting cost may be based on a weighted function, where the selected port 150, time, and waiting cost are variables included in the function.

[0082] The specialized vehicle 30 moves between a first location and a second location in an area below the automated storage and retrieval system 10 .

[0083] The first position is defined at a height below the automated storage and retrieval system 10, where there is a grid structure for storing storage containers 106 in grid cells 122, and where the storage containers 106 are handled by a container handling vehicle 200 running on top of the storage grid 104 and adapted to transfer the storage containers 106 via the conveyor trains 119, 120. More specifically, the first position is a position at the port 150 directly below the conveyor trains 119, 120.

[0084] The second location is the location where the special vehicle 30 is currently located. This can be, for example, a pick-up station or a deposit station where product items are removed from or placed into a storage container 106. The second location can also be a temporary location where the special vehicle is located while it awaits instructions as to which conveyor train 119, 120 it will interact with to deliver or retrieve a storage container 106.

[0085] The different steps of the method are performed in at least one operating controller 210 that is in electronic communication with a first controller 220 in each container handling vehicle 200 and a second controller 230 in each dedicated vehicle 30 .

[0086] In one embodiment, the at least one operational controller 210 is a master controller that communicates with a first type of controller 220 in each container handling vehicle 200 and a second type of controller 230 in each dedicated vehicle 30 .

[0087] In another embodiment, the at least one operation controller 210 is a master controller that is signally connected to sub-controllers that communicate with the first type of controller 220 in each container handling vehicle 200 and the second type of controller 230 in each special purpose vehicle 30. In this way, the master controller can delegate control of the container handling vehicles 200 and special purpose vehicles 30 to the sub-controllers. The master controller can select the port 150 for transferring the storage container 106 and the estimated target time for the transfer, for example, based on information from the underlying system. The sub-controllers can then allocate and select the container handling vehicles 200 and special purpose vehicles 30 to be used to transfer the storage container 106 at the port 150.

[0088] In one scenario, when a designated storage container 106 is to be transferred from a storage location to a dedicated vehicle 30, the first step is to determine in which storage column 105 and corresponding grid cell 122 the designated storage container 106 is stored. The operation controller 210 then determines which container handling vehicle 200 will be assigned for the job. The operation controller then sends instructions to the first controller 220 in the selected container handling vehicle 200, instructing it to pick up the storage container 106 from the determined grid cell 122 and lower the storage container to the selected port 150, which is located at the lower end of the identified free storage column 105 and its corresponding grid cell 122. This will be the first delivery column 119 described above.

[0089] If the designated storage container 106 is located below a stack of other storage containers 106 in the same storage row 105, the other storage containers 106 are first removed by the assigned container handling vehicle 200 or other container handling vehicles 200 assigned for this operation.

[0090] The selected port 150 is typically the port 150 or a group of ports 150 that are assigned to transfer storage containers 106 from a container handling vehicle 200 operating on top of the storage grid 10 to a dedicated vehicle 30 operating at a height below the container handling vehicle 200. This height may correspond to Figure 2 Example shown.

[0091] In another embodiment, the selected port 150 may change based on the currently free transport lanes 119. Determining the currently most suitable port 150 for use may be advantageous for larger systems operating many container handling vehicles 200 and specialized vehicles 30 in the same automated storage and retrieval system 10.

[0092] In one embodiment, the port 150 selected for transferring storage containers between the container handling vehicle 200 and the dedicated vehicle 30 is based on a compromise between the nearest free grid cell 122 and the corresponding free delivery column 119 having the delivery port 150 and the grid cell 122 corresponding to the storage column 105 in which the storage container 106 is stored.

[0093] All decisions regarding which container handling vehicle 200 and dedicated vehicle 30 to use to handle a given storage container 106 are based on the timing information. The tradeoff will be adjusted so that the waiting time between the container handling vehicle 200 and the dedicated vehicle 30 will be minimized when transferring the storage container 106 between them. Ideally, this means that the dedicated vehicle 30 arrives at the port 150 for pickup at approximately the same time that the storage container 106 is lowered to the port 150 by the container handling vehicle 200.

