System and method for detecting anomalies in tracks on a three-dimensional storage system

Abstract

A system (600) and method for condition-based maintenance of an automated storage and retrieval system, the automated storage and retrieval system comprising: a frame structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, a rail system (108) arranged on the frame structure (100) to provide container handling vehicles (201) for handling and transferring storage containers (106) to and from a storage column (105), and at least one container handling vehicle having at least two sensors configured to report the status of rails of the rail system (108).

Description

[0001] The present invention relates to a system and method for condition-based monitoring of an automated storage and retrieval system, and more particularly to a system and method for condition-based monitoring of an automated storage and retrieval system for detecting anomalies in a three-dimensional storage system. Background Art

[0002] FIG. 1 discloses a common prior art automated storage and retrieval system 1 having a frame structure 100 , and FIG. 2 and FIG. 3 disclose two different prior art container handling vehicles 201 , 301 suitable for operating on such a system 1 .

[0003] The frame structure 100 includes upright members 102, horizontal members 103, and a storage volume comprising storage columns 105 arranged in rows between the upright members 102 and the horizontal members 103. In these storage columns 105, storage containers 106 (also referred to as bins) are stacked one on top of the other to form stacks 107. The members 102, 103 may typically be made of metal, such as extruded aluminum profiles.

[0004] The frame structure 100 of the automated storage and retrieval system 1 includes a rail system 108 arranged across the top of the frame structure 100. A plurality of container handling vehicles 201 and 301 operate on the rail system 108 to lift and lower storage containers 106 from and into the storage array 105, and also to transport storage containers 106 over the storage array 105. The rail system 108 includes a first set of parallel rails 110 and a second set of parallel rails 111. The first set of parallel rails is arranged to guide the container handling vehicles 201 and 301 in a first direction X across the top of the frame structure 100, and the second set of parallel rails is arranged perpendicular to the first set of rails 110 to guide the container handling vehicles 201 and 301 in a second direction Y that is perpendicular to the first direction X. Containers 106 stored in the array 105 are accessed by the container handling vehicles through access openings 112 in the rail system 108. The container handling vehicles 201 , 301 can move laterally above the storage row 105 , ie in a plane parallel to the horizontal XY plane.

[0005] Upright members 102 of frame structure 100 may be used to guide storage containers during lifting and lowering of containers from and into row 105. Stack 107 of containers 106 is generally self-supporting.

[0006] Each prior art container handling vehicle 201, 301 includes a body 201a, 301a and first and second sets of wheels 201b, 301b, 201c, 301c that enable lateral movement of the container handling vehicle 201, 301 in the X and Y directions, respectively. In Figures 2 and 3, both wheels in each set are fully visible. The first set of wheels 201b, 301b is arranged to engage two adjacent rails in the first set of rails 110, and the second set of wheels 201c, 301c is arranged to engage two adjacent rails in the second set of rails 111. At least one of the sets of wheels 201b, 301b, 201c, 301c can be raised and lowered so that the first set of wheels 201b, 301b and / or the second set of wheels 201c, 301c can engage the corresponding set of rails 110, 111 at any time.

[0007] Each prior art container handling vehicle 201, 301 also includes a lifting device (not shown) for vertically transporting storage containers 106, for example, lifting storage containers 106 from and lowering storage containers 106 into storage rows 105. The lifting device includes one or more gripping / engaging devices adapted to engage with storage containers 106 and capable of being lowered from the vehicle 201, 301 such that the position of the gripping / engaging devices relative to the vehicle 201, 301 can be adjusted in a third direction Z, which is orthogonal to the first direction X and the second direction Y. A portion of the gripping device of the container handling vehicle 301 is shown in FIG3 , where the gripping device is designated by reference numeral 304. The gripping device of the container handling vehicle 201 is located within the vehicle body 301a shown in FIG2 .

[0008] Conventionally, and for the purposes of this application, Z=1 represents the topmost level of storage containers, i.e., the level directly below rail system 108, Z=2 represents the second level below rail system 108, Z=3 represents the third level, and so on. In the exemplary prior art disclosed in FIG. 1 , Z=8 represents the bottommost level of storage containers. Similarly, X=1…n and Y=1…n represent the position of each storage column 105 on a horizontal plane. Thus, as an example, and using the Cartesian coordinate system X, Y, Z shown in FIG. 1 , the storage container designated 106 ′ in FIG. 1 can be said to occupy the storage location X=10, Y=2, Z=3. Container handling vehicles 201, 301 can be said to be traveling in the level Z=0, and each storage column 105 can be identified by its X and Y coordinates.

