Automated storage systems and devices

Abstract

The present invention provides a drive belt assembly for a load handling device, the drive belt assembly comprising: a drive belt; a drive pulley; one or more driven pulleys; and a tensioning tool including a first tensioning arm and a second tensioning arm, the first tensioning arm having a fixed end located above an elbow and a rotatable distal end pivotally attached to the elbow, wherein the first tensioning arm is horizontally displaceable relative to the drive pulley and the driven pulleys, wherein the drive belt is routed around the first and second tensioning arms and the first and second tensioning arms are configured to apply pressure to the drive belt to tension the drive belt.

Description

Technical Field

[0001] This invention relates to an automated storage system apparatus. More specifically, but not limited to, a load processing apparatus operating on a storage system having stacked storage bins located within a grid structure. Background Technology

[0002] Methods for handling stacked containers have been well-known for decades. Some such systems, such as those described in US2,701,065, a patent granted to Bertel, involve independently arranged stacks to reduce the storage capacity associated with storing such containers while allowing access to specific containers when needed. Access to a specific container is achieved by providing a more sophisticated lifting mechanism that can be used to stack a specific container in a stack or remove a specific container from a stack. However, the cost of such systems is impractical in many cases, and they are primarily commercially available for storing and handling large freight containers.

[0003] The concept of using stacked individual containers and providing mechanisms for retrieving and storing specific containers has been further developed, for example, as illustrated by EP0767113B patent granted to Cimcorp. EP'113 discloses an automated load processor in the form of a rectangular tube for removing multiple stacked containers. This rectangular tube is lowered around the stack of containers and configured to grip containers from any layer within the stack. In this way, several containers can be lifted from the stack at once. The movable tube can be used to move several containers from the top of one stack to the top of another, or to move containers from the stack to an external location, or vice versa. Such systems are particularly useful in situations where all containers in a single stack contain the same product (referred to as a single-product stack).

[0004] In the system described in EP'113, the height of the tube must be at least the same as the height of the large container stack, so that the highest container stack can be extracted in a single operation. Accordingly, when used in enclosed spaces such as warehouses, the maximum height of the stack is limited by the tube's capacity to accommodate the load processor.

[0005] EP 1037828 B1 (Autostore) describes a system in which containers are stacked within a frame structure. This type of system is attached... Figure 1-4 The diagram illustrates this. The automated load handling device can be controlled to move around the stack of the track system on the top surface of the stack.

[0006] Occado Innovation Ltd.’s UK patent application GB2520104A describes a load processing device in which each automatic load processor covers only one grid space, thereby achieving high-density load processors and thus high throughput in a system of a given size.

[0007] In the aforementioned known automated picking systems, an automated load handling device is controllably moved around the top of a stack forming a grid of tracks. The designated load handling device lifts boxes from the stack; the lifted containers contain the inventory items needed to fulfill a customer order. The containers are then transported to a picking station, where the required inventory items are manually removed from the boxes and placed into delivery containers, which form part of the customer order and are manually filled and dispatched at the appropriate time. At the picking station, items can also be picked by industrial robots suitable for such work, such as those described in UK patent application GB2524383B filed by Occado Innovations Ltd.

[0008] like Figure 1 and Figure 2 As shown, stackable storage containers (referred to as boxes 10) are stacked on top of each other to form a stack 12. The stack 12 is set in a frame 14 in a warehousing or manufacturing environment. Figure 1 It is a schematic 3D view of frame 14, and Figure 2 This is a plan view showing a stack of individual boxes 10 12 arranged within frame 14. Each box 10 typically holds multiple products or inventory items, and the inventory items within the box 10 can be the same or different product types depending on the application scenario. Additionally, the boxes 10 can be physically separated to accommodate multiple different inventory items.

[0009] Frame 14 includes a plurality of vertical members 16 supporting horizontal members 18, 20. A first set of parallel horizontal members 18 is positioned perpendicular to a second set of parallel horizontal members 20 to form a plurality of horizontal grid structures supported by the vertical members 16. Members 16, 18, 20 are typically made of metal. Boxes 10 are stacked between members 16, 18, 20 of the grid frame structure 14, such that the grid frame structure 14 prevents horizontal movement of the stack 12 of boxes 10 and guides vertical movement of boxes 10.

[0010] The top layer of frame 14 includes tracks 22 arranged in a grid pattern, spanning the top of stack 12. See also Figure 3 and... Figure 4The track 22 supports a plurality of automated load handling devices 30. A first set 22a of the parallel track 22 guides the load handling device 30 to move across the top of the frame 14 in a first direction (X), and a second set 22b of the parallel track 22 is configured perpendicular to the first set 22a and guides the load handling device 30 to move in a second direction (Y) perpendicular to the first direction. In this way, the track 22 enables the load handling device 30 to move laterally in two dimensions in the XY plane, thereby allowing the load handling device 30 to be moved to a position above any stack 12.

[0011] Each load handling device 30 includes a carrier 32, which is configured to travel in the X and Y directions above the stack 12 on the tracks 22 of the frame 14. A first set of wheels 34 consists of a pair of wheels 34 located at the front of the carrier 32 and a pair of wheels 34 located at the rear of the carrier 32, configured to engage with two adjacent tracks of the first set 22a of the tracks 22. Similarly, a second set of wheels 36 consists of a pair of wheels 36 on each side of the carrier 32, configured to engage with two adjacent tracks of the second set 22b of the tracks 22. Each set of wheels 34, 36 can be raised and lowered such that either the first set of wheels 34 or the second set of wheels 36 can engage with the corresponding track sets 22a, 22b at any given time.

[0012] When the first set of wheels 34 engages with the first set of rails 22a and the second set of wheels 36 is lifted from the rails 22, the wheels 34 can be driven by a drive mechanism (not shown) fitted in the carrier 32 to move the load handling device 30 in the X direction. To move the load handling device 30 in the Y direction, the first set of wheels 34 must be lifted from the rails 22 and the second set of wheels 36 must be lowered to engage with the second set of rails 22a. The drive mechanism can then be used to drive the second set of wheels 36 to achieve movement in the Y direction.

[0013] In this way, one or more automatic load handling devices 30 can be controlled by a centralized control device (utility) (not shown) as follows: Figure 4 The stack 12 on the frame 14 moves around the top surface. Each automatic load handling unit 30 is equipped with a lifting tool 38 for lifting one or more boxes 10 from the stack 12 to access the desired product.

[0014] The main body of the carrier 32 includes a cavity 40, which is sized to hold the box 10. The lifting tool 38 includes a winch and a box gripper assembly 39. The lifting tool lifts the box 10 from the stack 12 and places it into the cavity 40 within the main body of the carrier 32. While in the cavity 40, the box 10 is lifted away from the track below, allowing the load handling device to move laterally to different locations on the grid. Upon reaching the target location (such as another stack, an access point in a storage system, or a conveyor belt), the box 10 can be lowered from the cavity and released from the gripper assembly 39.

[0015] In this way, multiple products can be accessed at once from multiple locations in the grid and stack.

[0016] The above description describes a storage system associated with, for example, a department store. Figure 4 A typical such storage system is shown, which has a plurality of load processing units 30 operating on a grid above the stack 12.

[0017] Figure 1 and Figure 4 The image shows a box 10 within a stack 12 of the storage system. It should be understood that a large number of boxes 10 can exist in any given storage system, and many different items can be stored in the boxes 10 within the stack 12. Each box 10 can contain different categories of inventory items within a single stack 12.

[0018] In a system described above and in UK patent application GB2517264A filed by Occado Innovations Ltd. (which is incorporated herein by reference), the storage system includes a series of boxes 10 that may further include delivery containers DT containing customer orders, or boxes 10 that may further include or contain inventory items to be picked. These different boxes 10, or combinations thereof, may be included in the storage system and accessed by the automated load handling device 30 described above.

[0019] It should be understood that automated or semi-automated storage and retrieval systems are not limited to systems specifically designed for department stores. For example, this technology can be used in freight, parcel handling, vehicle parking, indoor or hydroponic greenhouses and farming, modular construction, self-storage facilities, cargo handling, transport dispatch yards, production facilities, pallet handling, parcel sorting, airport logistics (ULD), and general logistics, and these are just some of the possible applications. It should also be understood that different types of storage and retrieval systems will have different technical requirements.

[0020] The applicant designed this invention in light of this background. Summary of the Invention

[0021] Various aspects of the present invention are set forth in the claims.

[0022] One objective is to provide lightweight load processing units. Another objective is to provide low-cost load processing units. Yet another objective is to provide modular load processing units that are easy or economical to maintain.

[0023] Another objective is to provide load handling devices made primarily of recyclable or environmentally friendly materials.

[0024] A load handling device is provided for lifting and moving storage containers (10) stacked in a grid frame (14) structure, the grid frame (14) structure including a first set of parallel rails or tracks (22b) and a second set of parallel rails or tracks (22a), the second set of parallel rails or tracks (22a) extending substantially perpendicular to the first set of parallel rails or tracks (22b) in a substantially horizontal plane to form a grid pattern including a plurality of grid spaces, wherein the grid is supported by a set of vertical members (16) to form a plurality of vertical storage locations below the grid for the containers (10) to be stacked between the vertical members and guided vertically through the vertical members. The load handling device comprises a plurality of grid spaces, including a main body and a reversing assembly. The main body is mounted on a first set of wheels (116) and a second set of wheels. The first set of wheels (116) is configured to engage with a first set of parallel tracks (22b), and the second set of wheels is configured to engage with a second set of parallel tracks (22a). The reversing assembly is configured to raise or lower the first set of wheels and / or lower / raise the second set of wheels relative to the main body, thereby engaging or disengaging the wheels from the parallel tracks. The reversing assembly includes a flexible mechanism having at least one elastically deformable member configured to move under the action of an external force, causing the wheels to rise or fall.

[0025] A load handling device is provided for lifting and moving storage containers stacked in a grid frame structure. The grid frame structure includes a first set of parallel rails or tracks and a second set of parallel rails or tracks. The second set of parallel rails or tracks extends substantially perpendicular to the first set of parallel rails or tracks in a generally horizontal plane to form a grid pattern comprising a plurality of grid spaces. The grid is supported by a set of vertical members to form a plurality of vertical storage locations below the grid for containers to be stacked between the vertical members and guided vertically through the plurality of grid spaces. The load handling device includes a main body and a reversing assembly. The main body is mounted on a first set of wheels and a second set of wheels. The first set of wheels is configured to engage with the first set of parallel rails, and the second set of wheels is configured to engage with the second set of parallel rails. The reversing assembly is configured to raise or lower the first set of wheels and / or lower / raise the second set of wheels relative to the main body, thereby engaging or disengaging the wheels from the parallel rails. The reversing assembly includes a linkage set having a traveler and a fixed support. A series of components between brace), wherein the movable part is configured to move under the action of an external force, causing the wheel to rise or fall.

[0026] It should be understood that each of the aforementioned components can be identical. Therefore, when the moving part moves relative to the fixed support, each component will move in a similar manner. It should be understood that the linkage can be considered as a single component between the moving part and the fixed support. However, this series of components typically includes two or more components or legs. A leg is provided between each end of the moving part and the fixed support to prevent twisting of the structure. Typically, this series of components may include five components. It should be understood that any number of components can be used depending on the requirements of the reversing assembly and the length and space available on the moving part and the fixed support.

[0027] The first and second sets of wheels can be driven independently of each other. When the load handling device is driven, only one set of wheels engages with the grid, so that the load handling device can be moved along the track to any point on the grid by driving only the set of wheels engaged with the track.

[0028] The advantage of directional assemblies that include flexible mechanisms or linkages is that they can reliably engage appropriate groups of wheels, thereby effectively and efficiently maneuvering load handling devices in the x and y directions on and around the grid to reach each grid space and move around other devices operating on the grid. Another advantage of flexible mechanisms or linkages for directional assemblies is that they can be made lightweight by utilizing material properties.

[0029] The steering mechanism can be connected to the first set of wheels and the second set of wheels. Accordingly, by selectively operating one set of wheels or the other set of wheels, the load handling device can be moved to any position on the grid.

[0030] The interlocking device can be a series of elastically deformable components including a flexible mechanism, or the linkage can be a series of pivotally connected rigid body components. Each of the series of components may include a pivotally connected two-part linkage. The joints between the components of the linkage are restricted in their rotation.

[0031] In this way, the series of components can rotate about a pivot point, joint, or hinge until it is stopped or restricted, and then move about a second pivot point, joint, or hinge. It should be understood that the interlocking links may include more than two joints. Advantageously, the movement of the series of components can be designed to manage the forces required to achieve the function of changing direction relative to the position of the group of wheels or some other parts of the load handling device by adjusting the length between each part of the two-part interlocking links and by adjusting the rotational limits. By managing the forces required to achieve the changing direction function, wear on the components of the load handling device can be managed. This, in turn, results in a more reliable device requiring less maintenance or fewer replacement parts.

[0032] The upper support can be placed horizontally relative to the lower support, and the corresponding ground support can also be referred to as the movable part.

[0033] A flexible mechanism can be stable in a neutral configuration, and it can also be stable in at least one other configuration. Similarly, a linkage can be stable in a neutral configuration and at least one other configuration.

[0034] In this way, the steering assembly has a "preferred" configuration or position, and if the deformation force is removed, the linkage or flexible mechanism will tend to stop or move to this "preferred" configuration or position. This makes it possible to select the first set of wheels, the second set of wheels, or both sets of wheels simultaneously. Advantageously, the load handling device can be set to move to a default position. Advantageously, this default position can passively (i.e., without input) automatically place the load handling device into a "safe" state.

[0035] The linkage and flexible mechanism can be in a stable configuration when either the first set of wheels is engaged with the rail or the second set of wheels is engaged with the rail. Alternatively, the linkage and flexible mechanism can be in a stable configuration when both the first set of wheels and the second set of wheels are engaged with the rail. Therefore, the linkage and flexible mechanism can have three stable configurations: a stable configuration when each set of wheels is engaged with the rail individually, and a stable "parking" configuration when both the first and second sets of wheels are engaged with the rail simultaneously.

[0036] The reversing assembly may include at least one linkage or compliant mechanism for each set of wheels. The linkage or compliant mechanism may be mechanically connected to coordinate movement between configurations. The mechanical connection may be a belt connecting two or more linkages, optionally said belt circumnavigating the body of the load handling device. Alternatively, the mechanical connection may be a chain. This ensures that each set of wheels is coordinated. This prevents the load handling device body from tilting and thus helps keep the load handling device within the tolerance of a single space during reversing operations. Accordingly, this reduces the risk of collisions caused by other load handling devices operating on adjacent tracks. It should be understood that any number of linkages or compliant mechanisms can be used to cause the reversing assembly to operate as described in the invention with the desired action. It should be understood that the first pair of opposite sides of the load handling device should operate together, while the vertical second pair of opposite sides should operate opposite to the first pair of sides. Therefore, the linkages or compliant mechanisms on the second pair of sides may be opposite to the compliant mechanisms on the first pair of sides.

