Method for operating a storage device

Abstract

The invention describes a method for operating a storage device (1) with which goods (4) are inserted into the storage device (1) in inward delivery containers at an inward delivery area (2), removed from the inward delivery containers, temporarily stored and removed from the storage device (1) in outward delivery containers in a predetermined order at an outward delivery area (3). It is desirable to be able to produce and / or operate such a storage device at low cost. To this end, it is a prerequisite that the goods are transferred from the inward delivery containers into stackable packaging units (5) and that the packaging units (5) are temporarily stored in block storage units (7), wherein the block storage units (7) have a plurality of stack compartments (8) and each stack compartment (8) is designed to receive a stack of packaging units (5), wherein the goods are removed from the block storage units in an order predetermined by the outward delivery area.

Description

[0001] The invention relates to a method for operating a storage installation, with which goods are inserted into the storage installation in inward delivery containers at an infeed area, removed from the inward delivery containers, temporarily stored, and removed from the storage installation in outward delivery containers in a predetermined order at an outfeed area.

[0002] The method can be applied to a storage installation in the field of food retail, for example. Here, the goods are delivered by one or more manufacturers, with the inward delivery taking place on, for example, pallets, and each pallet comprising a single type of goods. The goods are then removed from the inward delivery containers. This operation is also referred to as "unstacking". The unstacked goods are temporarily stored. The temporary storage takes place, for example, by transferring the goods into transport containers or transportable pallets and storing the transport containers or pallets in a temporary storage unit. In many cases, the temporary storage unit is designed as a high-bay warehouse with a stacking crane. The stacking crane stores the transport containers or pallets in the high-bay warehouse and removes them therefrom.

[0003] At the outfeed area, the goods must be arranged in the outward delivery containers in a predetermined order. This order takes into account, for example, that heavy goods are located at the bottom in the direction of gravity. Mechanically unstable goods should be arranged as high as possible in the direction of gravity, for example. The goods must therefore be inserted into the outward delivery containers in a specific order. In general, this is not easily achievable if the goods are transported directly from the high-bay warehouse or a corresponding flat warehouse to the outfeed area. Therefore, a buffer station is arranged before the outfeed area, in which the goods are temporarily stored again in order to be subsequently assembled in the outward delivery containers in the correct order. This requires installation space and storage components, which increase the costs.

[0004] The invention is based on the object of producing and / or operating a storage installation at low cost.

[0005] The object is achieved in a method of the type mentioned at the outset by transferring the goods from the inward delivery containers into stackable packaging units and temporarily storing the packaging units in a block storage unit, wherein the block storage unit has a plurality of stack compartments and each stack compartment is designed to receive a stack of packaging units, wherein the goods are removed from the block storage unit in an order predetermined by the outfeed area.

[0006] A block storage unit can also be referred to as a "stack storage unit" or a "container stack storage unit". In a block storage unit, a plurality of stack compartments are arranged in rows and columns in a matrix. Then, a plurality of packaging units are arranged in each stack compartment on top of one another. This means that the packaging units are arranged not only in two dimensions, but also in a three-dimensional structure. In this view, the high-bay warehouse also only has a two-dimensional structure, even though the individual goods are arranged on top of one another on a plurality of levels. However, on each level, there is only a two-dimensional arrangement of the goods in question, so that the third dimension can only be realized by individually accessing the levels with a stack crane. This, in turn, means, for example, that a location in the high-bay warehouse cannot be arbitrarily accessed, since it is always necessary to check whether a stack crane is available for the desired location and whether this stack crane is not blocked by another stack crane moving in the same aisle in the high-bay warehouse. The same applies to other storage devices in which the individual goods are arranged in one or more levels in a planar manner. The packaging units can have different shapes. It is important that the packaging units can receive goods and that the packaging units can be stacked on one another, so that a plurality of packaging units can form a stack even with goods received.

[0007] Preferably, the packaging units in each stack compartment comprise the same type of goods. Thus, at each point of the matrix, i.e. at each intersection of a row and a column, there is a unique assignment between a location and a good. This makes it possible to easily pick up the goods in a desired order or sequence and to bring them to the goods-out area, so that the desired sorting can already be achieved during picking.

[0008] Preferably, the packaging units are inserted into the stack compartments from below. In principle, the block storage unit can be fed from above or below. If the stack compartments are fed from below, i.e. the packaging units are inserted into the stack compartments from below and are also removed from the stack compartments downwards, the packaging units can be directly transported to the height at which they are led out of the block storage unit. No further transfer operations are necessary in this case.