[0009] The storage volume of the frame structure 100 is often referred to as a grid 104, wherein the possible storage locations within the grid are referred to as storage cells. Each storage column can be identified by its position in the X-direction and the Y-direction, while each storage cell can be identified by its container number in the X-direction, the Y-direction, and the Z-direction.

[0010] Each of the prior art container handling vehicles 201, 301 includes a storage compartment or space for receiving and loading the storage container 106 while transporting the storage container 106 across the rail system 108. The storage space may include a cavity centrally located within the vehicle body 201a (as shown in FIG2 ) and as described, for example, in WO 2015 / 193278 A1, the contents of which are incorporated herein by reference.

[0011] Figure 3 shows an alternative configuration of a container handling vehicle 301 having a cantilever structure. Such a vehicle is described in detail in, for example, US Pat. No. 317,366, the contents of which are also incorporated herein by reference.

[0012] The footprint of the central cavity container handling vehicle 201 shown in FIG2 can cover an area having dimensions in the X and Y directions that are approximately equal to the lateral extent of the storage array 105, for example, as described in WO 2015 / 193278 A1, the contents of which are incorporated herein by reference. As used herein, the term "lateral" can mean "horizontal."

[0013] Alternatively, the footprint of the center cavity container handling vehicle 101 may be larger than the lateral area defined by the storage rows 105 , for example as disclosed in WO 2014 / 090684 A1.

[0014] The guide rail system 108 typically includes a guide rail with grooves into which the vehicle wheels are inserted. Alternatively, the guide rail may include upwardly protruding elements, wherein the vehicle wheels include flanges to prevent derailment. These grooves and upwardly protruding elements are collectively referred to as tracks. Each guide rail may include a single track, or each guide rail may include two parallel tracks.

[0015] WO2018146304, the contents of which are incorporated herein by reference, shows a common configuration of a guide rail system 108 , including guide rails and parallel tracks in both the X and Y directions.

[0016] In the frame structure 100, most of the columns 105 are storage columns 105, i.e., columns 105 in which storage containers 106 are stored in stacks 107. However, some columns 105 may have other purposes. In Figure 1, columns 119 and 120 are dedicated columns used by container handling vehicles 201, 301 to unload and / or pick up storage containers 106 so that the storage containers can be transported to access stations (not shown) where the storage containers 106 can be accessed from outside the frame structure 100 or moved out of or into the frame structure 100. In the art, such locations are generally referred to as "ports," and the columns in which the ports are located may be referred to as "port columns" 119, 120. Transport to the access stations can be in any direction, i.e., horizontal, inclined, and / or vertical. For example, storage containers 106 can be placed in random or dedicated rows 105 within the frame structure 100 and then picked up by any container handling vehicle and transported to the port rows 119, 120 for further transport to an access station. Note that the term "inclined" means that the transport of storage containers 106 has a general transport orientation between horizontal and vertical.

[0017] In Figure 1, the first port column 119 can be, for example, a dedicated unloading port column, where container handling vehicles 201, 301 can unload storage containers 106 to be transported to an access or transfer station, and the second port column 120 can be a dedicated picking port column, where container handling vehicles 201, 301 can pick up storage containers 106 that have been transported from an access or transfer station.

[0018] The access station may typically be a picking station or an inventory station where product items are removed from or placed into the storage container 106. At the picking station or inventory station, the storage container 106 is typically not removed from the automated storage and retrieval system 1, but is returned to the frame structure 100 after access. The port may also be used to transfer the storage container to another storage facility (e.g., another frame structure or another automated storage and retrieval system), a transport vehicle (e.g., a train or truck), or a production facility.

[0019] A conveying system including conveyors is typically employed to transport storage containers between the port rows 119, 120 and the access station.

[0020] If the port rows 119 , 120 and the access station are located at different heights, the conveying system may include a lifting device with vertical components for transporting the storage containers 106 vertically between the port rows 119 , 120 and the access station.

[0021] The conveying system may be arranged to transfer storage containers 106 between different frame structures, for example as described in WO 2014 / 075937 A1 , the contents of which are incorporated herein by reference.