[0037] At least one elastically deformable member may be a hinge, and the flexible mechanism may include a series of main sections connected to the upper and lower supports via hinges. The hinge may include branch sections or spring sections. It should be understood that any other type of hinge with the desired characteristics may be used to achieve the desired flexible mechanism action.

[0038] Therefore, flexible mechanisms are configured to preferentially bend or flex at specific points in the shape. This, in turn, facilitates specific mechanical or dynamic mechanical actions of the flexible mechanism. Hinges can be designed to have a portion thinner than the trunk.

[0039] As mentioned above, flexible hinges can be replaced by another type of hinge. For example, the "moving" hinge of a flexible mechanism can be replaced by a pivotally connected rigid member that replicates similar movements. The pivot connection can be a hinge. The pivotally connected rigid member can be a linkage mechanism.

[0040] Each linkage or flexible mechanism may include at least one main section having a first type of hinge and at least one main section having a second type of hinge.

[0041] This method enables complex movements of linkages or flexible mechanisms. The first type of hinge can demonstrate one type of movement, while the second type of hinge can demonstrate a different type of movement. Using a series of columns or main members with different movement characteristics, linkages or flexible mechanisms can demonstrate combinations of movement characteristics.

[0042] In use, for example, when the upper bracket or the moving part moves in a first direction relative to the lower bracket, the main body with a hinge of the first type can engage with the upper and lower brackets in a stable configuration in the x direction, and / or when the upper bracket or the moving part moves in a second direction relative to the lower bracket, the main body with a hinge of the second type can engage with the upper and lower brackets in a stable configuration in the y direction.

[0043] The reversing mechanism can be driven by a single motor.

[0044] In this way, a single motor can be used to change the direction of movement of the load handling unit. It should be understood that the motor can be replaced with other starting tools, such as solenoids, hydraulic tools, pneumatic tools, servo tools, solid-state starting tools, etc. The advantage is that it can reduce overall cost and the weight of the load handling unit.

[0045] The reversing mechanism can be driven by more than one motor. Each individual flexible element of the reversing mechanism can be driven by a motor.

[0046] In this way, the load processing unit can have some redundancy, so that the load processing unit can continue to operate even if there is a partial failure, and thus prevent the entire load processing unit on the grid from becoming uncontrollable.

[0047] On the positive side, it provides a more robust reversing mechanism. It also reduces downtime for individual load processing units and the entire storage and retrieval system.

[0048] The linkage device or flexible mechanism may be made of plastic, polymer plastic, thermosetting plastic, thermoplastic plastic, metal, aluminum, aluminum alloy, iron, iron alloy, steel, steel alloy, magnesium, magnesium alloy, titanium, titanium alloy, zinc, zinc alloy, fiber reinforced composite, carbon fiber, graphite fiber, glass fiber, natural fiber, plant fiber, plastic fiber, paper, paperboard, rubber, epoxy resin or nylon.

[0049] Linkage devices or flexible mechanisms can be obtained through 3D printing. This allows for the creation of forms that are impossible with more traditional production methods. An advantage is that linkage devices or flexible mechanisms can be printed on demand or in 3D printing equipment near the location where the part is needed, thereby reducing logistical costs associated with transporting the part to the desired location. It should be understood that the 3D printing mentioned in this invention is more generally referred to as additive manufacturing, which involves adding material layer by layer.

[0050] Interlocking devices or flexible mechanisms can be significantly topologically optimized. In this way, they can be optimized to reduce the total amount of material used. Alternatively, they can be optimized to remain within certain stress limits to ensure that they operate below fatigue limits within the operating temperature range.

[0051] It should be understood that one set of wheels may be fixed relative to the frame or body of the load handling device, while the other set of wheels may be raised or lowered relative to the body of the load handling device. Alternatively, it should be understood that neither set of wheels may be fixed relative to the body of the load handling device, and the first and second sets of wheels may be configured to move in unison relative to the body of the load handling device in opposite vertical directions.

[0052] Therefore, it should be understood that the steering mechanism may be attached to or connected to the first set of wheels and the second set of wheels, or the steering mechanism may be attached to only one set of wheels.

[0053] According to another specific embodiment of the present invention, a method for changing the travel direction of a load handling device is provided, the method comprising the following steps: applying a force along a first direction F1 to a moving part of a reversing assembly, causing a linkage device or flexible mechanism to move to a stable configuration in the x-direction; or applying a force along a second direction F2 to a moving part of the reversing assembly, causing the linkage device or flexible mechanism to move to a stable configuration in the y-direction; or removing the force applied to the moving part of the reversing assembly, causing the linkage device or flexible mechanism to move to a neutral configuration or a rest configuration without elastic energy storage.

[0054] Therefore, flexible mechanisms can move between stable configurations.

[0055] The method may further include the following steps: receiving a signal from a centralized control device; controlling a steering assembly based on the received signal to (a) engage a first set of wheels with the track; (b) engage a second set of wheels with the track; or (c) engage the first and second sets of wheels with the track to park the load handling device; and optionally, when the first or second set of wheels is engaged with the track, driving the set of wheels forward or in reverse to maneuver the load handling device to a position on a grid determined by the centralized control device.

[0056] Therefore, the steering assembly can be controlled by a centralized control device and used to engage the group of wheels determined by the centralized control device. Once a (single) group of wheels is engaged, the centralized control device can drive the wheel to operate the load handling unit. Alternatively, the load handling unit can be "parked" by engaging both groups of wheels simultaneously.

[0057] The load processing device may further include a tool for sensing positions on the grid. The load processing device may further include a tool for lifting storage containers. The load processing device may further include a tool for transporting the lifted storage containers to a position on the grid. The load processing device may further include a tool for identifying various types of storage containers. The load processing device may also further include a tool for identifying a specific type of storage container. The load processing device can move autonomously without continued guidance from a centralized control device. The load processing device can be remotely controlled under the control of the storage system. The load processing device may further include a tool for sending signals to a centralized control utility and can move under the control of the centralized control utility. The load processing device may further include a tool for powering the reversing component. The load processing device may further include a drive component. The load processing device may have drive wheels. The load processing device may further include an identification tool.

[0058] A method is provided for altering the engagement of a set of wheels with a track in a load handling device, wherein the load handling device operates on a grid frame (14) structure including the track. The method includes the steps of: applying a force along a first direction F1 to a moving portion of a deflector assembly, causing a linkage or flexible mechanism to move to a stable configuration in the x-direction; or applying a force along a second direction F2 to a moving portion of the deflector assembly, causing the linkage or flexible mechanism to move to a stable configuration in the y-direction; or removing the force applied to the moving portion of the deflector assembly, causing the linkage or flexible mechanism to move to a neutral configuration.

[0059] The method further includes the steps of: receiving a signal from a centralized control device; and controlling the reversing assembly based on the received signal to (a) engage a first set of wheels with a first set of parallel tracks; (b) engage a second set of wheels with a second set of parallel tracks; or (c) engage the first and second sets of wheels with the first and second sets of parallel tracks to park the load handling device.

[0060] When the first or second set of wheels engages with the track, the method further includes the following steps: driving the set of wheels forward or in reverse to manipulate the load handling device to a position on the grid determined by the centralized control device.

[0061] A complete set of modular components for a load handling device is provided. This complete set includes at least one reversing component linkage or flexible mechanism.

[0062] The complete set of components may further include: at least two steering component linkage devices or flexible mechanisms and a conveyor belt; at least one steering motor; and / or a connector for connecting the steering components to the first set of wheels and the second set of wheels.

[0063] At least one component of the kit can be 3D printed.

[0064] The kit may further include at least one of the following: a set of wheels, a drive assembly, a gripper assembly, a lifting assembly, a communication system, and / or a sensing tool.

[0065] A grid-based storage and retrieval system is provided, comprising a grid frame (14) structure, at least one load processing device on the grid frame structure, and a centralized control device for controlling the at least one load processing device. The grid frame (14) structure includes a first set of parallel rails or tracks (22b) and a second set of parallel rails or tracks (22a). The second set of parallel rails or tracks (22a) extends substantially perpendicular to the first set of rails or tracks (22b) in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces. The grid is supported by a set of vertical members (16) to form a plurality of vertical storage locations below the grid, for containers (10) to be stacked between the vertical members and guided vertically through the plurality of grid spaces by the vertical members.

[0066] At least one load processing device may further include a communication tool; and the centralized control device of the storage system includes a communication tool for communicating with the communication tool on at least one load processing device.

[0067] Centralized control equipment remotely monitors the status of at least one load processing device.

[0068] If a fault or malfunction is detected in the load handling unit, it can be instructed to move to the maintenance area or grid edge using fault-free and non-malfunctioning tools.

[0069] The centralized control device can communicate with at least one load processing device running on the grid to instruct the load processing device to move to a specific location on the grid.

[0070] Additionally, the load handling device may be instructed to lift the container from the stack and move it to another location on the grid, and / or further instruct the load handling device to lower the container into the stack position below the grid.

[0071] A load handling device is provided for lifting and moving storage containers (10) stacked in a grid frame (14) structure, the grid frame (14) structure including a first set of parallel rails or tracks (22b) and a second set of parallel rails or tracks (22a), the second set of parallel rails or tracks (22a) extending substantially perpendicular to the first set of rails or tracks (22b) in a substantially horizontal plane to form a grid pattern including a plurality of grid spaces, wherein the grid is supported by a group of vertical members (16) to form a plurality of vertical storage locations below the grid for storage. The load handling device (10) is stacked between vertical members and guided by the vertical members in a vertical direction through a plurality of grid spaces. The load handling device includes: a body mounted on a first set of wheels (116) and a second set of wheels (118), the first set of wheels (116) being configured to engage with a first set of parallel tracks (22b), and the second set of wheels (118) being configured to engage with a second set of parallel tracks (22a). The first and second sets of wheels (116, 118) include wheels with spokes that connect the rim to the hub, and the wheels are at least partially elastically deformable.

[0072] The rim and hub can be made of a material that is rigid relative to the material of the spokes. The spokes of the wheel can be arranged in a mesh. A portion of the spoke mesh of the wheel can be compressed.

[0073] A wheel may include two or more layers, wherein a first type layer having radial spokes may be stacked with at least one second type layer having curved spokes. Thus, the wheel may include a wheel assembly. The curved spokes may include a first set curved in a clockwise direction and a second set curved in a counterclockwise direction. The first type layer may be sandwiched between two second type layers.

[0074] On the positive side, the wheels are designed to be lightweight, provide some shock absorption, offer some suspension for load handling, and reduce tire wear. Another advantage of this setup is the outward-bending plane of the outer layer. This allows the wheels to tolerate, for example, misaligned sections of the track and narrowing of the track width at transition points. The outward-bending plane allows the wheels to be squeezed and briefly narrowed in situations similar to when a poorly deformed wheel might attempt to lift itself off the track and derail.

[0075] Wheels can display combinations of properties, where the properties of each layer contribute to the overall properties of the wheel. Each layer can be designed to optimize specific properties, and the stacking or composite arrangement of wheels reveals all the properties embodied by those layers.

[0076] In this way, the wheel demonstrates its characteristic of advantageously providing specific directional stiffness and strength while still being able to absorb some of the vibrations generated by its movement on the track. Specifically, the spoke mesh design allows torsional stiffness to be kept within a specific range and thus prevents inaccuracies in the movement of the load handling device.

[0077] In this way, the wheels can generate good traction with the track and reduce wheel slippage. This allows for more accurate positional control of the load handling device on the grid, as the drive movement results in more consistent and predictable movement of the load handling device.

[0078] The rim of the second type layer may include a groove for accommodating an O-ring.

[0079] O-rings provide a contact point between the wheel and the rail. Therefore, the second type of layer can have O-rings at the rail-wheel interface. O-rings are typically made of rubber. This provides a certain amount of suspension for the wheel. O-rings are readily available and easily replaceable. It should be understood that any suitable material and arrangement can be used to provide traction between the wheel and the rail. For example, rubber strips can be attached to the wheel rim.

[0080] The wheel rim may include additional grooves for receiving additional O-rings. For example, the wheel may include two, three or more grooves for receiving O-rings.

[0081] The option to provide additional O-rings in the wheel's width or depth increases the contact rubber between the wheel and the track. It should be understood that the wheel may need to be modified in other ways to accommodate the extra space required to accommodate additional O-rings around the rim. For example, a different or improved drive arrangement may be necessary.

[0082] The additional O-rings and the proportionally increased contact area they provide better grip on wheels under heavier loads. In this way, the wheels can be used with load handling devices to carry larger loads. This, in turn, improves the efficiency of storage and retrieval systems, for example.

[0083] The first type layer can be a pulley, and its diameter can be smaller than that of the second type layer, thus creating a channel to accommodate the drive belt. The rim of the first type layer may include teeth for mating with the drive belt.

[0084] In this way, the first type layer can be configured not to contact or connect to the rail, but rather to become part of the drivetrain. Although the first type layer does not contact or connect to the rail and therefore does not support the load handling device, it can provide axle drive for the wheel and support the second type layer. Thus, the first type layer of the assembly can be part of the wheel hub, on which the second type layer is mounted for rail-wheel contact.

[0085] In this way, the first type of layer can be driven by a drive belt. The drive belt meshes with the first type of layer or pulley and can be used to drive the wheels of the second type of layer or load handling device to provide maneuverability. The arrangement of the drive belt in the grooves or channels ensures that the drive belt is maintained in the correct position to mesh with the wheel teeth. The fact that the wheel is driven by a drive belt pulley means that the wheel itself has greater design freedom. The combined characteristics of each layer and the direct drive provided by the pulleys / hubs of the first type of layer can, for example, drive the wheel with higher positional accuracy while resisting step changes in the track. In this way, the wheel can drive the load handling device to a specific location on a grid frame with multiple grid spaces.

[0086] The side of the rim can be at an angle to the plane of the wheel.

[0087] The outermost surface of the wheel can be angled. In this way, the wheel is less likely to derail while moving along the track. If the wheel bounces up due to a bulge in the track, such as at the transition between grid spaces, the angle of the rim or side can guide the wheel back to its original position and into contact with the track.

[0088] The hub may include bearings for rotatably mounting the wheel to the load handling unit body.

[0089] Wheels can be made of plastics, polymer plastics, thermosetting plastics, thermoplastic plastics, metals, aluminum, aluminum alloys, iron, iron alloys, steel, steel alloys, magnesium, magnesium alloys, titanium, titanium alloys, zinc, zinc alloys, fiber-reinforced composites, carbon fibers, graphite fibers, glass fibers, natural fibers, plant fibers, plastic fibers, paper, cardboard, rubber, epoxy resin, or nylon.

