Mesh checking module

Abstract

A method for measuring horizontal deviation in an automated storage and retrieval system, wherein the system comprises: a guide rail system including a first set of parallel guide rails and a second set of parallel guide rails, the first set of parallel guide rails being arranged to guide a container transport vehicle to move along a first direction (X) across the top of a frame structure, and the second set of parallel guide rails being arranged perpendicular to the first set of guide rails to guide the container transport vehicle to move in a second direction (Y) perpendicular to the first direction (X), the first set of parallel guide rails and the second set of parallel guide rails dividing the guide rail system into a plurality of grid cells; at least one container transport vehicle configured to operate on the guide rail system, wherein the at least one container transport vehicle is provided with at least one orientation sensor configured to measure at least one orientation of the sensor in a three-dimensional Cartesian reference frame. Parameters; a central control unit configured to receive, transmit, and process data signals from a container transport vehicle and configured to receive and process data signals from sensors, wherein the method includes the steps of: positioning the container transport vehicle at a predetermined position on a grid; transmitting data signals from the central control unit to the container transport vehicle, thereby commanding the container transport vehicle to move a distance along the grid in one direction (X, Y); measuring at least one orientation parameter using an orientation sensor at predetermined intervals to generate orientation measurement values, the orientation measurement values ​​indicating the orientation of the container transport vehicle in a three-dimensional Cartesian reference frame; transmitting data related to the orientation measurement values ​​to the central control unit; and using the central control unit to process the orientation measurement values ​​to identify deviations of the guide rail system from predetermined values.

Description

Technical Field

[0001] The present invention relates to an automated storage and retrieval system for storing and retrieving containers, and more particularly, to a method for measuring horizontal deviations in columns of a grid. Background Technology

[0002] Figure 1 discloses a typical prior art automated storage and retrieval system 1 with a frame structure 100, and Figures 2 and 3 disclose two different prior art container handling vehicles 201 and 301 suitable for operation on such system 1.

[0003] The frame structure 100 includes a plurality of upright members 102 and a plurality of horizontal members 103, which are supported by the upright members 102. The upright members 102 and the horizontal members 103 may typically be made of metal (e.g., extruded aluminum profiles).

[0004] The frame structure 100 defines a storage grid 104, which includes rows of storage columns 105 in which storage containers 106 (also referred to as boxes) are stacked one on top of another to form a stack 107. The storage grid 104 prevents horizontal movement of the stack 107 of storage containers 106 and guides vertical movement of the containers 106, but does not typically support the storage containers 106 in any other way when stacked.

[0005] The automated storage and retrieval system 1 includes a guide rail system 108 arranged in a grid pattern across the top of a storage grid 104. Multiple container handling vehicles 201, 301 operate on the guide rail system 108 to raise and lower storage containers 106 from and into storage columns 105, and also transport storage containers 106 above the storage columns 105. The guide rail system 108 includes: a first set of parallel guide rails 110 arranged to guide the container handling vehicles 201, 301 along a first direction X across the top of the frame structure 100; and a second set of parallel guide rails 111 arranged perpendicular to the first set of guide rails 110 to guide the container handling vehicles 201, 301 in a second direction Y perpendicular to the first direction X. In this way, the guide rail system 108 defines a grid column 112 above which the container handling vehicles 201, 301 can move laterally above the storage columns 105, i.e., in a plane parallel to the horizontal XY plane.

[0006] The control system 500 of the automatic storage and retrieval system 1 is shown communicating with vehicles 200 and 300.

[0007] Each prior art container handling vehicle 201, 301 includes a vehicle body 201a, 301a and a first set of wheels 201b, 301b and a second set of wheels 201c, 301c, which enable the container handling vehicle 201, 301 to move laterally in the X and Y directions, respectively. In Figures 2 and 3, two wheels in each set are fully visible. The first set of wheels 201b, 301b are arranged to engage with two adjacent rails in the first set of guide rails 110, and the second set of wheels 201c, 301c are arranged to engage with two adjacent rails in the second set of guide rails 111. Each set of wheels 201b, 301b, 201c, 301c can be raised and lowered, such that the first set of wheels 201b, 301b and / or the second set of wheels 201c, 301c can engage with the corresponding set of guide rails 110, 111 at any time.

[0008] Each prior art container handling vehicle 201, 301 also includes a lifting device (not shown) for the vertical transport of the storage container 106, for example, lifting the storage container 106 from the storage column 105 and lowering the storage container 106 into the storage column. The lifting device includes one or more clamping / engaging devices (not shown) adapted to engage with the storage container 106, and the clamping / engaging devices can be lowered from the vehicles 201, 301, thereby allowing the position of the clamping / engaging devices relative to the vehicles 201, 301 to be adjusted in a third direction Z orthogonal to the first direction X and the second direction Y.