[0094] In addition to the described minimum waiting time at the port 150, another aspect of consideration is to utilize the transport train 119 as efficiently as possible. This means that once a storage container has been transferred via the transport train, another storage container is transferred. Since the operation controller has a comprehensive overview of which containers will be transferred via the port 150 and in what order, the operation controller will continuously select and arrange the container handling vehicles 200 to handle the storage containers 106 so that as soon as the transport train 119 is free after transferring a storage container, a new transfer is performed.

[0095] By efficiently utilizing the transport trains 119, it is inevitable that fewer transport trains will be installed in the storage grid 104, thereby providing more storage capacity.

[0096] When a request is made to retrieve a specified storage container 106, the time taken to retrieve the storage container is estimated, and a decision is made as to which container handling vehicle 200 is available to pick up the storage container. The time taken to retrieve the container 106 is based on the location of the storage container in the stack of multiple storage containers 106, and the availability of the container handling vehicle 200 to retrieve the storage container. If the requested storage container 106 is located below other storage containers 106 in the storage column 105, the other storage containers 106 must be removed first. This will affect the time taken to retrieve the storage container 106 from its location in the storage column 105.

[0097] When the container handling vehicle 200 has retrieved the storage container 106, a determination is made as to the time taken to move the storage container to the selected cell 122 and lower the storage container to the corresponding port 150. The total time to retrieve the storage container from its location in the storage column 105 to deliver it to the port 150 is input data for selecting which dedicated vehicle 30 is selected to pick up the storage container.

[0098] When an instruction is sent from the operation controller 210 to the first controller 220 of the assigned container handling vehicle 200, a request is further sent to the second controller 230 in each dedicated vehicle 30, which has information of the selected port 150 at the first location for exchanging the storage container 106, and the estimated time when the storage container is expected to arrive at the port 150. The dedicated vehicle 30 that is available to pick up the storage container 106 at the estimated time then reports this to the operation controller 210. This may be a dedicated vehicle 30 that is not currently handling a storage container 106, or a dedicated vehicle 30 that is currently returning a storage container for storage in the automated storage and retrieval system 10.

[0099] In one embodiment, once a designated storage container 106 has been requested and the total time for delivering the storage container to the port 150 has been estimated, the dedicated vehicle is provided with timing information regarding the time the storage container 106 is expected to arrive at the designated port 150 .

[0100] In another embodiment, updated timing information related to the time when the storage container 106 arrives at the port 150 is continuously estimated and sent to these dedicated vehicles. Since the traffic of different container handling vehicles 200 running on the rail system 108 on the storage grid 104 may be complex and often changing, this can provide a more flexible and accurate way to control the dedicated vehicles 30 to provide the minimum waiting time for picking up the storage container 106 at the port 150.

[0101] Based on the responses from these special vehicles 30, the operation controller 210 will assign a designated special vehicle 30 to retrieve the designated storage container 106 from the first location at the port 150 and bring it to the second location. The second location can be, for example, a pickup station as described above. The special vehicle 30 assigned to pick up the storage container 106 will depend on different factors, such as the location of the special vehicle 30 at the time of the request, the task the special vehicle is currently performing, etc.

[0102] In another scenario, when a designated storage container 106 is to be stored in the storage row 105 by first transferring the storage container to a port 150 by a dedicated vehicle 30 , the first step is to determine which port 150 at the first location the storage container 106 is to be transferred to.

[0103] As mentioned above, port 150 is usually predefined when the system is set up. Figure 1 and Figure 2 In the example shown and the corresponding description above, the port 150 at the second transfer lane 120 is used to transfer the storage container 106 from the dedicated vehicle 30 to the container handling vehicle 200 .

[0104] The operations controller 210 will always have a high level overview and control over the movement and operation of all container handling vehicles 200, special purpose vehicles 30 and storage containers 106 within the system. Thus, it will be known which special purpose vehicle 30 is transferring a specified storage container 106 to a port 150.

[0105] The next step of the method is to send a command from the operating controller 210 to the second controller 230 in the dedicated vehicle 30 to transfer the storage container 106 from its current location (representing the second location) to the selected port 150 at the first location.