[0090] Specifically, the spokes are made of polyurethane or nylon, the hub and rim are made of nylon, and the O-rings are made of rubber.

[0091] Wheels can be obtained through 3D printing. Wheels can be significantly optimized in terms of topology.

[0092] In this way, wheels can be designed with specific characteristics. This allows wheels to be printed at or near the location where the component is needed, avoiding complex supply chains.

[0093] A drive belt assembly for a load handling apparatus is provided, the drive belt assembly comprising: a drive belt; a drive pulley; one or more driven pulleys; and a tensioning tool including a first tensioning arm and a second tensioning arm, the first tensioning tool having a fixed end above an elbow and a rotatable distal end pivotally attached to the elbow, wherein the first tensioning arm is horizontally displaceable relative to the drive pulley and the driven pulleys, the drive belt is routed around the first and second tensioning arms, and the first and second tensioning arms are configured to apply pressure to the drive belt to tension the drive belt.

[0094] A drive belt assembly in which the driven wheel is movable vertically relative to the drive wheel between raised and lowered configurations; and in which the tensioning tool may have configurations corresponding to the raised and lowered configurations of the driven wheel respectively, and the tensioning tool is movable between these configurations.

[0095] A load processing device for operation on a grid-frame storage structure is provided, comprising a first set of parallel rails or tracks (22b) and a second set of parallel rails or tracks (22a), the second set of parallel rails or tracks (22a) extending substantially perpendicular to the first set of parallel rails or tracks (22b) in a generally horizontal plane to form a grid pattern comprising a plurality of grid spaces, wherein the grid is supported by a set of vertical members (16) to form a plurality of vertical storage locations below the grid for containers (10) to be stacked between the vertical members and guided vertically through the plurality of grid spaces by the vertical members, the load processing device comprising a body mounted on a first set of wheels (116) and a second set of wheels, the first set of wheels (116) being configured to engage with the first set of parallel rails (22b) and the second set of wheels being configured to engage with the second set of parallel rails (22a), wherein the first set of wheels (116) and the second set of wheels (118) are driven by corresponding drive belts, wherein the first set of wheels (116) and the second set of wheels (118) are driven wheels.

[0096] The load handling device may include four drive belt assemblies, which are disposed on each side of the load handling device to drive corresponding driven wheels.

[0097] The load handling device may further include a reversing assembly configured to raise or lower a first set of wheels and / or lower or raise a second set of wheels relative to the drive wheels to engage or disengage the wheels from the parallel track, wherein the tensioning tool of the drive belt assembly is configured to pretension the drive belt as the driven wheels move between raised, lowered, and parked configurations.

[0098] In this way, the drive belt assembly can be pre-tensioned by a tensioning tool to ensure engagement between the drive belt, drive pulley, and driven pulley. It should be understood that as the pulley moves between lowered and raised positions, without a tensioning tool, the path length of the drive belt will change and could potentially become slack and slip. The drive belt, and more specifically the tensioning tool, is configured to compensate for changes in the belt path length, thus keeping the drive belt path length approximately constant and ensuring the belt is tensioned as needed to maintain the necessary contact with the drive and driven pulleys for actuation. When the driven pulley is in the raised position, the path length around the tensioning tool increases the drive belt path length as the belt follows the bend in the first tensioning arm to compensate for the reduction in the vertical distance between the traveler mount and the pulley. Advantageously, the tensioning tool substantially prevents the drive belt from becoming slack. Advantageously, the tensioning tool ensures the drive belt is taut when driven, thus preventing belt slippage on the driven pulley. Without pre-tensioning, the drive belt may slip without engaging the driven and drive pulleys, or wear due to poor engagement with the drive pulley.

[0099] It should be understood that the path length of the drive belt may not change linearly as the reversing assembly operates. The change in path length will depend on the geometry of the reversing assembly.

[0100] Pretension refers to the amount of tension applied to the drive belt by a tensioning device before it is driven to ensure that the belt will not slip relative to the pulley. During operation, when the belt is being driven, it is under high tension to transmit the force from the drive pulley to the driven pulley. The speed at which the belt moves is a function of the motor and the load in the system.

[0101] It should be understood that the driving tool can be a chain drive instead of a drive belt. In some arrangements, the drive belt may be toothless.

[0102] A drive belt assembly in which the movement of the driven wheel and the tensioning tool between configurations can be mechanically coordinated.

[0103] The drive belt assembly may further include a reversing assembly configured to raise or lower the driven pulley relative to the drive pulley, wherein the tensioning tool of the drive belt assembly is configured to pretension the drive belt as the driven pulley moves between raised, lowered, and parked configurations.

[0104] Drive belt assembly, wherein the tensioning tool can be mechanically connected to the reversing mechanism.

[0105] The tensioning tool can be set to move with the driven pulley. In this way, provided the system is functioning correctly and the pulley's position determines, the drive belt is always tensioned by the tensioning tool.

[0106] The drive belt assembly, wherein the vertical movement of the driven wheel and the movement of the tensioning tool can be initiated by the same actuator.

[0107] A drive belt assembly in which the tension force that can be applied to the drive belt varies depending on the position of the first tension arm and / or the second tension arm.

[0108] The time required for peak force to change direction in a drive belt assembly may differ from the time required for peak force to be applied during tensioning.

[0109] A reversing motor used to move the driven wheel vertically can also be used to move the tensioning tool. The advantage is that the tensioning tool does not require an additional motor.

[0110] It should be understood that the force required to activate the steering mechanism and the force required to activate the tensioning tool will differ over time. Due to the geometry of the tensioning tool, the time when the tensioning tool requires peak force will be slightly earlier or later than the time when the steering assembly requires peak force. In this way, the additional load applied by the tensioning tool to the actuation motor is controlled to occur outside the instantaneous time when the steering assembly applies a high load to the actuation motor, so the required motor size will not increase due to the tensioning tool.

[0111] It should be understood that the reversing assembly can tension the drive belt due to changes in the vertical distance between the driven and drive pulleys. In some cases, the distance between the pulley seat and the "middle ring" or upper support / moving part may be temporarily longer than when the pulley is in the drive position. It should be understood that the belt needs to be stretched when it is on such a "bump," and a larger motor is required to pass through the "bump." There is a possibility that the belt may break. It should be understood that the tensioning tool can compensate for this simply by tensioning the belt after the "bump." Therefore, this may prevent belt wear and prevent strain on the motor from traveling along the belt path involving complex and interactive reversing and belt tensioning arrangements.

[0112] The drive belt assembly may further include a sensing tool for monitoring belt tension and optionally may further include a tool for adjusting belt tension.

[0113] The drive belt assembly may further include a sensing tool for determining a drive belt failure or malfunction.

[0114] In this way, the condition and tension of the drive belt can be monitored. If the belt is slightly stretched, the path length of the drive belt can be increased by a similar amount by adjusting the belt adjustment tool. This allows for adjustment of the tension and belt path or route in the "stopped" state without the need for replacement or adjustment by removing the belt from the load handling unit. Additionally, this allows for fine-tuning of the belt. Adjustments can be made between drive actions while the load handling unit is running on the storage system grid. Of course, if the belt is significantly stretched, it may need to be replaced when the load handling unit is being maintained in the maintenance area. Furthermore, the sensing tool can also detect when the drive belt or drive system fails. During operation, since the load handling unit typically has a drive belt assembly and tensioning tool on each side, even if one side of the belt fails, the load handling unit can still be fully operated via the driven pulleys of the other sets to return to the edge of the grid or the maintenance area for repair, rather than getting stuck on the grid and needing to shut down at least part of the grid for recovery.

[0115] A load handling device is provided for lifting and moving storage containers (10) stacked in a grid frame (14) structure. The load handling device includes a first set of parallel rails or tracks (22b) and a second set of parallel rails or tracks (22a), the second set of parallel rails or tracks (22a) extending substantially perpendicular to the first set of parallel rails or tracks (22b) in a generally horizontal plane to form a grid pattern comprising a plurality of grid spaces, wherein the grid is supported by a set of vertical members (16) to form a plurality of vertical storage locations below the grid for containers (10) to be stacked between the vertical members and guided vertically through the plurality of grid spaces by the vertical members. The load handling device includes a body and a gripper assembly, the body being mounted on a first set of wheels (116) and a second set of wheels (118), the first set of wheels (116) being configured to engage with the first set of parallel rails (22b) and the second set of wheels (118) being configured to engage with the second set of parallel rails (22a), the gripper assembly being used to latch the storage containers (10), wherein the gripper assembly includes a deformable bending mechanism movable between a locking configuration and a releasing configuration.

[0116] The gripper component can be self-locking.

[0117] The load handling device can grip and lift a storage container. The gripper assembly is stable in at least two configurations and self-locking at least in the locking configuration. The gripper operates below the fatigue limit of the material and can repeatedly move between positions. In this way, the load handling device can firmly and reliably grip the storage container for lifting and moving it.

[0118] A bistabilizing buckling element may include: an actuator; two or more gripping arms having hook ends; and a number of hinge arrangements corresponding to the number of gripping arms, wherein each hinge arrangement is deformable and connects a corresponding gripping arm to the actuator. The hinge arrangement includes a fulcrum and first and second deformable portions connected to each end of the fulcrum. The fulcrum is generally triangular. In the locked configuration, the fulcrum engages with the gripping arms and the flexible mechanism is in an open or wide state; in the released configuration, the first and second portions of the hinge are buckled and the flexible mechanism is in a closed or narrow state.

[0119] The hook end of the gripper arm allows the gripper to lock onto the mating part of the storage container, while the fulcrum means that the gripper cannot move through the stable locked position unless it malfunctions and bends. Therefore, the configuration of the gripper assembly itself ensures that the gripper is reliably fixed to the storage container for lifting and moving the storage container.

[0120] The hinge arrangement may be connected to the gripper arm but spaced apart from the hook end, and the fulcrum may extend above or below the line between the first and second hinge arrangements. The gripper assembly may include two or more bending mechanisms. The gripper assembly may include four bending mechanisms.

[0121] It should be understood that the specific arrangement will depend on the intended use of the gripper assembly, and the intended scope is not limited to the specific embodiments disclosed in this invention.

[0122] The load handling apparatus may further include tools for lifting storage containers, wherein the tools for lifting storage containers include a gripper plate and a gripper assembly mounted on the gripper plate. The tools for lifting storage containers are releasably mounted on the frame or body of the load handling apparatus. A lifting belt may be attached to the gripper arm.

[0123] Bending mechanisms can be obtained through 3D printing.

[0124] A method is provided for using a gripper assembly of a load handling device, wherein when a bent member is inserted into a mating recess of a container, the bent member engages with the container and moves into a locking configuration.

[0125] When the flexible mechanism is in the locked configuration and an actuation force is applied to the gripper assembly, the flexible mechanism can move from the locked configuration to the released configuration.

[0126] A complete set of modular components for a load handling device is provided. This complete set includes at least one gripper assembly flexure.

[0127] Other variations and advantages will become apparent from the following explanation. Attached Figure Description

[0128] This invention will be described in conjunction with the accompanying drawings, wherein:

[0129] Figure 1 It is a three-dimensional schematic diagram of a frame structure used to enclose multiple stacked boxes in a storage system;

[0130] Figure 2 yes Figure 1 A top view of a portion of the frame structure shown;

[0131] Figures 3(a) and 3(b) show the results from the use of... Figure 1 and Figure 2 Figure 3(c) is a perspective view of one form of an automatic load handling device used in conjunction with the frame structure, viewed from the rear and front, while Figure 3(c) is a perspective view of a known load handling device that is lifting a box.

[0132] Figure 4 It includes installations Figure 1 and Figure 2 A three-dimensional schematic diagram of a known memory system with a plurality of load processor devices of the type shown in Figures 3(a), 3(b) and 3(c) on a framework structure;

[0133] Figure 5 This is a schematic diagram of the load processing device;

[0134] Figure 6 ac is a schematic diagram of a flexible mechanism linkage device for engaging the first and second sets of wheels of a load handling device, as part of a reversing assembly according to one embodiment of the present invention.

[0135] Figure 7 AC is a perspective view showing the load handling device, which shows the flexible mechanism and wheels in relation to... Figure 6 Similar positions in the middle;

[0136] Figure 8 The example illustrates a flexible mechanism with various bending hinge arrangements, used as part of a reversing component, in a neutral or docking configuration;

[0137] Figure 9 ab provides examples of flexible mechanisms used in reversing components, in the first and second stable configurations;

[0138] Figure 10 a and Figure 10 b are a plan view and a perspective view of a wheel with spokes used in a load handling device, respectively.

[0139] Figure 11 a and Figure 11 b are the plan view and perspective view of the first type of wheel used in the load handling device, respectively;

[0140] Figure 12 a and Figure 12 b are plan and perspective views of the second type of wheel used in the load handling device, respectively.

[0141] Figure 13 a and Figure 13 b shows a schematic force diagram of a portion of a second type of layer of wheels used in a load handling device;

[0142] Figure 14 The wheel chassis was shown;

[0143] Figure 15 The drive assembly used with the grouped wheels is shown;

[0144] Figure 16 The boosting component was displayed;

[0145] Figure 17 Another arrangement of the lifting components is shown;

[0146] Figure 18a -c is a schematic diagram of the gripper assembly in (a) locked configuration, (b) moving from locked configuration to released configuration, and (c) released configuration;

[0147] Figure 19 ab shows schematic illustrations of the gripper assembly in (a) the locked configuration and (b) the released configuration;

[0148] Figure 20 ab provides examples of load handling devices with and without raised containers;

[0149] Figure 21 It is a plan view of the drive assembly with tensioning tools;

[0150] Figure 22 yes Figure 21 A 3D view of the driving components shown;

[0151] Figure 23 ac is a plan view of the drive components and tensioning tools, in which Figure 23 (a) The middle wheel is in the position where it is connected to the track. Figure 23 (b) The middle wheel is in a neutral position or docked. Figure 23 (c) The middle wheel is raised or disconnected from the track;

[0152] Figure 24 AC is a plan view of the drive assembly and tensioning device, illustrating the relative positions of the tensioning tool and wheel on the load handling device resting on the surface. Figure 24 In (a), the wheel in the y-direction is lowered to a position where it engages with the surface, and the wheel in the x-direction is raised and disconnected from the track. Figure 24 (b) The middle wheel is in a neutral position or at rest, and both the wheels in the x and y directions are engaged with the track, while... Figure 24 (c) The wheel in the x-direction is lowered while the wheel in the y-direction is raised;

[0153] Figure 25 A plan view of the load handling unit is provided, showing the arrangement of the drive motors;

[0154] Figure 26 a and Figure 26 b are a top plan view and a perspective view of a spoked wheel used in a load handling device, respectively. Figure 26c It is a side view of a wheel including a plurality of O-rings that serve as tires;

[0155] Figure 27 a and Figure 27 b shows a schematic force diagram of a portion of a lattice-layer type wheel;

[0156] Figure 28 a shows that it is suitable for matching Figure 26 The diagram shows the in-wheel motor of the types of wheels listed in the example. Figure 28 b shows a side view of the hub motor;

[0157] Figure 29 a and Figure 29 b are respectively related to assembly to Figure 28 The types of hub motors listed Figure 26 Plan and side views of the types of wheels listed;

[0158] Figure 30 This is a plan view of a rigid body linkage device as part of a reversing component according to one embodiment of the present invention.