[0009] Preferably, the packaging units are inserted into the stack compartments and removed from the stack compartments by means of a loading vehicle, which can be moved in a loading compartment below the stack compartments. By means of the loading vehicle, it is possible to easily and effortlessly reach, i.e. access, each stack compartment.

[0010] In this respect, it is preferable that the loading vehicle can be moved in at least two different directions. The loading vehicle can then be guided in the loading compartment to each stack compartment, so that in the case of a plurality of loading vehicles in use, they can also avoid one another. Furthermore, the removal of the packaging units with the corresponding goods from the block storage unit becomes highly flexible, which has a positive effect on the sorting at the goods-out area.

[0011] Preferably, the loading vehicle is used to transport the packaging units to a sorting device upstream of the dispatch area. If the loading vehicle removing the packaging units from the block storage unit can also be used outside the block storage unit, then no further transfer operation is required, so that the method can be carried out in less time and with less technical equipment work.

[0012] Preferably, a loading vehicle is used which is capable of transporting more than one packaging unit at the same time. Thus, the loading vehicle can initially approach a stacking compartment and remove one or more packaging units therefrom. If transport space is still available, the loading vehicle can subsequently be driven to another stacking compartment in order to pick up another packaging unit at this other stacking compartment. The loading vehicle does not then have to move to the sorting device after each pick-up of a packaging unit. It can already be used to pre-sort the packaging units. The loading vehicle can remove different packaging units from the block storage unit, for example, by approaching different stacking compartments and removing one or even more packaging units in different cases.

[0013] Preferably, a loading vehicle is used which uses a transport carriage, wherein the carriage inserts the packaging units into the stacking compartments and removes the packaging units from the stacking compartments.

[0014] The carriage preferably has its own lifting drive and its own power supply for the devices for lifting and lowering the packaging units connected to the carriage and can thus carry out a storage or retrieval operation while the loading vehicle is working elsewhere until the respective carriage has completed its storage or retrieval operation and can be picked up again.

[0015] In another embodiment, it is also possible for the carriage not to have its own lifting drive for the devices for lifting and lowering the packaging units, but to be coupled to the drive in the loading vehicle by suitable coupling devices. Of course, in this case the loading vehicle remains in place until the storage or retrieval operation of the carriage is complete.

[0016] Other combinations of drive and power supply of the carriage with lifting devices coupled to the loading vehicle are also conceivable. For example, mention should be made of a drive in the carriage and a wireless or contact-based power supply via the loading vehicle or via contact pieces or inductive loops in the floor. In this case, the carriage can be controlled by wireless or contact-based signal transmission from the loading vehicle or from a central control system.

[0017] Preferably, packaging units are used which have at least two different filling / removal directions. This makes it even more flexible to insert goods into the packaging units and to remove goods from the packaging units.

[0018] Preferably, the first filling / removing direction extends in the direction of gravity, and the second filling / removing direction extends perpendicular to the direction of gravity. Then, the goods can be inserted into the packaging unit from above, i.e. in the direction of gravity, using for example an automated machine or an automated handling device. Then, during removal, the goods can be removed or pushed out of the packaging unit transversely to the direction of gravity, so that no force is needed here to lift the goods. This is particularly advantageous if an operator is to perform the removal. It is also possible to provide for insertion from the side and removal from the top, or in the same way insertion and removal from the side or top.

[0019] The application is described below with reference to preferred exemplary embodiments in conjunction with the accompanying drawings. Shown therein are:

[0020] Figure 1 A first embodiment of a storage device is shown,

[0021] Figure 2 A second embodiment of a storage device is shown,

[0022] Figure 3 A first embodiment of a loading vehicle is shown,

[0023] Figure 4 A second embodiment of a loading vehicle is shown,

[0024] Figure 5 A loading vehicle with a rack is shown, and

[0025] Figure 6 A schematic view of a packaging unit is shown, and

[0026] Figure 7 A third embodiment of a storage device is shown.