[0022] When a storage container 106 stored in one of the plurality of rows 105 disclosed in FIG1 is to be accessed, one of the plurality of container handling vehicles 201, 301 is instructed to retrieve the target storage container 106 from the location where the target storage container 106 is located and transport the target storage container to the unloading port row 119. This operation includes moving the container handling vehicle 201, 301 to a position above the storage row 105 where the target storage container 106 is located, using a lifting device (not shown) of the container handling vehicle 201, 301 to retrieve the storage container 106 from the storage row 105, and transporting the storage container 106 to the unloading port row 119. If the target storage container 106 is located deep within the stack 107, i.e., one or more other storage containers 106 are located above the target storage container 106, this operation also includes temporarily moving the storage containers located above before lifting the target storage container 106 from the storage row 105. This step, sometimes referred to in the art as "digging," can be performed by the same container handling vehicle that is subsequently used to transport the target storage container to the unloading port array 119, or by one or more other cooperating container handling vehicles. Alternatively or additionally, the automated storage and retrieval system 1 can have container handling vehicles 201, 301 dedicated to the task of temporarily removing storage containers 106 from the storage array 105. After the target storage container 106 has been removed from the storage array 105, the temporarily removed storage container 106 can be replaced in the original storage array 105. However, the removed storage container 106 can alternatively be relocated to another storage array 105.

[0023] When a storage container 106 is to be stored in one of the plurality of rows 105, one of the plurality of container handling vehicles 201, 301 is instructed to pick up a storage container 106 from the pick port row 120 and transport it to a position above the storage row 105 where the storage container will be stored. After removing any storage container 106 that is at or above the target location within the stack 107, the container handling vehicle 201, 301 positions the storage container 106 at the desired location. The removed storage container 106 can then be lowered back into the storage row 105 or relocated to another storage row 105.

[0024] In order to monitor and control the automatic storage and retrieval system 1, such as monitoring and controlling the position of each storage container 106 within the frame structure 100, the contents of each storage container 106; and the movement of the container handling vehicles 201, 301, so that the desired storage container 106 can be transported to the desired position at the desired time without the container handling vehicles 201, 301 colliding with each other, the automatic storage and retrieval system 1 includes a control system 500, which is typically computerized and typically includes a database for keeping track of the storage containers 106.

[0025] One problem with storage grids is that over time, dust and dirt accumulate on the tracks where container-handling vehicles travel. This can damage the vehicles and lead to unnecessary costs and risks. Furthermore, the tracks and even the frames of the lower-level storage units can wear out over time. As it currently stands, there's no way to monitor for potential failures. If an error occurs in a problem area, the robot must stop to detect the problem. This is a costly and time-consuming way to address the issue.

[0026] Another issue with the current situation is that inspecting the storage facility's legs is not easy. If there are alignment issues in the columns, grippers, with or without containers, can collide with the columns during ascent or descent, which can lead to equipment damage over time. This requires shutting down the storage facility, which is expensive and time-consuming. Summary of the Invention

[0027] The invention is set forth and characterized in the independent claim, while the dependent claims describe further characteristics of the invention.

[0028] In one aspect, the present invention relates to a system for condition-based monitoring of an automated storage and retrieval system, the system comprising: a frame structure forming a three-dimensional storage grid structure for storing storage containers for storing items, wherein the grid structure forms vertical storage columns, each vertical storage column having a horizontal area defined by the size of an access opening of the vertical storage column, and wherein the frame structure comprises a rail system arranged above the storage columns, the rail system comprising a plurality of rails extending in an X-direction and a Y-direction to form a grid, the rails defining a boundary of each access opening on top of each storage column, the rail system extending in the X-direction Available routes are provided in the A or Y direction for container handling vehicles to carry and transfer storage containers to and from storage columns, wherein at least one container handling vehicle has two or more sensors for monitoring a section of guide rail adjacent to the container handling vehicle, and the sensors are part of a monitoring system, the sensors are configured to report the status of the guide rails of the grid system and upload such information to one or all of a central computer system, a cloud system and / or an image analysis and processing system, and wherein the two or more sensors are at least one camera and a pendulum and / or a level, and / or an accelerometer and / or a sound detection device.

[0029] Furthermore, at least one sensor may be a camera mounted on the side of the container handling vehicle in the direction of travel of the container handling vehicle such that the camera is oriented to view an area of ​​the rail system at a height below that of the at least one camera on the container handling vehicle.

[0030] Furthermore, the container handling vehicle may have cameras on all sides of the container handling vehicle such that the cameras are oriented to view an area of ​​the rail system that is at a height below that of the at least one camera on the container handling vehicle.

[0031] Additionally, the central computer system, cloud storage, and / or image analysis and processing system may be configured to process information collected by the at least one sensor.

[0032] At least one camera on each side of the container handling vehicle may be pointed downward from the horizontal at an angle between 0°-89° in the direction of travel of the container handling vehicle.

[0033] At least one camera of the container handling vehicle is mounted on a roof of the container handling vehicle, the camera being capable of pointing downwards at an angle between 0°-89° from a horizontal position.

[0034] The at least one sensor may be in the form of a pendulum and / or a level and / or an accelerometer and / or a sound detection device.