[0159] Figure 31 ad showed Figure 30 The deconstructed portion of a single two-part linkage link in a rigid body linkage device of the type shown.

[0160] Figure 32 yes Figure 30 A three-dimensional view of the rigid body linkage device shown;

[0161] Figure 33a -c displays Figure 30-32 A rigid body linkage device, wherein the first set of wheels is engaged ( Figure 33c The wheels are in the parking position. Figure 33a ) and the second set of wheels has been engaged ( Figure 33b );

[0162] Figure 34 This is a side view of the wheel seat and linkage mechanism;

[0163] Figure 35 It is an isometric drawing of the wheel seat and the linkage mechanism;

[0164] Figure 36 ab shows a graph of the tension of the drive belt versus the height of the wheel used for the reversing function;

[0165] Figure 37 This is an exploded diagram of the wheel, showing each component;

[0166] Figure 38 A shows a plan view of the assembled wheels. Figure 38 b shows a cross-sectional view of the wheel taken along line XX;

[0167] Figure 39 The spring layers of the wheel are shown, with 39a being a plan view and 39b being a perspective view;

[0168] Figure 40 It is a plan view of the pulley layer of the wheel;

[0169] Figure 41 The wheel contact disc is shown, in which Figure 41 'a' is a floor plan. Figure 41 b is a 3D image. Detailed Implementation

[0170] In this document, the word "include" and its derivatives are used to indicate inclusion, not exclusion. For example, "x includes y" is to include the following possibilities: x includes one and only one y, includes multiple y's, or includes one or more y's and one or more other elements. If exclusion is required, language such as "x consists of y" will be used, meaning that x includes only y and excludes no other elements.

[0171] In this document, “movement along the n-axis” (and related terms), where n is one of x, y, and z, is used to indicate movement approximately along or parallel to the n-axis, regardless of the direction (i.e., towards the positive end or the negative end of the n-axis).

[0172] In this document, the word "connection" and its derivatives are used to encompass the possibilities of direct and indirect connections. For example, "x connects to y" is used to include the possibility that x can be directly connected to y without any intermediary components, as well as the possibility that x can be indirectly connected to y through one or more intermediary components. When a direct connection is required, the terms "directly connected," "directly connected," or similar terms will be used. Similarly, words such as "support," "installation," and their derivatives are also used to encompass the possibilities of direct and indirect connections.

[0173] In this document, terms such as “load handling unit,” “vehicle,” and “robot” are used interchangeably. Similarly, the terms “body,” “frame,” and “skeleton” for a load handling unit, “track” and “railway” for a storage frame, and “box,” “container,” or “tote” for a storage system are used interchangeably. “DT” or “delivery tote” refers to a tote containing completed or partially completed orders. “ST” or “storage tote” refers to a tote containing items or delivery tote currently being stored in a storage and retrieval system.

[0174] As is generally understood, flexible mechanisms convert input forces and displacements into output forces and displacements through the elastic deformation of the mechanism's main body. The deformation and displacement, or movement, of a flexible mechanism are determined by the mechanism's material properties, shape, and geometry. When a flexible mechanism is subjected to a force and deforms, elastic energy is stored within it. When the force is removed, the flexible mechanism typically returns to its original shape or configuration by releasing the stored elastic energy. The stored elastic energy can be stored in the material itself, or it can be stored within the mechanism due to its shape or geometry.

[0175] The choice of materials for flexible mechanisms is important to ensure that they move as intended. For example, rubber materials may cause damage to the mechanism system because their elastic properties can be lost as heat, while rigid materials may be unsuitable because they cannot bend without cracks.

[0176] The manufacturing method can also affect the movement and properties of flexible mechanisms. For example, 3D printing technology can be used to create complex shapes and geometric properties.

[0177] Typically, when no force is applied to a flexible mechanism and there is no stored elastic energy, a flexible mechanism is described as being in a "docked" or neutral position.

[0178] Flexible mechanisms often include rigid interlocking links connected by rotational (i.e. bending) joints.

[0179] In some forms, flexible mechanisms can be “distributed.” Distributed flexible mechanisms can be designed by selectively removing material from the allowable build volume and combining this with modeling methods, such as the finite element method, which determines how a given volume deforms under load. The mapping between input load and output deflection and load resulting from each removal of material from the allowable build volume is predictable, allowing for the evaluation of the suitability of a given shape for the current task. Many shapes can be iteratively tested using topology optimization algorithms. The resulting shapes have the added advantage of typically lacking prominent buckling hinges but distributing deformation throughout the shape, which reduces surface stress in the material under load and mitigates fatigue in that section.

[0180] Alternatively, several components can work together to form a flexible mechanism.

[0181] Various flexible mechanisms can be used as part of the load handling device described in this invention.

[0182] The flexible mechanism topology can highly mimic rigid body interlocking links, including bending pivots. Accordingly, rigid body interlocking links can replace one or more flexible mechanisms described in this invention.

[0183] An advantage is that flexible mechanisms can be used to provide a "default" position that the mechanism returns to without external input. This default position can be designed as a "safe" position. Advantageously, this can be designed as a safety feature. For example, when a system or part of a system malfunctions, devices operating within that system can return to their default-safe position until control and operation are restored. This could, for example, be placing a load handling device in a "parking" configuration, rendering it immobile until the problem is resolved.

[0184] The other uses and advantages of flexible mechanisms will become apparent from the following description.

[0185] As is generally understood, topology is related to the geometric dimensions and shape properties of an object.

[0186] The object can be designed to meet the mechanical requirements of the load and ensure that each part of the component or mechanism can move freely as needed.

[0187] Artificial intelligence (AI) computing techniques (or, in some cases, machine learning (ML)) can be used to meet structural and mechanical requirements and dynamic loads using specific materials, while simultaneously achieving specific secondary objectives, such as reducing overall weight, staying within stress limits, or providing specific material thermodynamic properties. Therefore, after designing a specific function, AI can be used to "topology optimize" components to create shapes that would not be commonly designed otherwise. For example, instructions can be given to the AI ​​such as, "Never bend joint 1 beyond X when implementing function Z, and never exceed stress Y."

[0188] Various components of the load handling device are suitable for topology optimization. Exemplary components include, but are not limited to, corner brackets, components of the phase-shifting assembly, wheels, and the main body.

[0189] The other uses and advantages of topology optimization will become apparent from the following explanation.

[0190] The load processing apparatus and related methods disclosed in this invention are designed to operate on the storage and retrieval system described above, in conjunction with existing technologies. The storage and retrieval system can be modified to accommodate the load processing apparatus described in this invention. Furthermore, the load processing apparatus operating on the grid of the storage and retrieval system is intended to operate together with or simultaneously with other devices operating on the grid. The devices operating on the grid can all be of the same type, or two or more devices can operate on the grid simultaneously.

[0191] The load handling device described in this invention is designed for lightweight construction and relatively inexpensive manufacturing. Furthermore, as will be understood from the following description, the load handling device is largely modular, simple to maintain, and / or inexpensive because components can be easily assembled and replaced. Where possible, components are made of recyclable or environmentally friendly materials.

[0192] The load handling device 100 includes a skeleton 102, a body or frame that supports, carries, or encloses other components of the load handling device, such as batteries and related electronics, controllers and communication devices, motors for driving wheels, motors for driving lifting components, and other sensors and systems. The skeleton 102 includes recesses sized to accommodate containers or boxes when lifted by the lifting components. The skeleton structure of the load handling device helps ensure easy access to components.

[0193] As noted above, regarding the other load handling devices, each load handling device is configured to travel in the x and y directions above the container or box stack 12 and on the track 22 of the frame 14.

[0194] See Figure 5-7Each load processing unit is equipped with two sets of wheels 116, 118, which run on tracks at the top of the frame of a storage system of the type described above. At least one wheel in each set of wheels 116, 118 is driven to move the carrier 102 along the tracks in the x and y directions, respectively. The wheels 116, 118 are arranged around the outer periphery of the load processing unit frame. One set of wheels 116 can move vertically to lift that set of wheels 116 away from its corresponding track, while the wheels of the other sets remain in contact with the track, thereby allowing the load processing unit to change direction, as will be described below. In some cases, both sets of wheels 116, 118 can simultaneously be in contact with their respective tracks.

[0195] The component that causes the wheels or each set of wheels to be displaced relative to each other and the frame 102 of the load handling device along the vertical or z-direction is located within the main body or frame 102 of the load handling device.

[0196] like Figure 5-7 As shown, the first and second sets of wheels 116 and 118 can be raised off the track or lowered onto the track via a reversing assembly. The reversing assembly includes a flexible mechanism 110 or a linkage device located on the opposite side of the load handling device frame 102.

[0197] Each directional flexible mechanism 110 can deform along the first and second directions. Figure 6 Examples include three positions of the flexible mechanism 110 relative to the vehicle frame 102, the positions of the wheels 116 and 118 below it relative to the vehicle frame 102, and the tracks in each position. Figure 7 This is a perspective view of the load processing device, showing its location relative to... Figure 6 The flexible mechanism 110 and the wheel are located in similar positions as shown.

[0198] When no force is input, the flexible mechanism 110 is in a "parked" or neutral position, meaning that the flexible mechanism 110 does not undergo elastic deformation, and the two sets of wheels 116 and 118 are flush and rest on the surface. In this arrangement, the load handling device cannot move in the x or y direction, and the load handling device is in a parked state, such as... Figure 6 As shown in 7a and 7a, the elastic deformation of the flexible mechanism 110 is related to the arm that holds each wheel and can move in the vertical (or z) direction to raise or lower the wheel.

[0199] When the first input force F1 is applied, the main body of the flexible mechanism 110 deforms along a first direction. The displacement of the main body of the mechanism is converted into vertical movement to lower the first set of wheels 116 and raise the second set of wheels 118. The wheels of the first set of wheels 116 move downwards to engage with the track and support the vehicle, while the wheels of the second set of wheels 118 move upwards to leave the track, as... Figure 6 As shown in c and 7c. In this way, vehicle 100 can be driven in the x-direction.

[0200] When the second input force F2 is provided in the opposite direction to the first input force, the main body of the flexible mechanism 110 deforms in the second direction. The displacement of the main body of the mechanism is converted into vertical movement to raise the first set of wheels 116 and lower the second set of wheels 118, thereby allowing the load handling device to be supported by the second set of wheels 118 and driven along the y-direction, as... Figure 6 As shown in b and 7b.

[0201] The flexible mechanism 110 is connected to the first and second sets of wheels 116 and 118 via a transmission interlock. Therefore, in this way, the flexible mechanism 110 provides a means for changing the direction of travel of the load handling device 100.

[0202] It should be understood that Figure 6 The flexible mechanism 110 exemplified by ac includes a series of columns or trunk sections attached to a track or support. The columns or trunk sections 111 are attached to the track or support 112 by relatively narrow portions that preferentially bend when a horizontal force is applied to the track or support. Thus, the narrow portions can be considered as hinges 113.

[0203] Consider in more detail the shape of the flexible mechanism 110 used for direction change and combine it with Figure 8 As an example, the flexible mechanism 110 includes a number of columns or trunk sections 111 attached to the upper and lower supports 112a, b via a series of upper and lower hinges. Figure 8 Example a is a flexible mechanism 110 in which each main trunk is attached with a branched bending hinge 120. Figure 8 Example b illustrates a flexible mechanism 110 in which each main stem is attached with a zig-zag spring-type bend hinge 121. The main stem 111 of the zig-zag spring hinge additionally has a tether 123 to properly hold the main stem 111 between the upper and lower supports 112.

[0204] like Figure 9 As shown, the bending hinge can be of two types: branched and spring-type. In the branched type, the main trunk 111 is attached to the support 112 at each end by thin flexible branches 120, which extend from points on opposite sides of the main trunk 111 and spaced a short distance from each end of the main trunk 111 to the support 112. In the spring-type, the main trunk 111 is attached to the support 112 at each end by thin bending springs 121, which extend from the end of the main trunk 111 to the support 112. Some material has been removed from each main trunk 111 to create the truss structure and reduce the overall weight of the flexible mechanism 110.

[0205] It should be understood that the embodiments provided by this invention are merely some ways to achieve the desired characteristics of the flexible mechanism 110. Other arrangements are foreseeable and can be determined using machine learning or AI techniques to meet the requirements. Furthermore, machine learning can be used to optimize the designed topology, thereby reducing the weight of the directional flexible mechanism 110.

[0206] When the flexible mechanism 110 is mounted to or supported by the load handling device frame 102, it should be understood that the lower support 112b remains in a fixed position between a pair of wheels 116 or 118. Simultaneously, when a force is applied to the upper support 112a, the elastic deformation of the flexible mechanism causes the upper support 112a to undergo horizontal displacement relative to the lower support 112b. Accordingly, the upper support 112a may be described or referred to as the moving part 112a.

[0207] In the following paragraphs, references to the reversing assembly, the x-direction, and the y-direction relate to whether the first set of wheels 116 and the second set of wheels 118 engage with the track to allow travel in either the x or y direction. It should be understood that the x and y directions relative to the load handling device 100 depend on which surface is being referred to. The direction in which force F1 or F2 is applied, or the direction in which the resulting elastic deformation occurs, is either positive or negative within the same direction.

[0208] When the flexible mechanism 110 is along the first or x direction ( Figure 9 a) During deformation, the spring-type bending hinge 121 is compressed, and the end of the main stem 111 engages with the upper and lower supports 112 via the compression spring 121, while the branch-type bending hinges 120 are positioned to extend relative to their respective main stems 111. In this way, the load between the upper and lower supports 112 is supported by the spring-type main stem 111. The engagement of the main stem portion 111 with the upper and lower supports 112 means that the maximum displacement of the upper support (moving part) 112a relative to the fixed lower support 112b in the first or x-direction is limited.

[0209] When the flexible mechanism 110 is along the second or y direction ( Figure 9 (b) During deformation, the branched bending hinge 120 bends and becomes relatively parallel to the main trunk 111. The end of the main trunk 111 with the branched bending hinge 120 engages with the upper and lower supports 112, while the spring-type bending hinge 120 stretches and bends relative to the main trunk. In this way, the load between the upper and lower supports 112 is supported by the branched main trunk 111. The engagement of the main trunk 111 with the upper and lower supports 112 means that the maximum displacement of the upper support (moving part) 112a relative to the fixed lower support 112b in the second or y direction is limited.