[0027] Figure 1 A schematic view of a storage device 1 with an infeed area 2 and an outfeed area 3 is shown. At the infeed area 2, goods 4 are inserted into the storage device 1 and removed from an inward delivery container (not shown in more detail). The inward delivery container can for example be a pallet on which a plurality of similar goods 4 are arranged. The goods 4 are removed from the inward delivery container and transferred into a packaging unit 5, as Figure 6The packaging units 5 are shown in greater detail. The packaging units 5 are transported into the block storage unit 7 by means of a loading vehicle 6, which is designed as a driverless transport vehicle. The block storage unit 7 has a plurality of stack compartments 8 in which the packaging units 5 can be stacked. In other words, each stack compartment 8 is able to receive a plurality of packaging units 5 in the form of a stack. A prerequisite for this is that the packaging units 5 are stackable. For the stacking, they therefore have a stacking geometry which is arranged at the bottom in the direction of gravity and interacts with the stacking geometry which is arranged at the top of another packaging unit in the direction of gravity. Advantageously, all packaging units 5 have the same design.

[0028] The packaging units 5 are held in place by means of a holding device (not shown in greater detail) at the lower end of the respective stack compartment 8. For this purpose, the packaging unit to be stored is lifted until it has passed the holding device. During the subsequent lowering, the holding device then clamps the lowest packaging unit 5 and holds it in place.

[0029] For the removal, the loading vehicle 6 lifts the lowest packaging unit in the stack compartment 8 until this packaging unit 5 is released from the holding device. The holding device is then kept open until the lowest packaging unit has been lowered past the holding device and the next packaging unit above this packaging unit is then clamped, so that such a previously second last packaging unit then forms the lowest packaging unit 5.

[0030] It is also possible to provide for the removal of a plurality of packaging units 5 from the stack. In this case, a control mechanism must be provided which keeps the holding device open until the desired number of packaging units has been removed from the respective stack compartment 8.

[0031] The loading vehicle is not only used to insert the packaging units 5 into the block storage unit 7. It is also used to remove the packaging units 5 from the block storage unit 7 again and to feed them to the dispatch area 3.

[0032] The loading vehicle 6 can be moved on the floor 9 in two directions, as indicated by the arrows "X" and "Z" in Figure 1 In the simplest case, there are here only two directions perpendicular to each other. In a slightly more complex embodiment, it can be a prerequisite that the loading vehicle 6 can be moved in almost any two dimensions.

[0033] The loading vehicle 6 can also be used to drive the packaging units 5 out of the block storage unit 7 and to transport them to the dispatch area 3.

[0034] As mentioned above, the block storage unit 7 has a plurality of stack compartments 8. The letters "A", "B", "C", "D" and "E" show in simplified form that each packaging unit comprises the same type of 5 goods 4. Each stack compartment is therefore "homogeneous".

[0035] The stack compartments 8 are arranged in a matrix in columns and rows. Each stack compartment 8 is thus located at the intersection between a column and a row.

[0036] It is thus clearly defined within the matrix which of the goods A-E can be removed. Since the loading vehicle 6 can in fact move in any direction, the goods A-E can be removed in the order required for the subsequent ordering of the goods 4 at the dispatch area 3. The dispatch area thus dictates the order in which the packaging units 5 are removed from the block storage unit 7.

[0037] The loading compartments 10 in which the loading vehicle 6 can move are arranged below the stack compartments 8. The loading vehicle 6 inserts the packaging units 5 into the stack compartments 8 from below and also removes the packaging units from the stack compartments downwards.

[0038] The loading vehicle 6 can be used not only to insert the packaging units 5 into the stack compartments 8, but also to remove the packaging units therefrom. In Figure 1 In the exemplary embodiment shown, the loading vehicle 6 can also be used to transport the packaging units 5 to the dispatch area 3.

[0039] Figure 2 A modified embodiment of the storage installation 1 is shown, in which identical and corresponding elements are provided with the same reference numerals.

[0040] Here, the block storage unit 7 also has a plurality of stack compartments 8 in which the goods A-E are arranged. Also here, each stack compartment 8 is uniform.

[0041] In contrast to the exemplary embodiment shown, the stack compartments 8 are loaded from above here. To this end, a loading vehicle 6' is provided, which can move on the upper side of the block storage unit 7 in the direction of gravity. Figure 1

[0042] In order to transport the packaging units 5 provided with the goods 4, a further loading vehicle 6 is provided, which can move on the floor 9 and transport the packaging units 5 from the goods intake area 2 to the staging station 11. From the staging station 11, the loading vehicle 6' can pick up the packaging units 5 and transport them upwards. Once the packaging units 5 have reached above the block storage unit 7, they can be allocated to individual stack compartments 8.