[0035] At least one sensor may be mounted on a lifting platform of the container handling vehicle.

[0036] There may be at least one sensor connected to each wheel on the container handling vehicle.

[0037] The at least one sensor may be an accelerometer that detects whether the wheel is rotating.

[0038] The container handling vehicle may have sensors for monitoring the tilt and movement of the vehicle.

[0039] The at least one sensor may be a sound detection device on the lifting platform to detect whether the container handling vehicle hits an obstacle in the cell during lifting and lowering of the container into the cell of the storage system.

[0040] At least one camera may be mounted on a lifting platform of the container handling vehicle.

[0041] In a second aspect, the present invention relates to a method for condition-based maintenance of an automated storage and retrieval system, the automated storage and retrieval system comprising: a frame structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, wherein the grid structure (104) forms vertical storage columns (105), each vertical storage column having a horizontal area defined by the size of an access opening (112) of the vertical storage column (105), and wherein the frame structure comprises a rail system (108) arranged above the storage columns (105), the rail system comprising a plurality of rails extending in an X-direction and a Y-direction to form a grid, the rails defining a boundary of each access opening (112) on the top of each storage column (105), the rail system (108) extending in the X-direction and the Y-direction The invention provides available routes for a container handling vehicle (201) to carry and transfer storage containers (106) to and from a storage column (105), wherein the method includes the following steps: moving the container handling vehicle from one vertical storage column to another vertical storage column in a storage grid; taking an image of an area of ​​the guide rails, the area including the vertical storage columns; using a pendulum and / or a level, and / or an accelerometer and / or a sound detection device connected to the container handling vehicle to collect additional information about the guide rails on the grid; uploading the images to one or all of a central computer system, a cloud system and / or an image analysis and processing system; detecting anomalies in the tracks on the grid; and the central computer system, cloud system and / or image analysis and processing system making recommendations on where to repair and / or clean the storage grid based on an analysis of the storage system.

[0042] Here, capturing the image may include capturing the image straight down along the side of the vehicle while the container handling vehicle is stationary above the vertical storage row.

[0043] Capturing the images may include capturing images of the storage grid on each side of the container handling vehicle while the container handling vehicle is stationary above the vertical storage column.

[0044] Capturing the image may include using a camera mounted pointing downward from a horizontal plane at an angle between 0°-89°.

[0045] Detecting anomalies in tracks on the grid may include using machine learning to analyze uploaded images.

[0046] Capturing the image may include using at least one additional camera mounted on a lift platform of the container handling vehicle.

[0047] Machine learning is also used to analyze uploaded images to detect anomalies in tracks on the grid, including using at least one additional camera mounted on the lifting platform of the container handling vehicle.

[0048] The above mentioned problems are solved with the invention as described in this set of claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The following drawings are attached to facilitate understanding of the present invention. The accompanying drawings illustrate embodiments of the present invention which will now be described by way of example only. In the accompanying drawings:

[0050] FIG. 1 is a perspective view of a frame structure of an automatic storage and retrieval system in the prior art.

[0051] 2 is a perspective view of a prior art container handling vehicle having a centrally located cavity for carrying storage containers therein.

[0052] 3 is a perspective view of a prior art container handling vehicle having a boom for carrying storage containers underneath.

[0053] 4 is a side view of a prior art container handling vehicle in which containers may be stored on top of the vehicle.

[0054] Figure 5a is a side view of an embodiment of the present invention wherein a container handling vehicle with a central cavity solution has a downward pointing camera mounted to the side of the vehicle.

[0055] Figure 5b is a side view of an embodiment of the present invention wherein a container handling vehicle with a central cavity solution has an outwardly pointing camera mounted to the side of the vehicle.

[0056] Figure 6 It is a perspective view of a container handling vehicle with a central cavity concept, wherein the wheel set of the container handling vehicle has a swing function.

[0057] Figure 7a is a side view of an embodiment of the present invention of a container handling vehicle with a cantilever solution, with a camera pointing downwards.

[0058] Figure 7b 1 is a side view of an embodiment of the present invention of a container handling vehicle with a cantilever solution, with a camera pointing outward.

[0059] Figure 8a is a side view of an embodiment of the present invention wherein a container handling vehicle is provided with a cantilever solution wherein the lifting platform has a camera mounted therein pointing outwardly.

[0060] Figure 8b is a side view of an embodiment of the present invention wherein a container handling vehicle with a cantilever solution has a camera mounted to the lift platform pointing downward.

[0061] Figure 9a is a side view of an embodiment of the present invention wherein a container handling vehicle with a top load solution has a camera mounted to the side pointing downward.