[0210] The position of the upper support or moving part 112a relative to the lower support 112b on the load handling device 100 can be seen in [reference]. Figure 7 .

[0211] because Figure 9 The geometric characteristics of the flexible mechanism 110 shown indicate that the flexible mechanism 110 is stable or stopped in the x and y driving directions at the allowable displacement limits. The flexible mechanism 110 is also stable when no deformation force is applied and when the flexible mechanism 110 is in a stopped or neutral configuration and has approximately no stored elastic energy. In addition, in the stable x and y driving directions, a vertical load can be supported by the main body or column 111 of the flexible mechanism.

[0212] It should be understood that the flexible mechanism can be replaced by a fixed-pin pivot point rigid-body interlocking mechanism having a main or column member for supporting the load and having the same action as the flexible mechanism described above. Accordingly, the flexible mechanism of the above type can be considered a type of linkage device. Advantageously, the vertical load is not transported through the connecting joint of the pivot point, but rather the load is borne by the connecting member.

[0213] It should be understood that a reversing mechanism may include a combination of one or more types of flexible mechanisms and / or a fixed pin pivot point connection mechanism. Figure 30 -33 shows an embodiment of a rigid body linkage device 300 as a reversing component, which has a functional action similar to that of the flexible mechanism 110 described above, for engaging the first and second sets of wheels of the load handling device.

[0214] The linkage device 300 includes a series of pivotally linked two-part linkage links, such as Figure 30 and 32 As shown. For a single two-part linkage, the primary linkage component (main part) 311 is pivotally attached at one end to the movable part or upper support 312a at the knee joint 316, while the opposite end is hinged at the ankle joint 314 to the secondary linkage component (branch part) 313. The opposite end of the secondary linkage 313 is pivotally attached at the toe hinge 315 to the fixed or lower support 312b. Therefore, each single two-part linkage extends between the movable part 312a and the fixed support 312b. To manufacture the linkage device 300, a series of similar two-part linkages are arranged in parallel between the movable part support 312a and the fixed support 312b to form the linkage device 300, as shown below. Figure 30 and 32 As shown.

[0215] The rotation or angular movement of the knee joint 316, ankle joint 314, and toe joint 315 will be restricted as described below. At the knee joint 314, the primary linkage 311 has a single steering knuckle inserted between two steering knuckles of the secondary linkage 313. Figure 31 The diagram shows a breakdown of a single two-part linkage, in which... Figure 31a and 31b show the main linkage 311, while Figure 31 c and 31d show the secondary linkage 313.

[0216] like Figure 31 As shown in c, the secondary linkage 313 has steps 318 and 321 in the zx plane surface between the knee link 314 and the toe hinge 315. The steps 318 and 321 have inflection points located between the first part 318 and the second part 321. When the primary linkage 311 is attached to the secondary linkage 313 at the pivot 314, the steering knuckle surface 317 of the primary linkage 311 is in contact with the step surfaces 318 and 321 and is rotatable between the first part 318 and the second part 321 of the step surfaces.

[0217] Similarly, when the lower surface of the primary linkage 319 is in contact with the upper surface of the secondary linkage 320, the movement of the two linkages is restricted.

[0218] Now we will combine Figure 33a -c describes the movement of the two-part linkage device 300 when it is set between the moving part 312a and the fixed bracket 312b.

[0219] Figure 33a The linkage is shown in a neutral or parked position, where the first set of wheels 116 and the second set of wheels 118 engage with the track (as shown in the thumbnail), and the load handling device 100 cannot move in the x or y direction. In this position, no force F is applied to the moving part 312a, and the lower surface 319 of the main linkage 311 rests on the upper surface 320 of the secondary linkage 313.

[0220] exist Figure 33b In the diagram, a positive force F has been applied to the moving part 312a (i.e., from left to right). The application of the positive force F causes the main linkage 311 to rotate clockwise around the knee joint 316 and counterclockwise around the ankle joint 314. Rotation around the ankle joint 314 is limited by the surface 317, which is in contact with the surface 318. By moving the moving part 312a further to the right, the secondary linkage 313 is lifted away from the fixed support 312b by rotating clockwise around the toe hinge 315. Thus, the moving part 312a undergoes a positive horizontal displacement relative to the fixed support 312b. Through this positive displacement of the moving part 312a, the first set of wheels 116 is raised and the second set of wheels 118 is lowered to engage the track (as shown in the thumbnail), enabling the load handling device 100 to travel in the y-direction.

[0221] exist Figure 33cIn the diagram, a reverse force F (i.e., from right to left) has been applied to the moving part 312a. The application of the reverse force F causes the main linkage 311 to rotate counterclockwise around the knee joint 316 and clockwise around the ankle joint 314. Rotation around the ankle joint 314 is restricted by the surface 317 in contact with the surface 321, while the heels of both linkage parts are pushed into the fixed bracket 312b. Thus, the moving part 312a undergoes a horizontal displacement in the opposite direction relative to the fixed bracket 312b. Through this reverse displacement of the moving part 312a, the first set of wheels 116 is lowered to engage the track, while the second set of wheels 118 is raised (as shown in the thumbnail), enabling the load handling device 100 to travel in the x-direction.

[0222] It should be understood that between the x-direction travel position and the y-direction travel position, the linkage device moves through a neutral or stationary position.

[0223] The output of the flexible mechanism or linkage device 110, 300 is described below. Figure 34 and 35 The chassis 330, as further discussed, transmits the movement of the flexible mechanism to the wheels 116 and 118, and the chassis 330 converts the horizontal movement of the flexible mechanism into the vertical movement of the wheels.

[0224] In some arrangements, the upper support or movable part 112a may be attached to a rod arrangement that extends along the surface of the load handling device 100 between its various horizontal edges via sliding bearings. Conversely, the rod arrangement may be attached to the first and second ends of a corner piece that pivots about its respective edge. The corner piece may extend about a bend to a second surface perpendicular to the first surface, such that the linkage extends about the entire load handling device 100. In use, pivoting of the corner piece transmits vertical or z-direction movement to the wheel seat. Clockwise pivoting moves the wheel seat upward on the surface to raise the wheel and lowers another pair of wheels onto a surface perpendicular to the first surface, and vice versa.

[0225] The linkage between flexible mechanisms 110, 300 and the corner component can be considered a distributed flexible mechanism and is suitable for AI design. Furthermore, the corner component is an example of a device suitable for topology optimization.

[0226] like Figure 5 and Figure 7As shown, a first pair of flexible mechanisms 110, 300 are placed on opposite faces within the frame 102 of the load handling device to control the position of the first set of wheels 116, and a second pair of flexible mechanisms 110 are placed on orthogonally opposite faces within the frame 102 of the load handling device to control the position of the second set of wheels 118. Thus, each face of the load handling device includes a flexible mechanism 110. The pairs of flexible mechanisms 110, 300 are coupled by a conveyor belt 108 that generally surrounds the frame 102 of the load handling device and is mechanically coupled to the upper supports or moving parts 112a, 312a of the flexible mechanisms 110, 300. This ensures that the sets of wheels 116, 118 can be moved uniformly, for example by a bend, so that the sets of wheels in the x and / or y directions engage with the tracks of the storage system grid. In this way, the reversing assembly can be operated by a single motor. In some embodiments of the load handling device, the reversing motor may be located in or near a vertical bend to avoid occupying space within the frame and to improve accessibility. In some embodiments of the reversing assembly, the conveyor belt 108 may pass over one or more idle pulleys used to monitor the rotational rate as it moves between engagement positions in the x and y directions to detect failure of the belt 108 in real time. If the belt 108 or another part of the reversing assembly is about to fail, this information can be fed back to a centralized control device for processing to prevent robot collisions.

[0227] The linkage components may be supported by, for example, carbon fiber rods. The conveyor belt 108 may be, for example, a serrated polyurethane belt reinforced with glass fiber, steel fiber, or carbon fiber.

[0228] Figure 34 and 35 The arrangement of the reversing linkage 300 is shown in more detail, showing how it is attached to the wheels 116 and 118 and disposed on each side of the load handling device 100. Figure 34 A side view of the wheel seat or wheel chassis and linkage 330 is shown, while Figure 35 The image shows isometric views of the wheel chassis and linkage 330 on each side of the load handling device. It should be understood that... Figure 34 and 35 Compare Figure 14 The wheel chassis and linkage or wheel seat 330 are shown in more detail.

[0229] The linkage device 300 is mounted on each side of the load handling device and connected to the wheels 116, 118 of the load handling device 100 via a wheel chassis 330. As described above, the upper support or moving part 312a of the reversing linkage device is fixed vertically (in the z-direction), while the lower support 312b is capable of vertical movement in response to the horizontal movement of the upper support 312a. The lower support 312b is fixed to the wheel chassis 330, thus enabling the reversing linkage device 300 to raise and lower the corresponding wheels 116, 118. The vertical movement of the chassis 330 is guided by the frame member 331 located at the bend of the load handling device.

[0230] It should be understood that the linkage device 300 is relative to Figure 30 The diagram for -33 can be reversed or mirrored. For example... Figure 35 As shown, the linkage device 300 for the x-direction wheel 116 is a mirror image of the linkage device 300 for the y-direction wheel 118.

[0231] In this way, when wheels 116 and 118 are driven, the linkage device 300 will be in a state of... Figure 33c The position shown is such that the main linkage 311 is generally vertical. Advantageously, in this position, the weight borne by the linkage 300 and the load handling device is oriented through the linkage components 311, 313 rather than through the pivots 314, 315, 316.

[0232] As will be explained below, the distance between wheels 116, 118 and the main body 102 of the load handling device changes as the linkage 300 moves between the above-wheel position, the parked position, and the below-wheel position. Changes in wheel height can apply additional tension to the drive belt 271, or can cause the drive belt 271 to become slack (the drive belt arrangement will be detailed below). The geometry of the two-part linkage can be selected to better limit or avoid additional tension applied to the drive belt 271.

[0233] Figure 36 a and 36b compare the links in the drive belt that are connected by a single component. Figure 36 a) A change of direction and a two-part connecting link having geometric properties similar to those described above. Figure 36 b) The resulting tension. In the graph, the force on the drive belt is shown on the x-axis, while the wheel height is shown on the y-axis. In both graphs, curves in the x and y directions are plotted using a single-component linkage. At + / - 1, one set of wheels 116 or 118 is raised, while another set of wheels 118 or 116 engages with the track.

[0234] exist Figure 36In diagram a, when the curves intersect, both sets of wheels engage with the track on the zero line, i.e., at their parking position. As shown in the diagram, the curve descends below the zero line along a sinusoidal path. The difference between the zero line and the minimum value represents the maximum additional force applied to the drive belt during the change of direction. The value of the maximum additional force depends on the length of the individual component linkage or flexible mechanism. Figure 36 As shown in b, by employing a two-part linkage, the curve follows a complex compound path. This path depends on the relative length between the first linkage member 311 and the second linkage member 313, as well as the rotational limits at pivot points 314 and 315. The path follows the first path 1 as it rotates around the first pivot point, and upon reaching the rotational limit, the path bends and follows the second path 2 according to the rotation around the second pivot point. In the parking position, the wheel is slightly raised. The path then continues to rejoin the sinusoidal path and follow the movement of the single member. This compound path can be configured to prevent falling below the baseline during a change of direction, thereby preventing additional tension on the drive belt.

[0235] It should be understood that additional motors may be used for each reversing flexible mechanism 110, 300, or group of reversing flexible mechanisms. Such an arrangement can provide redundancy for the reversing components, provide additional torque for operating the reversing components, or eliminate the need for a conveyor belt 108 that completely surrounds the load handling device frame 102.

[0236] It should be understood that when using more than one motor, they can be operated independently. However, for efficient direction changing, these motors are coordinated to operate synchronously to raise and lower each set of wheels simultaneously.

[0237] It should be understood that variations in the arrangement of the reversing components can result in similar characteristics and are within the scope of the invention.

[0238] The flexible mechanisms 110 and 300 can be operated by providing input forces F1 and F2 in the first and second directions respectively through a motor, solenoid, worm gear, lead screw mechanism or any suitable tool fitted inside the device frame 102.

[0239] As noted above, each load processing unit is equipped with two sets of wheels 116, 118, which run on tracks provided at the top of the frame of the storage system of the type described above. The first set of wheels 116 or the second set of wheels 118 is driven to move the carrier 102 along the tracks in the x and y directions, respectively. The wheels 116, 118 are positioned around the outer periphery of the frame 102 of the load processing unit.

[0240] Figure 10-13 Examples include wheel 150 in the first and second sets of wheels 116, 118 used in the load handling apparatus described in this invention.

[0241] Wheel 150 has a sandwich structure, with each layer giving the wheel different optimized characteristics. Between the hub and the rim, the spokes are arranged in a mesh 155.

[0242] Intermediate layer, inner layer, or first type layer 151 ( Figure 11 The wheel has a number of radial spokes 156 that connect the hub to the rim. The middle layer spokes are designed to optimize compressive strength. The rim has a plurality of gear teeth 157 for engaging with the drive belt. The first type layer 151 can be made of a rigid load-bearing material (such as epoxy resin). Thus, the first type layer 151 is part of the drivetrain.

[0243] Outer layer or second type layer 152 ( Figure 12 The gear teeth 157 of the intermediate layer 151 are assembled to each face of the intermediate layer 151 and have a diameter slightly larger than that of the intermediate layer 151 to create a channel 153 therebetween, with the gear teeth 157 of the intermediate layer 151 located at the bottom of the channel 153. In this way, when the drive belt is received in the channel 153, it will remain in place to engage with the gear teeth of the intermediate layer 151.

[0244] The spokes of the outer layer 152 are bent and configured to form mesh 158. A first set of spokes 159a is bent clockwise, while a second set of spokes 159b is bent counterclockwise, overlapping the first set. These two sets of spokes are joined or fused at their intersection. The inner spoke arrangement is designed to optimize torsional stiffness. The outer spoke arrangement is designed to maximize torsional stiffness while allowing radial deflection. In some embodiments, the inner and outer spoke arrangements may be of the same shape. Generally, the inner layer is made of a material with better stiffness than the outer layer, and radial deflection is reduced through a thick shell or rim.