[0043] Similarly, an allocation station 12 is provided on the other side of the block storage unit 7, at which the loading vehicle 6' can allocate the packaging units 5 removed from the block storage unit 7. From there, it can be transported by a further loading vehicle 6 to the dispatch area 3.

[0044] ​Here, for the sake of clarity, the staging station 11 and the distribution station 12 are arranged on different sides of the block storage unit 7. The two stations can also be arranged on the same side of the block storage unit 7. They can also be arranged on sides perpendicular to each other.

[0045] Figure 3 A first embodiment of the loading vehicle 6 is shown, which can move in two directions "X" and "Z". With reference to the illustration, these directions are from left to right (direction "X") and perpendicular to the drawing plane (direction "Z"). The loading vehicle 6 has a lifting device 13 with which the packaging units 5 with goods 4 can be moved in the direction of gravity and in the direction opposite to the direction of gravity, which is shown by the arrow "Y". Figure 3

[0046] If the loading vehicle 6 moves on the upper side of the block storage unit 7, the transport of the packaging units 5 proceeds downwards for storage and upwards for retrieval. This is not shown in Figure 3 .

[0047] Figure 3 The loading vehicle 6 shown in can store a single packaging unit 5 in the block storage unit 7, remove a single packaging unit therefrom and transport the single packaging unit.

[0048] Figure 4 A modified embodiment is shown, in which the loading vehicle 6 can transport two packaging units at the same time. These directions correspond to those in Figure 3 .

[0049] Furthermore, the loading vehicle 6 has an opener 14, which can be moved in the direction Y' in order to keep the aforementioned holding device open until the desired number of packaging units 5 has been removed.

[0050] Figure 5 Another option for transporting the packaging units 5 is shown.

[0051] In this case, the loading vehicle 6 transports a carriage 15, which in turn stores or removes the packaging units 5 in or from the stacking compartment 8. These directions correspond to those in Figure 3 .

[0052] The loading vehicle 6 is provided with a motor (not shown) that can operate the lifting device 13.

[0053] The rack 15 can be designed as an "active rack". In this case, the unit 16 is a motor attached to the rack and comprising a power source. In this way, the rack can autonomously perform the removal and dispensing operations without the aid of the vehicle's auxiliary drive means, since the motor M moves the lifting unit 13' connected to the rack 15 below the packaging unit 5 by means of a mechanical power transmission device (not shown).

[0054] The rack 15 can also be designed as a "passive rack". In this different case, the unit 16 is designed as a coupling device by means of which the vehicle 6 provides the drive force and the power source for the movement of the lifting device 13'. Corresponding vehicle components are coupled to the unit 16, which moves the lifting unit 13' connected to the rack 15 below the packaging unit 5 by means of a mechanical power transmission device (not shown).

[0055] In this case, an opener 14 similar to that of Figure 4 is attached to the rack 15 and fulfils the above-mentioned functions.

[0056] Figure 6 An example of a packaging unit 5 in which goods 4 are received is shown. The packaging unit has a base 17 on which the goods 4 rest. Two side walls 18 are erected on the base, which can be connected to each other by means of a rear wall 20 and a strut 19 at the front side. The rear wall 20 can also be replaced by another strut 19. The side walls 8 are higher than the goods 4, so that a plurality of packaging units 5 can be stacked on top of each other. In the simplest case, the underside of the packaging unit 5 forms a planar geometry, which can cooperate with a corresponding planar geometry on the upper side of another packaging unit in order to form a stack.

[0057] In a manner not shown in more detail, hinged walls can also be attached to the struts 19.

[0058] The base 17 can have anti-slip devices for the goods 4. Furthermore, integrated lowering elements can be provided with which the goods 4 can be lifted during removal. Furthermore, the base 17 can have slots into which load handling devices can engage, or other recesses that allow the insertion of lifting rams.

[0059] The packaging unit 5 has two mutually perpendicular filling / removal directions 21, 22. With the filling / removal direction 21, the goods 4 can be inserted into the packaging unit 5 from above or removed therefrom, for example with grippers. The other filling / removal direction 22 is perpendicular thereto, i.e. also perpendicular to the direction of gravity. This makes it possible to remove the goods 4 from the packaging unit 5 or insert them there by pushing or pulling.

[0060] Figure 7A third embodiment of the storage installation 1 is shown. Identical and functionally identical elements are provided with the same reference signs.