[0009] Conventionally and for the purposes of this application, Z=1 represents the uppermost layer of grid 104, i.e., the layer immediately below the guide rail system 108; Z=2 represents the second layer below the guide rail system 108; Z=3 represents the third layer, and so on. In the exemplary prior art grid disclosed in FIG1, Z=8 represents the bottommost layer of grid 104. Similarly, X=1...n and Y=1...n represent the position of each grid column 112 in the horizontal plane. Therefore, as an example, and using the Cartesian coordinate system X, Y, Z shown in FIG1, it can be said that the storage container identified as 106' in FIG1 occupies the grid position or cell of X=10, Y=2, Z=3. It can be said that the container transport vehicles 201, 301 travel in the Z=0 layer, and each storage column 105 can be identified by its X and Y coordinates.

[0010] Each prior art container handling vehicle 201, 301 includes a storage compartment or space for receiving and storing the storage container 106 during transport on 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 WO2015 / 193278A1, the contents of which are incorporated herein by reference.

[0011] Figure 3 shows an alternative configuration of the container handling vehicle 301 with a cantilever structure. Such a vehicle is described in detail in, for example, NO317366, the contents of which are also incorporated herein by reference.

[0012] The area occupied by the central cavity container transport vehicle 201 shown in Figure 2 can cover an area in the X and Y directions that is approximately equal in size to the lateral extent of grid column 112 (i.e., the extent of grid column 112 in the X and Y directions), for example, as described in WO2015 / 193278A1, the contents of which are incorporated herein by reference. The term “lateral” as used herein may mean “horizontal”.

[0013] Alternatively, the area occupied by the central cavity container transport vehicle 101 may be larger than the lateral area defined by the grid column 112, for example, as disclosed in WO2014 / 090684A1.

[0014] The guide rail system 108 can be a single-track guide rail system, as shown in Figure 4. Alternatively, the guide rail system 108 can be a dual-track guide rail system, as shown in Figure 5, thereby allowing container transport vehicles 201, whose occupied area generally corresponds to the lateral area defined by grid columns 112, to travel along a row of grid columns, even if another container transport vehicle 201 is located above a grid column adjacent to that row. Both single-track and dual-track guide rail systems, or a combination of single-track and dual-track guide rail arrangements in guide rail system 108, form a grid pattern in the horizontal plane P, which includes a plurality of rectangular and consistent grid positions or grid cells 122, wherein each grid cell 122 includes a grid opening 115, which is defined by a pair of tracks 110a, 110b of a first set of tracks 110 and a pair of tracks 111a, 111b of a second set of tracks 111. In Figure 5, grid cells 122 are indicated by dashed boxes.

[0015] Therefore, tracks 110a and 110b form multiple pairs of tracks extending in the X direction, which are defined by multiple rows of grid cells, and tracks 111a and 111b form multiple pairs of tracks extending in the Y direction, which are defined by multiple rows of grid cells.

[0016] As shown in Figure 6, the width Wc of each grid cell 122 is typically in the range of 30 cm to 150 cm, and the length Lc of each grid cell is typically in the range of 50 cm to 200 cm. The width Wo and length Lo of each grid opening 115 are typically 2 cm to 10 cm smaller than the width Wc and length Lc of the grid cell 122.

[0017] In the X and Y directions, adjacent grid cells are arranged to contact each other, so that there is no space between them.

[0018] In storage grid 104, most grid columns 112 are storage columns 105, i.e., in grid columns 105, storage containers 106 are stored in a stacked manner 107. However, grid 104 typically has at least one grid column 112 that is not used for storing storage containers 106, but includes a location where container handling vehicles 201, 301 can unload and / or pick up storage containers 106 so that the storage containers can be transported to an access station (not shown) where the storage containers 106 can be accessed from outside grid 104 or moved in or out of grid 104. In the art, such locations are commonly referred to as “ports,” and the grid columns 112 containing the ports can be referred to as “port columns” 119, 120. Transport to the access station can be in any direction, i.e., horizontal, inclined, and / or vertical. For example, storage container 106 can be placed in random or dedicated grid columns 112 within storage grid 104, and then picked up and transported by any container handling vehicle to ports 119, 120 for further transport to the retrieval station. Note that the term "tilted" means that the transport of storage container 106 has a conventional transport orientation between horizontal and vertical.

[0019] The grid 104 in Figure 1 includes two port columns 119 and 120. The first port column 119 may be, for example, a dedicated unloading port column, in which container handling vehicles 201, 301 can unload storage containers 106 to be transported to an access station or transfer station, and the second port column 120 may be a dedicated pick-up port column, in which container handling vehicles 201, 301 can pick up storage containers 106 that have been transported from an access station or transfer station to grid 104.

[0020] The storage station is typically a picking station or a retrieval station where product items are removed from or placed into storage container 106. At the picking station or retrieval station, storage container 106 is not typically removed from the automated storage and retrieval system 1, but is returned to grid 104 after retrieval. The port can also be used to move storage containers in or out of grid 104, such as transferring storage container 106 to another storage facility (e.g., another grid or another automated storage and retrieval system), transport vehicle (e.g., a train or truck), or production facility.