[0062] Figure 9b is a side view of an embodiment of the present invention wherein a container handling vehicle with a top load solution has a camera mounted to the side pointing outward.

[0063] Figure 10a is a side view of an embodiment of the present invention wherein a container handling vehicle with a central cavity solution has a roof mounted camera.

[0064] Figure 10b is a side view of an embodiment of the present invention wherein a container handling vehicle with a cantilever solution has a roof mounted camera. DETAILED DESCRIPTION

[0065] In the following, embodiments of the present invention will be discussed in more detail with reference to the accompanying drawings. It should be understood, however, that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0066] According to a preferred embodiment of the present invention, monitoring the status of the storage and retrieval system can be accomplished by at least one container handling vehicle traveling from one column to another and performing measurements.

[0067] In an alternative embodiment of the present invention, a container handling vehicle operating on the storage and retrieval system can monitor the status of the storage and retrieval system while operating.

[0068] In yet another embodiment of the present invention, at least one container handling vehicle can travel from one column to another and perform measurements at regular intervals to detect loose frames or damaged grid legs, or any other measurements that cannot be performed during normal operation. Inspection for dust, dirt, or debris in the tracks of the storage and retrieval system can be performed by the container handling vehicles during normal operation.

[0069] The frame structure 100 of the automatic storage and retrieval system 1 is constructed according to the prior art frame structure 100 described above in conjunction with Figure 1, namely a plurality of upright members 102 and a plurality of horizontal members 103, the plurality of horizontal members being supported by the plurality of upright members, and in addition, the frame structure 100 includes a first, upper guide rail system 108 in the X direction and the Y direction.

[0070] The frame structure 100 further comprises storage compartments in the form of storage rows 105 arranged between the components 102 , 103 , wherein storage containers 106 can be stacked in stacks 107 within the storage rows 105 .

[0071] The frame structure 100 can be of any size. In particular, it should be understood that the frame structure can be significantly wider and / or longer and / or deeper than that disclosed in Figure 1. For example, the frame structure 100 can have a horizontal extent of greater than 700×700 columns and a storage depth of greater than 12 containers.

[0072] FIG. 1 is a perspective view of a frame structure of an automatic storage and retrieval system in the prior art.

[0073] 2 , 3 and 4 are perspective views of prior art container handling vehicles having a centrally located cavity for carrying storage containers therein, with a cantilever solution for carrying storage containers beneath the container handling vehicle, wherein the containers are stored on top of the vehicle.

[0074] Figure 5a is a side view of an embodiment of the present invention wherein a container handling vehicle with a central cavity solution has cameras mounted to the side of the vehicle with the cameras pointing downward.

[0075] Cameras are mounted on each side of the container handling vehicle. Each camera points downward to capture an image of the track that frames the column on which the container handling vehicle is positioned. This solution provides a close-up image of the track, making it possible to determine if an object is present in the track and, alternatively, what that object is. While repairs can be made without shutting down the entire storage and retrieval system, knowing the object on the track makes it easier to determine whether it requires immediate attention or can be addressed later during a slower time of day.

[0076] Figure 5b is a side view of an embodiment of the present invention wherein a container handling vehicle with a central cavity solution has an outwardly pointing camera mounted to the side of the vehicle.

[0077] In this solution, there are cameras on each side of the container handling vehicle. The cameras are pointed downward at a certain angle. The angle of the camera can be 0°-89° downward from the horizontal line, which means from straight down to almost horizontal.

[0078] In another approach, the cameras can be movable, allowing you to have a camera on each side, which can cover 180° from straight down to straight up. This approach allows a container handling vehicle to obtain multiple images from each side of the container handling vehicle. This approach has multiple benefits. It allows a central computer system or cloud service or image analysis and processing system to obtain more images of each column. This allows analysis tools to determine how the frame or track or grid has moved due to the weight of the container handling vehicle. Therefore, if you can obtain multiple images from different angles, from different sides, and with and without weight on the track directly above the column, it is easier to determine how bad the actual situation is.

[0079] Figure 6 This is a perspective view of a container handling vehicle with a central cavity design, where the wheel sets of the container handling vehicle have an oscillation function. This oscillation function allows the two sets of wheels to move at an angle. This requires additional measuring instruments on the robot's oscillating element, and if the robot oscillates to the maximum angle, there is a risk that the unevenness of the unit will exceed the tolerance of the robot, potentially leading to a collision.

[0080] Another way to detect unevenness of the track is to add at least one electronic level. This will indicate by how many degrees the track is deviating and whether it is a wobble that, for example, a container handling vehicle can withstand or whether it requires immediate attention and blocking of part or all of the storage and retrieval system.