[0106] The last step is to assign a container handling vehicle 200 to retrieve the designated storage container 106 from the port 150 at the first location. The container handling vehicle will then transfer the storage container to the determined grid cell 122.

[0107] A specific scenario provides an efficient way to utilize the dedicated vehicle 30. In this scenario, the dedicated vehicle 30 is instructed to first transfer a storage container 106 from the second location to the first location at the port 150 at the corresponding second delivery line 120. Then, the dedicated vehicle 30 is instructed to immediately pick up another storage container 106 from the port 150 at the corresponding first delivery line 119.

[0108] In one embodiment of the present invention, the operation controller 210 can control the speed of the special vehicle 30 and the container handling vehicle 200 based on the speed at which people and / or robotic arms pick up items from / place items in storage containers 106 at the picking stations. In this way, different picking stations can operate at different speeds. This will ensure smooth handling of the storage containers 106 and will avoid blocking of the special vehicles 30 at specific picking stations.

[0109] In the following example, a scenario is described where a container handling vehicle 200 is performing an exchange of storage containers 106. When a storage container 106 is to be retrieved from a storage location in the automated storage and retrieval system 10, the container handling vehicle 200 performs a storage container exchange by returning one storage container 106 to the automated storage and retrieval system 10 for each storage container 106 delivered to the dedicated vehicle 30. This involves the operation controller 210 sending a signal to the container handling vehicle 200 indicating that the container handling vehicle must be ready to receive another storage container 106 immediately after delivering one storage container 106. This may involve the container handling vehicle 200 not always raising its lifting device to the top of the unit 122, but being able to detach from the storage container when the storage container 106 is to be transferred to the dedicated vehicle 30. A second dedicated vehicle 30 will then be arranged next to the dedicated vehicle 30 receiving the storage container 106, the second dedicated vehicle carrying the storage container 106 to be returned for storage, and moving into position immediately after the first dedicated vehicle 30 has moved away. The same container handling vehicle 200 may then quickly pick up the returned storage container 106 and place the storage container back into the automated storage and retrieval system 10 .

[0110] In another scenario, where the storage container 106 is to be returned to the storage grid 104 without exchanging the storage container 106, the operation controller 210 will send a signal to the controller of the selected container handling vehicle 200 that is not currently handling the storage container 106, indicating that the dedicated vehicle 30 requires the container handling vehicle 200 to move to the specified grid cell 122 or to a selected grid cell 122 among the selected grid cells 122. The controller of the selected container handling vehicle 200 will then instruct the container handling vehicle to move to the given grid cell 122 or to one of the selected grid cells 122 that the container handling vehicle can most efficiently reach. The port 150 corresponding to the selected grid cell 122 is then communicated to the controller of the dedicated vehicle 30 that is returning the storage container to the storage grid 104 by the operation controller 210, and the dedicated vehicle 30 will begin its movement to the selected port 150. Once the container handling vehicle 200 has moved to the selected grid cell 122, the container handling vehicle will lower its lifting device to just above the dedicated vehicle operation, i.e., at the port 150, so that the container handling vehicle is ready to pick up the storage container 106 immediately once the dedicated vehicle 30 arrives at the selected port 150.

[0111] As will be appreciated from the above discussion, the operation controller 210 controls and coordinates the operation of the container handling vehicle 200 and the special purpose vehicle 30. Ideally, the container handling vehicle 200 and the special purpose vehicle 30 have minimal waiting time when transferring storage containers 106 between the container handling vehicle and the special purpose vehicle. To achieve this, coordination of the operation of the container handling vehicle 200 and the special purpose vehicle 30 is performed. This is based on timing information.

[0112] When handling a storage container 106, there will be different operations that contribute to the transit time of the container handling vehicles 200 and the special purpose vehicles 30. When a request is made to retrieve a storage container 106 from a storage column 105, the first operation is to decide which container handling vehicle 200 is to pick up the storage container, and then decide the time it takes to move the selected container handling vehicle 200 from its current position to the cell 122 corresponding to the storage column 105 storing the requested storage container 106. Which container handling vehicle 200 is selected will depend on the location of these container handling vehicles 200 on the grid and the different routes that these container handling vehicles can take to reach the cell 122 above the requested storage container 106.