[0245] Figure 13 Showing Figure 12 A portion of the spokes 159 of the outer layer 152 of the type shown. Additionally, Figure 13 The direction of the force applied to the wheel during use is indicated. Figure 13 In diagram a, for simplicity, a single clockwise curved spoke 159a and a single counterclockwise curved spoke 159b are shown extending from the hub 160 to the rim 161. When rotational force is applied to the wheel as indicated by the arrows around the circumference of the wheel, the force is transmitted along the spokes 159 in the indicated direction. Figure 13 In b, for simplicity, the radial portion of the spoke mesh 158 is shown as comprising segments 162 located between nodes of a plurality of clockwise-curved spokes 159a and a corresponding number of counterclockwise-curved spokes 159b. When compressive force is applied to the second type layer 152 as indicated by the downward arrow at the bottom of the wheel, the opposite rotational force is transmitted at each node of the mesh segment.

[0246] The rim 161 of the outer layer 152 is deeper than the rim of the middle or inner layer 151. The outer surface of the rim is angled relative to the plane of the wheel, with each side forming half of a "V," providing a smoother surface. This helps ensure that the wheel remains within the track or rail of the storage system grid and runs smoothly between the grid spaces. The outer layer 152 may be made of nylon material, allowing it to bend and, due to its low coefficient of friction, the rim to slide or roll smoothly along the track or rail. The flexibility of the outer layer 152 provides a degree of shock absorption and suspension for the wheel 150. The spoke mesh 158 can be considered a flexible mechanism. Thus, the outer layer can be referred to as a spring-loaded section.

[0247] A groove 163 is provided on the circumferential edge of the outer layer to accommodate an O-ring 164. The O-ring 164 may be made of a relatively flexible material (such as rubber) to provide traction or grip between the wheel 150 and the track, and to absorb impacts on the track between grid spaces. The O-ring 164 can be thought of as the tire of the wheel 150. The flexibility of the outer layer 152 reduces wear on the O-ring.

[0248] In addition to different geometric properties, the middle and outer layers can be endowed with different characteristics by using different materials. For example, curved spokes can be made of a material that is more flexible than radial spokes, thus giving the wheel some suspension in addition to any suspension provided by the O-rings. Furthermore, the rim and hub can be made of a more rigid material to provide support for maintaining the shape of the wheel.

[0249] The hub 160 is assembled through each layer of the wheel and has a bearing at the center for rotating the wheel 150 to the load handling device frame 102. This allows the wheel 150 to be easily replaced if it wears or is damaged during use.

[0250] A pair of wheels 150 can be used as Figure 14 The wheels are coupled to the frame 102 via a wheel chassis 165. The chassis 165 extends between the first and second wheels 150 and includes first and second axle seats 166, which help maintain the relative position between the first and second wheels 150. In this way, the entire chassis arrangement 165 moves along the vertical z-direction as the steering assembly is operated. Alternatively, the first and second wheels 150 may be movable relative to the chassis arrangement 165, for example, along a slot in the chassis, such that the chassis is fixed relative to the frame body 102 of the load handling device.

[0251] The sets of wheels 116, 118 further include part of a drive assembly for the load handling device, enabling the load handling device to move on the grid. Each set of wheels 116, 118 is provided with a drive belt assembly 170.

[0252] Drive belt assembly 170 includes, for example Figure 15The drive belt 171 shown is arranged with pulleys and gears for engaging the serrated edges of a pair of wheels 116, 118 on one side of the load handling device 100. The serrated drive belt 171 engages with both wheels 150. The drive belt 171 is guided by slave wheels 172 mounted on the load handling device frame 102 and two tensioning wheel arrangements 173. The tensioning wheel arrangements 173 are movably mounted to the load handling device frame 102 by springs (not shown) and are used to keep the drive belt 171 under tension and maintain engagement between the drive belt 171 and the wheels 150. A drive wheel 174 is provided mounted to the load handling device frame 102.

[0253] Drive wheels are driven by (in) Figure 15 (Not shown) The motor shaft is connected to pulleys and gears arranged in a 175-axis drive.

[0254] The load handling device 100 provides a drive assembly 170 for each pair of wheels 150. Pairs of wheels on opposite sides include sets of wheels 116 and 118. Drive wheels 174 on opposite sides of the load handling device share the same motor shaft, such that each pair of wheels 150 is driven at the same speed at the same time. Therefore, only one motor is needed to drive the load handling device 100 forward and backward in the first x-direction, and only one motor is needed to drive the load handling device 100 forward and backward in the second y-direction. This arrangement better reduces the space requirements of the load handling device and reduces the number of required components. The first set of wheels 116 and the second set of wheels 118 can be selectively driven under the control of the load handling device.

[0255] exist Figure 15 In this arrangement, it should be understood that when the group of pulleys 116 and 118 are moved out of their original positions to engage with the grid track, the drive belt may become slack because the distance between the upper part of the drive belt assembly 170 and the pulley changes as the pulley is lowered and raised. Accordingly, depending on the selected reversing assembly, an additional tensioning mechanism may be required. For example, a freewheeling pulley on the mechanical linkage connected to the reversing assembly can be used to keep the nominal drive belt length constant throughout the movement of the reversing mechanism.

[0256] Figure 21-24 Another different drive belt assembly 270 is illustrated. Similar to drive belt assembly 170, drive belt assembly 270 is provided for the surface of each set of wheels 116, 118 or load handling unit 100. The upper portion of drive belt assembly 270 is mounted to the upper portion of load handling unit frame 102. The lower portion of drive belt assembly 270 extends around the wheels 116 or 118 mounted on the lower portion of chassis 165 or load handling unit frame 102.

[0257] and Figure 15Similarly, in the illustrated arrangement, the drive belt assembly 270 includes a drive belt 271 pulley gear arrangement for engaging the serrated edges of a pair of pulleys 116, 118 on one side of the load handling device 100. The serrated drive belt 271 engages with both pulleys 116 or 118, typically the tire type 150 described above. The drive belt 271 is guided by pulleys 272 mounted on the upper part of the load handling device frame 102. The drive belt assembly 270 further includes a tensioning tool. This tensioning tool may also be referred to as a pretensioning tool.

[0258] It should be understood that when the reversing mechanism 110 raises pulleys 116 or 118, the belt path length shortens. This is because the vertical distance between the upper part of the device frame and pulleys 116 or 118, with the reversing mechanism 110 installed, is reduced due to the vertical movement of pulleys 116 or 118 between their below-pulley and above-pulley positions. If the drive belt is not otherwise tensioned or pre-tensioned, it will become slack and may lose contact with drive pulleys 175, 275 and driven pulleys 116 or 118. Such loss of contact would disable the drive belt assemblies 170, 270 of the load handling device. Additionally, the slack drive belts 171, 271 may become entangled in devices running on adjacent tracks.

[0259] The upper part of the tensioning tool is mounted on the upper part of the device frame 102, which is also equipped with the reversing mechanism 110, and is coupled to the reversing mechanism 110.

[0260] The first arm 273 of the tensioning tool extends from one end of the reversing mechanism 110, has a bend at the midpoint, and a guide wheel at the distal end. The first arm 273 is rotatable about a pivot point at the midpoint bend between various positions. The second arm 274 is rotatably mounted to the device frame 102 at a pivot point next to the reversing mechanism 110 at the opposite end of the first arm 273. The second arm 274 has a guide wheel at its distal end.

[0261] Other components of the tensioning tool are mounted on the lower part of the chassis 165 or frame 102. A fixedly mounted pulley 276 guides the drive belt 271 from the wheel 116 and around the pulley 277. The pulley 277 can be moved in the direction indicated by the arrow to adjust and / or determine the path length of the drive belt 271. It should be understood that additional pulleys 276 may be used.

[0262] A fixed belt length is typically used, and the belt path length is adjusted via additional pulleys to fine-tune the path length to roughly match the fixed belt length. It should be understood that the belt can be stretched under tension, and this is an element of the geometric design of the drive belt assembly.

[0263] As shown in the 3D view of the tensioning tool Figure 22As shown, the drive belt wiring passes through the first and second tensioning arms 273 and 274. The rotating portions of the first arm 273 and the second arm 274 are as follows... Figure 23 As shown in position c, the arms are biased towards the wheel. Arms 273 and 274 can be biased by any suitable tool, such as a simple spring arrangement. In the neutral or parked position, the steering mechanism 110 is positioned approximately at the center of its range of motion. In the neutral position, arm 273 is slightly angled to the shaft fixed to the end of the steering mechanism. The second arm 274 is in a parked position, slightly angled downwards from the upper part of the frame body 102. The drive belt 271 is configured to move through the guide wheel at the distal end of the first arm 273 and is subjected to reduced directional force from that guide wheel, and the drive belt 271 is configured to move through the guide wheel at the distal end of the second arm 274 and is subjected to reduced directional force from that guide wheel. In the neutral position, the drive belt 271 engages with the drive wheel 274 and the driven wheel 116, but is neither relatively taut nor relatively slack; that is, the drive belt 271 is not pre-tensioned.

[0264] For example, regarding the Y-axis steering wheel 118 Figure 23 a, 24a and regarding the x-axis wheel 116 Figure 24 As shown in Figure c, when wheels 116 and 118 are in the lowered or under-wheel position to engage with the surface or track under the control of the steering mechanism 110, the steering mechanism 110 is laterally moved to be positioned closer to the second arm 274. In this position, the distal end of the first arm 273 is rotated at the bend about the pivot point in the opposite direction to the neutral position. The drive belt 271 is configured to move through a guide wheel at the distal end of the first arm 273, and this guide wheel is pulled toward the drive belt 271 to apply force to the drive belt. The drive belt 271 is configured to move through a guide wheel at the distal end of the second arm 274 and is subjected to a reduced directional force from this guide wheel. As a result, in the engaged or under-wheel position, the tensioning tool applies some tension force to the drive belt 271 through the first arm 273, thereby relatively tightening or pre-tensioning the drive belt 271. On the positive side, the tensioning tool helps ensure that the drive belt 271 remains engaged with the drive wheel 275 and the driven wheel 116 or 118 when the wheel 116 or 118 is in the underside position to engage the surface or track.

[0265] For example, regarding the Y-axis steering wheel 118 Figure 23 c, 24c and about the x-axis wheel 116 Figure 24As shown in diagram a, when wheels 116 and 118 are in the raised position, thus disengaging them from the surface or track, the reversing mechanism 110 is laterally moved to be positioned away from the second arm 274. In this position, the distal end of the first arm 273 is rotated in the same direction at a larger angle compared to the neutral position. The drive belt is positioned against another guide wheel at the midpoint bend of the first arm 273 and the guide wheel at the distal end of the first arm 273. The arrangement of the belt above the first arm 273 in the raised wheel position increases the path length of the drive belt 271 on the first side of the tensioning tool. Since the drive belt 271 remains approximately the same length regardless of the position of the tensioning tool due to the increased path length on the first side, and because the belt path on the first side is extended, the drive belt 271 is pulled an equal amount toward the distal end of the second end 274 on the second side of the tensioning tool to shorten the belt path, and thus the second part is aligned more vertically by rotation. On the positive side, the tensioning tool compensates for the reduction in vertical distance between the upper part of the frame 102 and the wheel base 165 so that the belt is pulled tight enough without becoming too loose to disconnect from the drive wheel 275 or the driven wheel 116 or 118.

[0266] On the positive side, since the tensioning tool is directly connected to the reversing mechanism 110, the tensioning tool operates in sync with the reversing mechanism 110.

[0267] Accordingly, since the reversing mechanism 110 raises and lowers the group pulleys 116 and 118 respectively, the tensioning drive belt 271 does not require additional control or separate activation function.

[0268] Considering that the tensioning tool is in use during the transition process from wheel 118 being on top to wheel 118 being on the bottom (i.e., from... Figure 24 c Figure 24 b to Figure 24 a) First, the elbow joint is bent downwards and belt 271 is pulled inwards by the biasing tool on both the first and second sides. The biasing tool applies a small force, just enough to prevent belt 271 from slackening and to ensure that the belt teeth engage with the various pulleys with clearance. Figure 24 c).

[0269] During the transition, the load is transferred from the first set of pulleys 116 to the second set of pulleys 118. Approximately halfway through the transition, the reversing motor operates at full power or its peak load to achieve the pulley change required for the reversing operation. At this time, the belt 271 is relatively slack. The tensioning tool adds extra work to the reversing motor to rotate the elbow joint of the first arm 273 relative to the biasing tool. As the second set of pulleys 118 begins to bear the load of the device, the elbow is straightened so that the distal end of the shaft of arm 273 is approximately aligned with the fixed end of the first arm 273, and the distal guide pulley directly applies a large pre-tension force to pull the belt 271 ( Figure 24 b).

[0270] Finally, once the load has been transferred to the second set of pulleys 118, the elbow is pulled by the biasing tool to the position it has already rotated to prevent belt 271 from becoming slack. Figure 24 a).

[0271] It should be understood that the positioning of the elbow on the first arm 273 allows the tensioning tool to switch to the point where the control band 271 requires the maximum force for pre-tensioning.

[0272] By separating the force requirements of the reversing mechanism 110 from those of the tensioning tool, it may be possible to better reduce the size of the required motor.

[0273] The tensioning tool can be adjusted and biased towards the underside of the wheel or the parking position, rather than above the wheel. It should be understood that other tensioning tools can be used.

[0274] The tensioning tool is used to tighten and maintain the engagement of the drive belt 271 with the wheels 150, 116 when the wheel is positioned to engage or disengage with the surface, or when the wheel is in a neutral position or during the transition between the engaged and disengaged positions.

[0275] It is known that, ideally, there should be six teeth in contact between the drive belt and the drive pulley for a belt drive assembly to function. This can be ensured by including additional pulleys to provide a larger drive assembly.

[0276] During operation of drive arrangement 270, drive belt 271 is driven by drive wheel 275. The path of drive belt 271 to drive wheel 275 is assisted by mega drive wheel 278. Mega drive wheel 278 is placed adjacent to drive wheel 275 and orients drive belt 271 such that a greater number of teeth engage between drive wheel 275 and drive belt 271 compared to when mega drive wheel is not present. Typically, about six or more teeth of drive belt 271 engage with drive wheel 275 when using mega drive wheel 278.

[0277] It is known that in gear drive arrangements, backlash is a motion error that occurs when the drive direction changes from front to back or from back to front. It exists because there is always a small gap between the training face of the drive tooth on the driven belt and the leading face of the tooth behind it, and this gap must close before the force can be transferred in the new direction. The amount of backlash depends on the size of the gap. In an ideal drive belt / gear arrangement, there is no gap between the teeth of the drive belt and the teeth of the wheel. However, this would require perfect manufacturing and uniform dimensional characteristics throughout the system. With the use of a drive belt, additional backlash may occur due to belt tension. At least some of the backlash occurring during changes in the front-to-back direction can be compensated for through spoke design. Accordingly, it should be understood that appropriate materials should be selected. For example, the drive belt 171 can be made of polyurethane, steel strand-reinforced rubber, fiber-reinforced rubber, etc. Figure 25 A top view of the load handling device is provided, showing the arrangement of drive motors suitable for driving drive assembly 170 or 270. A first drive motor 290 is coupled to a first drive shaft 292 via a first gear arrangement 291. This drive shaft extends along the y-direction through the width of the load handling device to drive assembly 170 or 270 to drive wheel 116 along the x-direction. Motor 290 is positioned facing one end of drive shaft 292. Therefore, the length of drive shaft 292 to the first side is less than the length of drive shaft 292 to the facing side. It is known that torsional stiffness decreases with increasing length. Accordingly, assuming both sides of drive shaft 292 are made of the same material, the shorter drive shaft has a proportionally reduced diameter compared to the longer drive shaft to ensure torsional stiffness matching between each side. In another arrangement, the two sides of the drive shaft may be made of different materials to match torsional stiffness. For example, the shorter one may be made of aluminum, while the longer one may be made of carbon fiber with a similar diameter. In this way, the two opposite sides of the load handling device are driven by the same motor 290 and receive the same torque.