[0061] The storage installation 1 in turn has block storage units 7 with a plurality of stacked compartments 8 in which the packaging units 5 can be stacked. Different hatch lines show the packaging units 5, each of which comprises different objects or goods. Thus, only one type of goods or objects is arranged in each stacked compartment 8. The stacked compartments 8 are thus sorted by type.

[0062] The loading compartment 10 below the stacked compartments 8 is here designed in such a way that it is possible to drive a loading vehicle 6 with a plurality of packaging units 5 back and forth below the stacked compartments 8. This has several advantages.

[0063] As can be seen in the left half of Figure 7 the loading vehicle 6 can remove a plurality of similar packaging units 5 from the goods-in area 2 and transport them to the stacked compartments 8. It is then possible to fill the stacked compartments 8 with similar packaging units 5 in a shorter time.

[0064] This is indicated by the arrow A.

[0065] Figure 7 The right half of shows the picking operation.

[0066] The loading vehicle 6 is driven in the direction of the arrow B into the loading compartment 10 to a position C at which it can pick up a first packaging unit 5. In the present exemplary embodiment, the loading vehicle 6 picks up two packaging units 5 here.

[0067] The loading vehicle 6 then moves (arrow D) to a further position E at which it can pick up a different packaging unit 5, which however comprises a different type of goods or objects. The stack with the different packaging units (two identical and different packaging units 5) can then be moved to the goods-out area 3 (arrow F). This makes it possible to perform the sorting at the same time as the packaging units 5 are being collected, so that the picking at the goods-out area 3 can be further simplified and accelerated.

[0068] In all embodiments, it is preferable if the stacked compartments 8 are filled only with similar packaging units 5 (i.e. with a fill sorted by type).

[0069] However, it can also be a prerequisite that there are “mixed” stacked compartments 8 so that the loading vehicle 6 can reach the packaging units 5 within the stack which are not located at the lower end of the stacked compartments 8 by repositioning. This can occur if the utilization of the storage capacity is more important than the short travel times of each loading vehicle and order.

[0070] With the block storage units 7, it is possible to realize the sequencing of the goods without the need for additional buffer storage devices and thus without additional space requirements.

Claims

1. Method for operating a storage installation (1) with which goods (4) are inserted into the storage installation (1) in inward delivery containers at an inward delivery area (2), removed from the inward delivery containers, temporarily stored and removed from the storage installation (1) in a predetermined order in outward delivery containers at an outward delivery area (3), wherein, The goods (4) are transferred from the inward delivery container into stackable packaging units (5) and the packaging units (5) are temporarily stored in block storage units (7), wherein the block storage units (7) have a plurality of stack compartments (8) and each stack compartment (8) is designed to receive a stack of packaging units (5), whereby the goods (4) are removed from the block storage units (7) in an order predetermined by the dispatch area, wherein the packaging units (5) are inserted into the stack compartments (8) from below, wherein the packaging units (5) are inserted into and removed from the stack compartments (8) by means of loading vehicles (6) which can be moved in loading compartments (10) below the stack compartments (8), wherein loading vehicles (6) are used which can transport more than one packaging unit (5) at the same time and wherein the packaging units (5) are pre-sorted using the loading vehicles (6).

2. The method of claim 1, wherein, The packaging units (5) in each stack compartment (8) comprise the same type of goods (4).

3. The method of claim 1, wherein, The loading vehicles (6) can be moved in at least two different directions.

4. The method according to claim 1 or 3, characterized in that, The loading vehicles (6) are used to transport the packaging units (5) to a sorting device upstream of the dispatch area (3).

5. The method according to claim 1 or 2, characterized in that, Loading vehicles (6) are used which have a transport carriage (15), wherein the carriage (15) inserts the packaging units (5) into the stack compartments (8) and removes the packaging units from the stack compartments (8).

6. The method of claim 5, wherein, Carriages are used which have their own lifting drive and devices for connecting to the carriage and for lifting and lowering the packaging units.

7. The method of claim 5, wherein, Carriages are used which are coupled to the drive in the loading vehicle by a coupling device in order to operate devices for connecting to the carriage and for lifting and lowering the packaging units.

8. The method of claim 1 or 2, wherein, Packaging units (5) are used which have at least two different filling / removal directions (21, 22).

9. The method of claim 8, wherein, A first filling / removal direction (21) extends in the direction of gravity and a second filling / removal direction (22) extends perpendicular to the direction of gravity.

10. The method of claim 6, wherein, The lifting drive has its own power supply.

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