[0113] If the route is a straight line along a track, the time to reach the destination unit 122 will be controlled by the vehicle's acceleration, top speed, and deceleration. If a tortuous route is required, in addition to these factors, the time required to lower and raise the second set of wheels and travel in a vertical direction will also help determine which container handling vehicle 200 is best for retrieving the requested storage container 106.

[0114] The next operation may include first removing the other storage containers 106 placed on top of the requested storage container 106. This digging operation may consume a significant amount of time, depending on at which height below the topmost storage container 106 the requested storage container 106 is located. The digging operation may be performed by other container handling vehicles 200 other than the container handling vehicle selected to bring the storage container 106 to the port 150. In this way, the requested storage container 106 may be ready to be picked up when the selected container handling vehicle 200 has arrived at its location.

[0115] The next operation is to bring the storage container 106 from the cell 122 corresponding to the storage column 105 from which it was retrieved to the selected cell 122 of the selected storage column 105 having the port 150. The last step that contributes to the total elapsed time from requesting a storage container 106 until it is available at the port 150 is lowering the storage container 106 to the port 150.

[0116] The different time estimates are based on empirical data and the operating speed of the selected container handling vehicle 106. When the operation controller begins sending information of the selected port 150 at the first location and the time when the requested storage container is ready to be picked up at the port 150 to the plurality of dedicated vehicles 30, the estimated total time that the requested storage container 106 is available at the port 150 is an input value. As described above, the estimated total time can be continuously updated and sent to the plurality of dedicated vehicles 30.

[0117] Figure 3 An example is shown that illustrates the steps performed when retrieving a box / storage container 106. In this example, box #341 is retrieved from the storage grid 104.

[0118] The first step 300 is to determine the location (x,y,z) of the requested box #341, for example (2,5,4). This means that the requested box is stored in grid cell (2,5) on the 4th floor, i.e., there are 3 other storage containers 106 stacked on top of the requested box. In step 310, this location is signaled to the robot / container handling vehicle 200.

[0119] The robots currently available to carry the box will report this and, as shown in step 320, the operations controller will receive signals from those robots 200 that are ready to pick up box #341.

[0120] In step 330, the robot 200 with the shortest travel time to grid cell (x,y), in this case cell (2,5), is selected. This is computationally based - the available routes (that are not blocked) are quite complex since other robots are constantly moving on the grid. When a particular robot is selected, it is instructed to move to grid cell (x,y), i.e. (2,5) in this example, and pick up the box, see step 340. Since this box is stored below three other boxes, the other boxes must first be removed before box #341 can be accessed. This operation can be performed by the selected robot itself or by other robots. These other robots can be dedicated to this task. Ideally, when the selected robot reaches the destination cell, box #341 has been dug out.

[0121] The next step 350 is to select which port 150 to use to transfer the box #341 to the dedicated vehicle 50. The number of available ports 150 and the locations of the ports 150 and their corresponding grid cells 122 depend on the structural features of the storage grid 104. Larger systems will generally be configured with more ports 150 than smaller systems. Although only one port 150 may be used, at least two ports 150 will provide a more efficient solution, where one port can be used to transfer the box 106 from the robot 200 to the dedicated vehicle 30 while another port can be used to transfer the box from the dedicated vehicle 30 to the robot 200.

[0122] In larger systems, several ports 150 may be grouped together and / or spread out so that different locations within the area covered by the storage grid 106 are covered.

[0123] The port 150 selected for transfer of the box and the time when the box will arrive at the port 150 are signaled to the dedicated vehicle 30, see step 360.

[0124] Those dedicated vehicles 30 that are currently available to tote box #341 will report this, and as shown in step 370, the operations controller will receive signals from those dedicated vehicles 30 that are ready to pick up the box.