[0278] Similarly, a vertically positioned second drive motor 290' is coupled to a second drive shaft 292' via a second gear arrangement 291'. This drive shaft extends along the x-direction through the width of the load handling device to drive drive assembly 170 or 270 along the y-direction to drive wheel 116.

[0279] On the positive side, the drive motor arrangement requires only two motors to drive the load handling device in the forward and reverse directions along the x and y directions.

[0280] In another arrangement, the drive assembly may include four drive motors, one of which drives one drive assembly 170 or 270.

[0281] On the positive side, the control of the load handling device is simplified because a limited number of actions and components are required to manipulate the load handling device, thus reducing the amount of action coordination required. In this arrangement, each of the eight wheels 150 on the load handling device is a driven wheel 150.

[0282] In larger, lightweight units, the bends of the load handling unit can be multifunctional and have space for mounting and integrating numerous components of the load handling unit. The drive motor can be mounted on the top portion or the bend of the load handling unit.

[0283] An advantage is that this installation location requires less fixtures. Another advantage is that this arrangement allows for shorter cables to transmit power and data to the actuators. A further advantage is that this arrangement places many of the complex components of the load handling unit in easily accessible locations, thereby reducing maintenance time and labor costs.

[0284] Figure 26-29 Another wheel design 250 is exemplified for use as the first and second sets of wheels 116, 118 in the load handling device described in this invention. Wheel 250 is designed for use with a hub motor. As shown, the hub 260 has a large diameter to accommodate the hub motor. Therefore, the distance between the hub 260 and the rim is shortened, and the spokes 259 are confined to thin strips between the hub 260 and the rim.

[0285] The hub 260 has a wide edge and includes a number of attachment points 251 for securing the wheel 250 to the hub motor.

[0286] Spokes 259 are configured to form a truss arrangement. Spokes 259 can be straight or curved, and arranged alternately clockwise or counterclockwise. In some arrangements, spokes 259 can be configured as two overlapping, oppositely oriented helical sections. The spoke arrangement is designed to maximize torsional stiffness while allowing radial deflection.

[0287] Figure 27 Showing Figure 26 A portion of the spokes 159 of the outer layer 152 of the type shown are arranged. Additionally, Figure 27 The direction of the force applied to the wheel during use is indicated. For simplicity, [the following is not provided:] and Figure 13 Similarly, only a small portion of spoke 259 is shown. See also Figure 27 a. When rotational force is applied to the wheel as indicated by the arrow around its circumference, the force is transmitted along spokes 159 in the indicated direction. See also Figure 27 b. When the compressive force is applied as indicated by the downward arrow at the bottom of the wheel, the opposite rotational force is transmitted through each node where the spokes 259 meet the edge of the hub.

[0288] A series of grooves 263 are provided on the circumferential edge of the wheel 250 to accommodate a corresponding number of O-rings 264. The O-rings 264 may be made of a relatively flexible material (such as rubber) to provide traction and grip between the wheel 250 and the track, and to absorb impacts on the track between grid spaces. The O-rings 264 can be considered as tires for the wheel 250. The flexibility of the wheel 250 reduces wear on the O-rings 264 during use.

[0289] Wheel 250 may be made of a single layer, or wheel 250 may have a sandwich structure similar to wheel 150.

[0290] like Figure 26 As shown, considering that wheel 250 is in the radial direction between the O-ring 263 tire and the outer plane of the wheel, the thin interlayer 265 provides a gap between the tire or body of wheel 250 and the outer edge plane. This gap allows wheel 250 to deform or squeeze into a narrower track.

[0291] Combination Figure 26 and 27 The wheel 250 of the described type is suitable for being driven by a hub motor. Accordingly, this type of wheel has a direct drive arrangement in use, rather than a driven arrangement as described in other parts of the invention.

[0292] Figure 28 An example is a hub motor 280 suitable for use with wheel 250, and Figure 29 An example is a hub motor 280 with a wheel 250 mounted on it. The hub motor 280 includes a motor 281, a wheel seat 282, and a mounting plate 283 for mounting the hub motor 280 on a vehicle.

[0293] Figure 37-41 Another wheel design 350 is exemplified for use as the first and second sets of wheels 116, 118 in the load handling device described in this invention.

[0294] Figure 37 An exploded view of wheel 350 is shown, illustrating its various components. Roughly from the center, wheel 350 includes pulley 351. Spring sections or spring layers 352 are mounted to various faces of pulley 351, and O-rings 364 are fitted to the edges of spring sections 352. First and second torque limiting discs or contact discs 354 are then assembled together via the central hub of pulley 351 and spring sections 352. First and second bearings 355 are fitted into contact discs 354. Finally, a front cover disc 356 is fitted onto bearings 355 and connected to a rear cover disc (not shown) via screws or bolts 357. Figure 38 A shows a plan view of the assembled Wheel 350, and Figure 38 b shows along Figure 38A cross-sectional view of wheel 350 taken from line XX of a. As shown in the cross-sectional view, channel 353 is located between O-rings 364. As described in the invention, channel 353 can accommodate a drive belt that engages with the teeth of pulley 351 to drive wheel 350. As described above, O-rings 364 engage with rails or surfaces to support the load handling device to which they are attached.

[0295] Figure 39 The spring layer 352 of wheel 350 is shown in more detail, divided into a flat surface. Figure 39 a and three-dimensional Figure 39 b. Similar to wheels 150 and 250 described above, spokes 359 are bent in clockwise and counterclockwise directions to form a mesh or lattice for transferring force between the hub and rim. Spring layer 352 will be made of an elastic material, allowing it to bend or deform. The inner circumference of spring layer 352 includes a notch 360 located in a groove 358 of contact disc 354. Additionally, towards the outer edge of the spoke section, spring layer 352 includes a number of regularly spaced grooves 361 for fitting with similarly spaced protrusions 362 on the front and rear sides of pulley 351, see [link to relevant documentation]. Figure 37 and 40 It should be understood that the grooves and notches or spaced protrusions ensure proper alignment of the wheels when assembled and allow for quick manual assembly by, for example, a technician.

[0296] Figure 40 A plan view of pulley layer 351 and more details are shown, in which the teeth are around the circumference; protrusions 362 are slightly inside the circumference and regularly spaced around the surface; notch 363 is located in groove 358 of contact disc 354 (similar to notch 360).

[0297] at last, Figure 41 Contact plate 354 was displayed. Figure 41 'a' is its plan view. Figure 41 b is its perspective view. It should be understood that the contact disc 354 restricts the outward extension of the spring layer to section 352. In addition, the contact disc 354 helps prevent the spokes from getting tangled in nearby objects.

[0298] See Figure 38 a. It should be understood that the diameter of the contact disc 354 is slightly smaller than the diameter of the spoke section. In this way, the rim of the wheel 350 can be allowed to flex inward, for example, to compensate for narrowing or unevenness of the track.

[0299] It should be understood that notches 360, 363 and grooves 358, as well as grooves 361 and protrusions 362, assist the proper alignment of each layer of pulley 350 and ensure that the driving force applied to the circumferential teeth of pulley 352 is transferred to spring layer 352 to drive the load handling device.

[0300] It should be understood that, although they have been combined Figure 10-15 The characteristics of wheels 21-25 were explained and combined. Figure 26-29 Other features were explained and combined Figure 37-41 Further features have been described, but the inventors still anticipate combinations of features derived from any of the accompanying drawings and related descriptions. For example, a driven wheel may include a plurality of O-ring tires, or a hub motor-driven wheel may have a layered structure.

[0301] In the variations of wheels 150, 250 and 350 illustrated and described, it should be understood that the wheel may not be axisymmetric, i.e., the wheel may include a spring layer only on one side of the support or pulley layer.

[0302] As noted above, a load handling unit typically includes a space or frame cavity for accommodating a container. This cavity is sized sufficiently to allow the container to fit within the cavity, enabling the load handling unit to move through the grid at the top of the storage frame without the underside of the container hitting the grid or another part of the storage frame. Once the load handling unit has reached its intended destination, a container lifting mechanism controls a lifting belt to lower the gripper assembly and the corresponding container out of the load handling unit and into the intended position.

[0303] The intended location could be the exit point of a container stack or storage frame, or, if the load processing unit has moved to collect containers for storage in a storage frame, the intended location could be the entry point of a storage frame.

[0304] Ocado's GB2001012.0 patent describes various booster components, all of which are incorporated herein by reference.

[0305] Figure 16 and 17 The image shows lifting assemblies 180 and 190 of the load handling device 100 for raising and lowering the container 10. Lifting assemblies 180 and 190 include gears 182 and 192 and motors 181 and 191.

[0306] Common shafts 183 and 193 extend through gears 182 and 192 to the first and second lifting drums 184 and 194, around which the lifting belt 185 is wound. A first end of the lifting belt is attached to the lifting drums 184 and 194, while a second end is attached to a gripper disc. A pulley 186 is used to guide the lifting belt 185 to the gripper disc attached to the end of the lifting belt 185 and / or to adjust the tension of the lifting belt 185. The gripper disc is used to lock the load that can be raised and lowered by the lifting assemblies 180 and 190.

[0307] exist Figure 16In the case of component 180 shown, the first and second lifting belts 185 are otherwise wound around the drum 184. Thus, when the first and second drums 184 are rotated by the motor 181 to lower the gripper disc, both belts 185 unfold at the same time and at the same speed. Conversely, the lifting belts 185 wrap around or wind around the lifting drum 184 at the same time and at the same speed, thereby lifting the weight or load supported by the gripper disc.

[0308] exist Figure 17 In the case of component 190 shown, the first and second lifting belts 185 are each wound around the spools 194 at each end of the shaft 193.

[0309] For components 180 and 190, at each end of shafts 183 and 193, belts 185 unfold from the top and bottom of drums 184 and 194 respectively to balance the forces applied to the components.

[0310] It should be understood that for a given length of lifting belt 185, the diameter of drum 184 must be greater than that of each drum 194. Accordingly, gear 182 is larger than gear 192, and the required torque generated by motor 181 is also greater than that generated by motor 191.

[0311] Lifting assembly 180 has the advantage of requiring fewer components. Lifting assembly 190 has the advantage of smaller drum 194, gear 192, and motor 191. In both cases, the space required by the lifting assembly within the main body of the load handling device 100 is reduced.

[0312] The exemplified lifting arrangement has various advantages, including: cost savings and space savings within the load handling unit compared to arrangements containing more motors; since all are driven by the same motors 181 and 191, the winding and unwinding rates of the reels or drums 184 and 194 do not need to be synchronized, which allows them to wind and unwind at the same rate without additional gear arrangements, control, or other interventions; and only one control unit is needed to control the raising and lowering of the lifting drums 184 and 194.

[0313] As will be discussed further below, the gripper plate attached to the far end of the lifting belt 185 has one or more gripper assemblies mounted thereon for locking the storage container.

[0314] Components of the lifting assembly can be mounted directly or indirectly to a frame that is releasably mounted to the load handling device. For example, the lifting assembly can be mounted on a beam or rod placed in a bracket mounted on the skeleton of the load handling device. The bracket can be 3D printed and optimized for weight. In this way, the lifting assembly is used to lift containers into the skeletal gaps of the load handling device. It should be understood that, conversely, the lifting device is used to lower containers from the load handling device to a position in the stack below the grid.

[0315] Configuring a lifting component to achieve better releasable installation on the load handling unit means that the lifting component can be easily removed and replaced by another lifting device (e.g., if the previous component requires maintenance or repair), which allows the corresponding load handling unit to return to a working state more quickly.

[0316] Communication cable reels can also be mounted on the lifting assembly to send control commands from the control unit to the gripper assembly. The communication cable can transmit sensor data to the control unit, for example, to ensure the gripper disc locks the container. The communication cable can also be raised and lowered via the gripper disc.

[0317] In another arrangement, communication between the lifting assembly and the control equipment can be wireless. The lifting assembly or TGA (tray gripper assembly) can be semi-automated.

[0318] Before the lifting assembly raises or lowers the gripper assembly and any engaged container, the reversing mechanism preferably ensures that both the first set of wheels 116 and the second set of wheels 118 of the load handling unit are engaged with their respective tracks. This provides additional stability as the lifting assembly raises and lowers, and also helps to ensure that any failure of the wheels, or more wheels themselves, that would cause the load handling unit to move along the tracks is offset by the other set of wheels currently in contact with the tracks. This avoids damage to the storage frame that could occur if the gripper assembly is in a lowered configuration while the load handling unit is still attempting to move.

[0319] The gripper plate includes at least one gripper assembly configured to align with a recess or hole in the upper surface of the storage container, thereby locking the storage container in place. More commonly, the gripper plate includes two or more gripper assemblies. Typically, the gripper plate includes four gripper assemblies positioned corresponding to matching recesses on the container.

[0320] Figure 18-19An example is provided for use in the load handling apparatus described in this invention. The gripper assembly includes a bending mechanism 210 movable between a locked and a released bistable configuration. The bending mechanism 210 includes an actuator 211, two gripping arms 212 having hook ends 213, and two bending hinge arrangements connecting the gripping arms 212 to the actuator 211. Each bending hinge arrangement includes a triangular base structure 214, a first deformable section 215 located between the actuator and the base structure, and a second deformable section 216 located between the base structure and the gripping arms 212. The deformable sections 215 and 216 are thinner than the other sections of the bending mechanism 210. In this way, when an appropriate force is applied to the bending mechanism 210, the deformable sections preferentially bend or flex.

[0321] See Figure 18 In locked configuration ( Figure 18a In the configuration, the base structure 214 engages or abuts against the corresponding gripper arm 212. In the locking configuration, the bending mechanism 210 is open or wide, and the gripper arm is extended. The bending mechanism 210 can be as follows: Figure 18a As indicated by the solid arrow, a downward force is applied to the actuator, which is then moved into the locking configuration. The actuator 211 is in the downward position relative to the gripper arm 212.