[0081] Figure 7a is a side view of an embodiment of the present invention of a container handling vehicle with a cantilever solution, with a camera pointing downwards.

[0082] Cameras are mounted on each side of the container handling vehicle. Each camera points downward to capture an image of the track that frames the column on which the container handling vehicle is positioned. This solution provides a close-up image of the track, making it possible to determine if an object is present in the track and, alternatively, what that object is. While repairs can be made without shutting down the entire storage and retrieval system, knowing the object on the track makes it easier to determine whether it requires immediate attention or can be addressed later during a slower time of day.

[0083] Figure 7b 1 is a side view of an embodiment of the present invention of a container handling vehicle with a cantilever solution, with a camera pointing outward.

[0084] In this solution, there are cameras on each side of the container handling vehicle. The cameras are pointed downward at a certain angle. The angle of the camera can be 0°-89° downward from the horizontal line.

[0085] In another approach, the cameras can be movable, allowing you to have a camera on each side, which can cover 180° from straight down to straight up. This approach allows a container handling vehicle to obtain multiple images from each side of the container handling vehicle. This approach has multiple benefits. It allows a central computer system, or cloud service, or image analysis and processing system to obtain more images of each column. This allows analysis tools to determine how the frame, track, or grid has moved due to the weight of the container handling vehicle. Therefore, if you can obtain multiple images from different angles, from different sides, and with and without weight on the track directly above the column, it is easier to determine how bad the actual situation is.

[0086] Figure 8a is a side view of an embodiment of the present invention wherein a container handling vehicle is provided with a cantilever solution wherein a lifting platform has a camera mounted thereon pointing outwardly.

[0087] The cameras, all pointing outward, allow the present invention to capture images as the lifting platform of the container handling vehicle is lowered into the column. This solution also allows for capturing images of the grid legs by lowering the lifting platform all the way down the column. Furthermore, since it becomes darker as you descend the column, lights can be provided on the lifting frame.

[0088] It is also possible to use other types of equipment besides cameras to check the status of the columns down the column. An example of this could be a LiDAR. This would be a good way to check the height position of the rails and the levelness of the frame down the column.

[0089] Figure 8bis a side view of an embodiment of the present invention wherein a container handling vehicle with a cantilever solution has a downwardly pointing camera mounted to a lift platform.

[0090] A camera is provided that can be moved around to cover the entire area below the lift platform. This allows the present invention to capture images as the lift platform of the container handling vehicle is lowered into the column. This solution also allows for capturing images of the grid legs by lowering the lift platform all the way down the column. Furthermore, since it becomes darker as you descend the column, a light can be provided on the lift frame.

[0091] It is also possible to use other types of equipment besides cameras to check the status of the columns down the column. An example of this could be a LiDAR. This would be a good way to check the height position of the rails and the levelness of the frame down the column.

[0092] Although Figure 8a and Figure 8b The figures in FIG show a container handling vehicle with a cantilever solution, but the technical feature of attaching one or more cameras to the lifting platform of the container handling vehicle can also be applied to the central cavity solution.

[0093] Figure 9a is a side view of an embodiment of the present invention wherein a container handling vehicle with a top load solution has a downward pointing camera mounted to the side.

[0094] Cameras are mounted on each side of the container handling vehicle. Each camera points downward to capture an image of the track that forms the frame of the column on which the container handling vehicle is positioned. This solution provides a close-up image of the track, making it possible to determine if an object is present in the track and, alternatively, what that object is. While repairs can be made without shutting down the entire storage and retrieval system, knowing what the object is on the track makes it easier to determine whether it requires immediate attention or can be addressed later during a slower time of day.

[0095] Figure 9b is a side view of an embodiment of the present invention wherein a container handling vehicle with a top load solution has an outwardly pointing camera mounted to the side.

[0096] In this solution, there are cameras on each side of the container handling vehicle. The cameras are pointed downward at a certain angle. The angle of the camera can be 0°-89° downward from the horizontal line.

[0097] In another approach, the cameras can be movable, allowing you to have a camera on each side, which can cover 180° from straight down to straight up. This approach allows a container handling vehicle to obtain multiple images from each side of the container handling vehicle. This approach has multiple benefits. It allows a central computer system, or cloud service, or image analysis and processing system to obtain more images of each column. This allows analysis tools to determine how the frame, track, or grid has moved due to the weight of the container handling vehicle. Therefore, if you can obtain multiple images from different angles, from different sides, and with and without weight on the track directly above the column, it is easier to determine how bad the actual situation is.