[0125] As indicated in 380, a selected dedicated vehicle 30 is assigned to pick up bin #341. This dedicated vehicle will typically be the dedicated vehicle 30 with the best travel time to a particular port 150. This dedicated vehicle may also be the dedicated vehicle with the shortest travel time to the assigned port 150. This dedicated vehicle 30 will then be instructed to move to the selected port 150, pick up bin #341, and move the bin to another location, see step 390. The port is at a first location and the other location is a second location, such as a conveyor belt at a pickup station.

[0126] In one embodiment, the robot 200 is instructed to stay at the grid cell 122 where the port 150 is located, and the robot's lifting device is maintained at the port to return another box 106 to the storage grid 106, see step 395. This will save time because the robot 200's lifting device is already at the port 150 when the robot 200 is instructed to store another box 106 in the storage grid 104.

[0127] Figure 4 An example is shown illustrating the steps performed when storing a box / storage container 106. In this example, box #292 is to be stored in the storage grid 104. Port 150 may be located at grid cell (7, 1), for example.

[0128] The port 150 for transferring the bin 106 to the storage grid 104 is selected, see step 410. Which port 150 is used to transfer bin #292 to the robot 200 will depend on various factors, such as the number of available ports 150 and the locations of the ports 150, as in the previous examples above.

[0129] When the port 150 to be used is determined, the dedicated vehicle 150 is instructed to move to the selected port 150, see step 420. Information about the selected port 150 and the time when box #292 will be available at the port is sent to the robot 200, see step 430.

[0130] The robots currently available to carry the box will report this and, as indicated in step 440, the operations controller will receive signals from those robots 200 that are ready to pick up box #292.

[0131] Considering a dedicated vehicle 150 for delivering box #292, the robot 200 with the best travel time to grid cell (7,1) and to when the robot's lift is available at port 150 will be selected and assigned to retrieve the box, see step 450. This is computationally based - the available routes (that are not blocked) are quite complex since other robots are constantly moving on the grid. The selected robot 200 is instructed to move to grid cell (7,1), lower the robot's lift to port 150, pick up box #292, and place the box at location (x,y,z) for storage.

[0132] In one embodiment, the dedicated vehicle 30 is instructed to stop at a port 150 to retrieve another box 106 from the storage grid 106, see step 465. This will save time when, for example, another robot 150 has already retrieved the box and lowered it to a nearby port 150.

[0133] Figure 5 A system is shown that enables control of the operation of a container handling vehicle 200 operating on top of a storage grid 104 and a remotely operated dedicated vehicle 30 operating at an elevation below an automated storage and retrieval system 10 so that the total transit time or waiting time cost for transferring storage containers 106 between the container handling vehicle and the dedicated vehicle is minimized or optimized based on a weighted function.

[0134] The system comprises an operation controller 210 which is signally connected to all robot controllers and all dedicated vehicle controllers. A communication path is provided between at least one operation controller 210, a first type of controller 220 in each container handling vehicle / robot 200 and a second type of controller 230 in each dedicated vehicle 30. In this way, one or more operation controllers 210 will always have an overview and control of the location and availability of the robots and dedicated vehicles. The interaction of these controllers enables the execution of the above-described method.