[0322] Bending mechanism 210 can be as follows Figure 18 As noted in section b, an upward force or pull is applied to actuator 211, moving it into an unlocked or released configuration. When such a force is applied, the first and second hinges 215, 216 bend or buckle, releasing the base structure 214 from engagement with the gripper arm. The bending of the first hinge 215 causes the base structure to pivot downward relative to the actuator. The bending of the second hinge 216 causes the base structure 214 to pivot upward relative to the gripper arm 212. Thus, actuator 211 moves to an upward position relative to the gripper arm 212, as... Figure 18 As indicated by the solid arrow c, pull the hook end 213 of the gripper arm together to enter a narrow or closed arrangement.

[0323] Figure 19 a and Figure 19 Example b illustrates another arrangement of the gripper with bending mechanism 220; similar features are indicated by the same notation. In Figure 18 In this configuration, the foundation structure 214 is connected to the gripper arm 212 and spaced apart from the hook end 213 of the arm. The foundation structure 214 extends below the line between the first and second hinges 215, 216. Figure 19 In another arrangement shown in a and 19b, the base structure 217 is generally connected to the gripper arm 212 at the hook end 213. The base structure 217 extends above the line between the first hinge 218 and the second hinge 219.

[0324] Figure 19 a shows a bending mechanism 220 in a locked configuration, with the base structure 217 engaged with the corresponding gripper arm 212. Figure 19 In configuration b, the bending mechanism 229 is in the release configuration. In this case, the actuator 211 is in the downward position relative to the gripper arm 212, and the first and second hinges 218 and 219 are... Figure 18 The first and second hinges 215 and 216 bend in opposite directions. Thus, the bending mechanism 220 can be moved into a locked configuration by applying an upward force to the actuator 211, and the bending mechanism 220 can be moved into an unlocked or released configuration by applying a downward force or thrust to the actuator 211.

[0325] As described above, the gripper assembly is used to lock the storage container 10, allowing the storage container to be lifted. The gripper assembly is configured to be compatible with the storage container 10. Typically, the storage container 10 has a recess around the edge of its upper surface.

[0326] In use, when in a narrow or bent configuration, the bending mechanism 210 is inserted into the recess. Once inserted, it can be used as... Figure 18a A downward force is applied to actuator 211 as indicated by the solid arrow. This puts bending mechanism 210 into a locked configuration, and bending mechanism 210 is wide. It is then impossible to remove bending mechanism 210 from the container recess. The hook end 113 of the gripper arm engages with the underside of the upper surface of container 10. Therefore, a lifting force can be applied to gripper arm 212 to lift the container.

[0327] It should be understood that the bending mechanism 220 can be used with the container 10 by applying an opposing force to the actuator 211.

[0328] In use, gripper assemblies 210 and 220 are mounted on the gripper disc as part of the load handling device. A lifting belt 185 is attached to the gripper arm 212. The actuator 211 can be operated, for example, by a solenoid motor or an electromagnet.

[0329] When used with the load handling device, grippers 210, 220 are used at each corner of the container 10 to lock the lifting assembly 200 to the container 10. The lifting assembly 200 is then operated to lift the container 10 into the frame gap of the load handling device 100 so that the container 10 can be transported by the load handling device. Figure 20 Example a is a load handling device without containers. Figure 20 b(and) Figure 5 An example is given of a load handling device with a container that has been raised into the gap.

[0330] It should be understood that gripper assemblies 210 and 220 may have more than two gripping arms and a corresponding number of bent hinge arrangements disposed around the actuator. In some arrangements, the additional gripping arms may make the attachment to the storage container more secure.

[0331] This arrangement allows a single motor to raise and lower the gripper plate, although it is quite clear from the above that two motors are preferred to provide some redundancy to the system, thereby providing a fault-tolerant load handling device.

[0332] As noted above, some parts of the load processing unit can be directly replaced or exchanged. Accordingly, the load processing unit can be considered to have modular components.

[0333] The main body of the load processing device can be considered as a skeleton, frame, or skeleton. An advantage is that this makes it easier to replace each module, as each module can be accessed directly or indirectly. A module can be self-contained, i.e., a single unit with a number of connecting parts, or a module can include multiple parts.

[0334] The module may include: a steering assembly, a wheel or a set of wheels, a drive assembly, a lifting assembly, a gripper assembly, a power supply tool, a communication tool, a control tool, a sensing tool, or a sensor package.

[0335] Of particular advantage is that this allows for more frequent replacement of components within or supported by the load handling device's frame; for example, it allows for easy removal of the load handling device's rechargeable battery from the frame and replacement with another rechargeable battery.

[0336] For automated operation, the load handling unit has its own power supply. The power supply can be rechargeable or battery-powered.

[0337] The battery can be located within the frame of the load handling device. For example, if the frame includes a hollow rod structure, then the battery can be inserted into the rod.

[0338] Ocado's WO2019170805 patent application describes various control and sensor arrangements, which are incorporated herein by reference.

[0339] The load handling unit is controlled by onboard control equipment.

[0340] Airborne control equipment may include transceiver units or communication tools for sending and receiving commands from the system's central control equipment. The load processing unit is capable of operating largely automatically based on commands or tasks from the central control equipment.

[0341] The airborne control equipment is capable of controlling and operating the steering mechanism, drive components, and lifting components according to instructions received from the central control equipment. The airborne control equipment further includes inputs from various sensors and cameras to provide feedback to the central control equipment regarding the status of the load handling unit and its surrounding environment.

[0342] Based on the status of the load handling device and the surrounding environment, the airborne control equipment operates the steering components, drive components, and lifting components to perform the task.

[0343] Accurate information about the status of the load processing unit is needed to determine the operating speed of the load processing unit, when the task will be completed, and whether the load processing unit can complete subsequent tasks.

[0344] Each load processor needs to be accurately positioned to allow for faster and / or accelerated drive while minimizing location errors, thereby reducing the spacing between load processors on the grid system and improving system efficiency.

[0345] More than one type of sensor can be used to determine the condition and environment of the load processing device, thereby verifying the accuracy of the received information. More than one sensor of the same type can be installed at different locations on the load processing device.

[0346] In this way, each sensor detects a different part of the operating environment of the load processing device. Multiple sensors are advantageous because they provide redundancy on the device; if one sensor fails to obtain appropriate information from the environment, one of the other sensors may be more successful.

[0347] Additionally, if one sensor is in a position where it cannot acquire environmental data (such as at a track intersection), another sensor may be able to acquire environmental data more successfully. Furthermore, other measurement data can be acquired through multiple sensors, such as determining the angle between sensors by comparing position measurement data from one sensor with the same position measurement data from a sensor mounted on the opposite side of the transport device, thus determining the direction of rotation.

[0348] Thus, while one advantage of the load processing device described in this invention is the elimination of redundancy, it should be understood that some redundancy on the load processing device may be necessary for certain reasons in order to operate in a larger system, such as for sensing positions on the grid.

[0349] The load processing device may include many different types of sensors, such as cameras, ultrasonic detectors, X-ray cameras, trundle or dead reckoning wheel arrangements, gyro scanners for reading markers provided on the grid, barcode scanners or QR code scanners; and RFID readers for identifying items stored in the system.

[0350] One type of sensor that can be used with the load processing device described in this invention is a low-cost top-view camera located in the frame. Such cameras can be used to detect track crossings and determine grid positions.

[0351] Sensors can be provided to evaluate the communication functions within the load handling device, measure the traction between the wheels and the grid track, measure the distance traveled, measure the travel speed, determine the grid position of the load handling device on the grid, and accurately locate the load handling device in a single grid space.

[0352] It should be understood that the load processing device may include all, one, or any combination of the features described above, and it is not necessary for the present invention to include all of the sensors and features described above in the working device.

[0353] It is expected that any one or more variations described in the preceding sections can be implemented in the same specific implementation of the load processing device.

[0354] The invention described herein is illustrated by way of example in conjunction with a load processing device for a department store retrieval system. It should be understood that the storage system and device described herein are not limited to the types of items stored and managed by this invention.

[0355] Furthermore, it should be understood that some specific embodiments of the present invention may be used in conjunction with manual processing equipment rather than load processing devices.

[0356] Many variations and modifications not explicitly mentioned above are also possible without departing from the scope of this specification and claims.

[0357] The exemplary implementation is summarized below:

[0358] A load handling device, wherein at least one elastically deformable member is a bending hinge, and the flexible mechanism includes a series of main sections attached to an upper support and a lower support via the bending hinge.

[0359] A load handling device, wherein the bending hinge includes a branch portion, or wherein the bending hinge includes a spring portion.

[0360] A load handling device, wherein each flexible mechanism includes at least one main section having a first type of bending hinge and at least one main section having a second type of bending hinge.

[0361] A grid-based storage and retrieval system comprising a grid frame (14) structure, at least one load processing device operating on the grid frame structure, and a centralized control device for controlling the at least one load processing device. The grid frame (14) structure includes a first set of parallel tracks or rails (22b) and a second set of parallel tracks or rails (22a). The second set of parallel tracks or rails (22a) extends substantially perpendicular to the first set of tracks or rails (22b) in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces. The grid is supported by a group of vertical members (16) to form a plurality of vertical storage locations below the grid, for containers (10) to be stacked between the vertical members and guided vertically through the plurality of grid spaces.

[0362] A system, wherein the at least one load processing device further includes a communication tool; and a centralized control device for the storage system includes a communication tool for communicating with the communication tool on the at least one load processing device.

[0363] A system in which the centralized control device remotely monitors the status of the at least one load processing device.

[0364] A system in which, if a fault or malfunction is detected in the load handling device, the load handling device is instructed to move to a maintenance area or grid edge using a fault-free or non-malfunctioning tool.

[0365] A system in which the centralized control device communicates with at least one load processing device running on a grid to instruct the load processing device to move to a specific location on the grid.

[0366] A system that further instructs a load handling device to lift a container from a stack and move the container to another location on a grid, and / or further instructs the load handling device to lower the container to a stack location below the grid.

[0367] A wheel, wherein the rim of the wheel includes one or more grooves for receiving an O-ring.

[0368] A wheel, wherein the rim includes three or more grooves for receiving an O-ring.

[0369] A wheel, wherein the wheel further includes an additional layer that provides a gap between the wheel's body and its outer plane. In this way, the wheel can be "squeezed" into a narrower shape to pass through narrower or misaligned sections of a track.

[0370] A wheel, wherein the wheel is a driven wheel.

[0371] A wheel, wherein the wheel is adapted to accommodate a hub motor.

[0372] Tensioning tool, in which the second arm is rotatably mounted.

[0373] Tensioning tool, wherein the drive belt is routed through the first tensioning arm and the second tensioning arm.

Claims

1. A drive belt assembly for a load handling device, the drive belt assembly comprising: Drive belt; Drive wheel; One or more driven wheels; Tensioning tool, the tensioning tool comprising: A first tensioning arm, having a fixed end located above the elbow and a rotatable distal end pivotally attached to the elbow, wherein the first tensioning arm is horizontally displaceable relative to the drive wheel and the driven wheel; and a second tensioning arm, The drive belt is routed around the first and second tensioning arms, and the first and second tensioning arms are configured to apply pressure to the drive belt to tension it; the driven wheel is movable in a vertical direction relative to the drive wheel between raised and lowered configurations; and the tensioning tool has a configuration corresponding to the raised and lowered configurations of the driven wheel, respectively, and the tensioning tool is movable between the corresponding configurations.

2. The drive belt assembly of claim 1, wherein the movement of the driven pulley and the tensioning tool between configurations is mechanically coordinated.

3. The drive belt assembly of claim 1, wherein the drive belt assembly further includes a reversing component configured to raise or lower the driven pulley relative to the drive pulley, wherein the tensioning tool of the drive belt assembly is configured to pretension the drive belt as the driven pulley moves between raised, lowered, and parked configurations.

4. The drive belt assembly of claim 3, wherein the tensioning tool is mechanically connected to the reversing assembly.

5. The drive belt assembly of claim 1, wherein the vertical movement of the driven wheel and the movement of the tensioning tool are initiated by the same actuator.

6. The drive belt assembly of claim 1, wherein the force applied to the drive belt varies depending on the position of the first tension arm and / or the second tension arm.

7. The drive belt assembly of claim 1, wherein the time required for peak force to change direction is different from the time required for peak force to tension.

8. The drive belt assembly of claim 1, wherein the drive belt assembly further includes a sensing tool for monitoring belt tension, and optionally further includes a tool for adjusting belt tension.

9. The drive belt assembly of claim 1, wherein the drive belt assembly further comprises a sensing tool for determining a fault or malfunction of the drive belt.

10. A load processing apparatus for operating on a grid-frame storage structure, the grid-frame storage structure comprising a first set of parallel tracks or rails (22b) and a second set of parallel tracks or rails (22a), the second set of parallel tracks or rails (22a) extending substantially perpendicular to the first set of parallel tracks or rails (22b) in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces, wherein the grid is supported by a set of vertical members (16) to form a plurality of vertical storage locations below the grid for containers (10) to be stacked between the vertical members and guided vertically through the plurality of grid spaces by the vertical members. The load handling device includes a main body mounted on a first set of wheels (116) and a second set of wheels, the first set of wheels (116) being configured to engage with a first set of parallel tracks (22b), and the second set of wheels being configured to engage with a second set of parallel tracks (22a), wherein the first set of wheels (116) and the second set of wheels (118) are driven by corresponding drive belt assemblies according to any one of claims 1-9, wherein the first set of wheels (116) and the second set of wheels (118) are driven wheels.

11. The load processing apparatus according to claim 10, wherein the load processing apparatus comprises four drive belt assemblies disposed on each side of the load processing apparatus for driving corresponding driven wheels.

12. The load handling apparatus of claim 10 or 11, further comprising a reversing assembly configured to raise or lower the first set of wheels and / or lower or raise the second set of wheels relative to the drive wheel, thereby engaging or disengaging the wheels from the parallel track, wherein the tensioning tool of the drive belt assembly is configured to pretension the drive belt as the driven wheel moves between raised, lowered, and parked configurations.

13. A set of modular components for a load handling apparatus, comprising at least one drive belt assembly according to any one of claims 1-9.

14. A grid-based storage and retrieval system comprising a grid frame (14) structure including a first set of parallel tracks or rails (22b) and a second set of parallel tracks or rails (22a), the second set of parallel tracks or rails (22a) extending substantially perpendicular to the first set of tracks or rails (22b) in a substantially horizontal plane to form a grid pattern comprising a plurality of grid spaces, wherein the grid is supported by a set of vertical members (16) to form a plurality of vertical storage locations below the grid for containers (10) to be stacked between the vertical members and guided vertically through the plurality of grid spaces; At least one load processing device according to any one of claims 10-12, operating on the grid frame structure; and Centralized control device for controlling the at least one load processing device.

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