[0098] Figure 10a The figure is a side view of an embodiment of the present invention, in which a container handling vehicle with a central cavity solution has a roof-mounted camera. By moving the camera around, it can capture images in all directions. This balance is achieved between whether the additional investment in the number of cameras is worthwhile or whether a longer shutdown of the storage and retrieval system is more expensive. Figure 10b is a side view of an embodiment of the present invention wherein a container handling vehicle with a cantilever solution has a top mounted camera. Figure 10a The same technical features presented in , except that the top-mounted camera is installed on a container handling vehicle with a cantilever solution instead of a central cavity solution.

[0099] An additional sensor used to detect problems with unevenness in the frame of the storage and retrieval system is a motion sensor. This motion sensor can detect movement in any direction. This movement is an indication that something is wrong with the track or frame of the storage and retrieval system, and the collected information can be sent to a central computer system, a cloud service, or an image analysis and processing system to analyze where problems exist in the storage and retrieval system. The motion sensor can provide information that images cannot provide, such as if a portion of the grid collapses when weight is placed on it. If the frame collapses (give way) when a container handling vehicle drives over it, the motion sensor can provide information such as how much it collapses and in which direction it collapses. Using this stored information, it is possible to find out where there may be problems in the frame.

[0100] During analysis, there is a benefit when you take measurements of adjacent columns. This allows the analysis program to gain information about the extent and location of the problem. Therefore, in a preferred embodiment of the present invention, if a problem is identified in one of the columns, the images and measurements of the adjacent columns can be used along with the information from the problematic column to gain an estimate of the extent of the problem. This can include whether the problem developed recently or has become progressively worse over time.

[0101] Adding a sound detection device to the container handling vehicle gripper makes it possible to detect if the container handling vehicle hits an obstacle in the cell during the lifting and lowering of containers into the storage system. The sound recorder can separate the undesirable noise from the background noise of the container handling vehicle's operation.

[0102] Cameras, lidar, sound and all other types of sensors can be assembled in a container which can be held by a lifting platform of a container handling vehicle or placed on top of a container handling vehicle according to FIG. 4 .

[0103] Furthermore, the container handling vehicles may be equipped with accelerometers to detect if the wheels are slipping on the tracks.

[0104] In the preceding description, various aspects of the transport vehicle and automated storage and retrieval system according to the present invention have been described with reference to illustrative embodiments. For purposes of explanation, specific numbers, systems, and configurations have been set forth to provide a thorough understanding of the system and its operation. However, this description is not intended to be construed in a limiting sense. Various modifications and variations of the illustrative embodiments, as well as other embodiments of the system, that are apparent to those skilled in the art to which the disclosed subject matter pertains are deemed to fall within the scope of the present invention.

[0105] Reference Signs List

[0106] Prior art (Figures 1-4):

[0107] 1. Automatic storage and retrieval system of existing technology

[0108] 100 frame structure

[0109] 102 Vertical members of frame structure

[0110] 103 Horizontal members of frame structures

[0111] 104 Storage Grid

[0112] 105 storage columns

[0113] 106 Storage Containers

[0114] Specific location of the 106' storage container

[0115] 107 Stacking

[0116] 108 rail system

[0117] 110 Parallel guide rails in the first direction (X)

[0118] 110a First guide rail in the first direction (X)

[0119] 110b Second guide rail in the first direction (X)

[0120] 111 Parallel guide rails in the second direction (Y)

[0121] 111a First guide rail in the second direction (Y)

[0122] 111b Second guide rail in the second direction (Y)

[0123] 112 access opening

[0124] 119 First port column

[0125] 120 Second port column

[0126] 201 Prior Art Storage Container Vehicle

[0127] 201a Body of the storage container vehicle 201

[0128] 201b Drive / wheel arrangement in the first direction (X)

[0129] 201c Drive / wheel arrangement in the second direction (Y)

[0130] 301 Prior Art Cantilever Storage Container Vehicle

[0131] 301a Body of the storage container vehicle 301

[0132] 301b Driving device in the first direction (X)

[0133] 301c Driving device in the second direction (Y)