Claims

1. A method for controlling the operation of a container handling vehicle (200) and a remotely operated dedicated container handling vehicle (30) so that the total elapsed time or waiting time cost of transferring a designated storage container (106) between the container handling vehicle and the dedicated container handling vehicle is minimized or optimized, wherein the dedicated container handling vehicle (30) operates at a height below an automated storage and retrieval system (10), the automated storage and retrieval system having a frame structure (100) defining a storage grid (104) for storing storage containers (106) in grid cells (122), and wherein the storage containers (106) are stored and retrieved by the container handling vehicle (200) operating on top of the storage grid (104), and wherein the following The steps are performed by at least one operation controller (210) that communicates with a first type of controller (220) in each container handling vehicle (200) and a second type of controller (230) in each dedicated container handling vehicle (30), characterized in that: - When transferring a designated storage container (106) from a storage column (105) and its corresponding grid cell (122) to a dedicated container handling vehicle (30): o Allocating and directing a container handling vehicle (200) from the grid unit (122) picking up the storage container (106) and lowering the storage container to a selected port (150) located at the lower end of the identified free conveyor train (119, 120) by sending instructions to a controller (220) of the first type of the assigned container handling vehicle (200), wherein the port is selected from a group of ports (150) that can be used to transfer the storage container (106), the selection being based on a weighted function that includes a compromise between a best-match travel time of the container handling vehicle (200) between the nearest available port (150) and the grid cell (122) to which the storage container (106) is to be transferred or to which the storage container (106) is to be transferred, and a travel time of an idle dedicated container handling vehicle (30) to that port (150); o moving the container handling vehicle (200) to the grid unit (122), picking up the storage container (106) and transporting the storage container to the grid unit (122) of the conveying column (119, 120) where the port (150) is located; o sending a signal to the dedicated container handling vehicle (30) including information of the selected port (150) at the first location and when the storage container (106) will be available at the port (150); o allocating and instructing a dedicated container handling vehicle (30) to retrieve the designated storage container (106) at the selected port (150) based on the response from the dedicated container handling vehicle (30); o moving the assigned dedicated container handling vehicle (30) to the selected port (150) at the first location, picking up the storage container (106) and bringing the storage container to a second location, - and / or when a designated storage container (106) is transferred to a grid unit (122) by a dedicated container handling vehicle (30) for storage in its corresponding storage column (105): o determining which port (150) at the first location to use, wherein the selected port (150) is included as variables in a weighting function along with time and waiting costs to obtain a compromise solution in which the container handling vehicle and the dedicated container handling vehicle (30) have the best matching travel time to the port; o sending instructions to a controller (230) of the second type of the dedicated container handling vehicle (30) to transport the storage container (106) from a current location representing the second location to the determined port (150) at the first location; o moving the dedicated container handling vehicle (30) from the second location to the determined port (150) at the first location; o sending a signal to the container handling vehicle (200), the signal including information of the determined port (150) from which the storage container (106) is to be retrieved; o based on the response from the container handling vehicle (200), assigning and instructing a container handling vehicle (200) to lift and retrieve the designated storage container (106) from the determined port (150) for use at the first location; ○ From the determined port (150) through the transport train (119, 120) The storage container (106) is lifted and the container handling vehicle (200) is moved to transport the storage container (106) to a grid cell (122) corresponding to the storage column (105) to which the designated storage container (106) is to be transferred; wherein, when the operation controller begins to send information of the selected port (150) at the first position and the time when the requested storage container (106) is ready to be picked up at the port (150) to the dedicated container handling vehicle (30), an estimated total time that the requested storage container (106) is available at the port (150) is an input value, wherein the estimated total time includes the excavation operation for retrieving the designated storage container (106) from the storage column (105) and the time to bring the storage container (106) from the grid cell (122) corresponding to the storage column (105) from which it is to be retrieved to the grid cell (122) of the selected storage column (105) having the port (150).

2. A system for controlling the operation of a container handling vehicle (200) and a remotely operated dedicated container handling vehicle (30) so that the total elapsed time or waiting time cost of transferring a storage container (106) between the container handling vehicle and the dedicated container handling vehicle is minimized or optimized based on a weighted function, wherein the dedicated container handling vehicle (30) operates at a height below an automated storage and retrieval system (10), the automated storage and retrieval system having a frame structure (100) defining a storage grid (104) for storing the storage containers (106) in grid cells (122), and wherein the storage containers (106) are stored and retrieved by the container handling vehicle (200) operating on top of the storage grid (104), and wherein at least one operation controller (210) communicates with a first type of controller (220) in each container handling vehicle (200) and a second type of controller (230) in each dedicated container handling vehicle (30), characterized in that The controller is adapted to perform the method according to claim 1 .

3. A computer program product comprising instructions for causing the system according to claim 2 to perform the steps of the method according to claim 1 to control the operation of the container handling vehicle (200) and the remotely operated dedicated container handling vehicle (30) when transferring storage containers (106) between the container handling vehicle (200) and the remotely operated dedicated container handling vehicle (30).

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