[0134] 304 clamping device

[0135] 500 control system

[0136] 600 Monitoring System

[0137] 701 Camera

[0138] 702 Pendulum and / or level and / or accelerometer

[0139] 703 Lidar and / or sound detection devices

[0140] X first direction

[0141] Y second direction

[0142] Z third direction

Claims

1. A system for condition-based monitoring of an automated storage and retrieval system, the automated storage and retrieval system comprising: A frame structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, wherein the grid structure (104) forms vertical storage columns (105), each of the vertical storage columns having a horizontal area defined by the size of an access opening (112) of the vertical storage column (105), and wherein the frame structure includes a rail system (108) arranged above the storage columns (105), the rail system including a plurality of rails extending in an X-direction and a Y-direction to form a grid, the rails defining a boundary of each access opening (112) on the top of each storage column (105), the rail system (108) extending in the X-direction. Or providing an available route in the Y direction for container handling vehicles (201, 301) to transport and transfer the storage containers (106) to and from the storage column (105), characterized in that at least one container handling vehicle has two or more sensors, which are used to monitor a section of the guide rail adjacent to the container handling vehicle, and the sensors are part of a monitoring system, the sensors are configured to report the status of the guide rail of the grid system and upload the information to one or all of a central computer system, a cloud system and / or an image analysis and processing system, and wherein the two or more sensors are at least one camera and a pendulum and / or a level, and / or an accelerometer and / or a sound detection device.

2. The system according to claim 1, wherein: At least one sensor is a camera mounted on a side of the container handling vehicle in the direction of travel of the container handling vehicle such that the camera is oriented to view an area of ​​the rail system at a height below that of the at least one camera on the container handling vehicle.

3. The system according to claim 1, wherein: The container handling vehicle can have cameras on all sides of the container handling vehicle such that the cameras are oriented to view an area of ​​the rail system that is at a height below that of the at least one camera on the container handling vehicle.

4. A system according to any one of the preceding claims, wherein: The central computer system, cloud storage and / or image analysis and processing system are configured to process information collected by at least one sensor.

5. A system according to any one of the preceding claims, wherein: At least one camera on each side of the container handling vehicle is pointed downward from the horizontal at an angle between 0° and 89° in the direction of travel of the container handling vehicle.

6. A system according to any one of the preceding claims, wherein: The at least one camera of the container handling vehicle is mounted on a roof of the container handling vehicle, the at least one camera pointing downward from a horizontal plane at an angle between 0°-89°.

7. The system according to claim 1, wherein: At least one sensor is mounted on the lifting platform of the container handling vehicle.

8. The system according to claim 1, wherein: There is at least one sensor connected to each wheel on the container handling vehicle.

9. The system according to claim 8, wherein: The at least one sensor is an accelerometer that detects whether the wheel is rotating.

10. The system according to claim 9, wherein: The container handling vehicle has sensors for monitoring the tilt and movement of the vehicle.

11. The system according to claim 7, wherein: At least one sensor is a sound detection device on the lifting platform to detect whether the container handling vehicle hits an obstacle in a cell during lifting and lowering of containers into the cell of the storage system.

12. A system according to any preceding claim, wherein: At least one camera is mounted on the lifting platform of the container handling vehicle.

13. A method for condition-based maintenance of an automated storage and retrieval system, the automated storage and retrieval system comprising: A frame structure (100) forming a three-dimensional storage grid structure (104) for storing storage containers (106) for storing items, wherein the grid structure (104) forms vertical storage columns (105), each of the vertical storage columns having a horizontal area defined by the size of an access opening (112) of the vertical storage column (105), and wherein the frame structure includes a rail system (108) arranged on the storage columns (105), the rail system including a plurality of rails extending in an X-direction and a Y-direction to form a grid, the rails defining a boundary of each access opening (112) on the top of each storage column (105), the rail system (108) providing an available route in the X-direction and the Y-direction for a container handling vehicle (201) to carry and transfer the storage containers (106) to and from the storage columns, wherein the method comprises the following steps: - moving a container handling vehicle from one vertical storage row to another vertical storage row in said storage grid, - taking an image of an area of ​​the rail, said area comprising the vertical storage rows, - using oscillators and / or levels, and / or accelerometers and / or sound detection devices connected to the container handling vehicles to collect additional information about the guide rails on the grid, - uploading said images to one or all of a central computer system, a cloud system and / or an image analysis and processing system, - detecting anomalies in the rails on the grid, - The central computer system, cloud system and / or image analysis and processing system makes recommendations on where to repair and / or clean the storage grid based on the analysis of the storage system.

14. The method according to claim 13, wherein Capturing the image includes capturing the image straight down the side of the container handling vehicle while the vehicle is stationary above the vertical storage row.

15. The method according to claim 13 or 14, wherein: Capturing images includes capturing images of the storage grid on each side of the container handling vehicle while the container handling vehicle is stationary above the vertical storage rows.

16. The method according to any one of claims 13 to 15, wherein Capturing the images involves using a camera mounted pointing downward from the horizontal at an angle between 0°-89°.

17. The method according to any one of claims 13 to 16, wherein Detecting anomalies in the rails on the grid includes using machine learning to analyze uploaded images.

18. The method according to any one of claims 13 to 16, wherein Capturing the image includes using at least one additional camera mounted on a lift platform of the container handling vehicle.

Images