[0021] Storage containers are typically transported between ports 119 and 120 and the access station using a transmitter system.

[0022] If ports 119, 120 and the access station are located at different horizontal levels, the conveyor system may include a lifting device with vertical components for vertically transporting storage container 106 between ports 119, 120 and the access station.

[0023] The transport system can be arranged to transfer storage containers 106 between different grids, for example as described in WO2014 / 075937A1, the contents of which are incorporated herein by reference.

[0024] When access is required for a storage container 106 stored in grid 104 as shown in Figure 1, one of the container handling vehicles 201, 301 is instructed to remove the target storage container 106 from its position in grid 104 and transport it to unloading port 119. This operation involves moving the container handling vehicles 201, 301 to a grid position above the storage column 105 where the target storage container 106 is located, removing the storage container 106 from the storage column 105 using the lifting device (not shown) of the container handling vehicles 201, 301, and transporting the storage container 106 to unloading port 119. If the target storage container 106 is located deep within stack 107, i.e., one or more other storage containers 106 are located above the target storage container 106, the operation also involves temporarily moving the storage container located above it before lifting the target storage container 106 from the storage column 105. This step (sometimes referred to in the art as "digging") can be performed using the same container handling vehicle subsequently used to transport the target storage container to unloading port 119, or using one or more other cooperating container handling vehicles. Alternatively or additionally, the automated storage and retrieval system 1 may have a container handling vehicle specifically designed for the task of temporarily removing storage containers from storage column 105. After the target storage container 106 has been removed from storage column 105, the temporarily removed storage container can be returned to the original storage column 105. However, the removed storage container can alternatively be repositioned to another storage column.

[0025] When storage container 106 is to be stored in grid 104, one of the container handling vehicles 201 and 301 is instructed to pick up storage container 106 from pick-up port 120 and transport the storage container to a grid position above the storage column 105 where it will be stored. After removing any storage container located at or above the target position within the storage column stack 107, container handling vehicles 201 and 301 position storage container 106 to the desired location. The removed storage container can then be lowered back into storage column 105 or repositioned to another storage column.

[0026] In order to monitor and control the automated storage and retrieval system 1, such as monitoring and controlling the position of each storage container 106 within the grid 104, the contents of each storage container 106, and the movement of container transport vehicles 201, 301, so that the required storage container 106 can be delivered to the required location at the required time without the container transport vehicles 201, 301 colliding with each other, the automated storage and retrieval system 1 includes a control system, which is typically computerized and typically includes a database for keeping track of the storage containers 106.

[0027] Importantly, the grid on which the container handling vehicle is operating must be level and in good condition for the system to function properly. Therefore, when constructing the grid, it is crucial that the floor is strong enough to support the weight and that it is level to ensure that the container handling vehicle can travel safely and operate normally on the grid.

[0028] Mesh systems can sometimes develop serious malfunctions sufficient to impact the operation of container handling robots. Typically, these malfunctions develop slowly over time, necessitating regular monitoring of the mesh's status. If left unchecked, such malfunctions can bring container handling vehicles to a halt or even damage them, requiring the mesh to be shut down for repairs.

[0029] Another problem with grids is that their failure can manifest as height differences between grid cells and even between different upright members of the grid, potentially causing wear and tear on various components of the storage system. Containers may be damaged by scraping the sides of the column, and the column may be damaged due to the scraping of containers. Furthermore, if the lifting platform of a container handling vehicle strikes an upright member of the column while lifting and lowering containers into and out of the grid, the lifting platform of the container handling vehicle may be damaged. Moreover, container handling vehicles may suffer damage due to uneven grid surfaces. For example, if the wheels do not contact the grid during transport, the wheels and the motors powering the wheels may be damaged. Summary of the Invention

[0030] In one aspect, the present invention relates to a method for measuring horizontal deviation in an automated storage and retrieval system, wherein the system comprises:

[0031] A guide rail system includes a first set of parallel guide rails and a second set of parallel guide rails. The first set of parallel guide rails is arranged to guide a container transport vehicle to move along a first direction (X) across the top of the frame structure. The second set of parallel guide rails is arranged perpendicular to the first set of guide rails to guide the container transport vehicle to move in a second direction (Y) perpendicular to the first direction (X). The first and second sets of parallel guide rails divide the guide rail system into multiple grid cells. At least one container transport vehicle is configured to run on the guide rail system, wherein the at least one container transport vehicle is equipped with at least one orientation sensor, the at least one orientation sensor being configured to measure at least one orientation parameter of the sensor in a three-dimensional Cartesian reference frame. A central control unit is configured to... The method receives, transmits, and processes data signals from a container transport vehicle and is configured to receive and process data signals from sensors. The method includes the following steps: positioning the container transport vehicle at a predetermined position on a grid; transmitting data signals from a central control unit to the container transport vehicle to command it to move a distance along the grid in one direction (X, Y); measuring at least one orientation parameter at predetermined intervals using an orientation sensor to generate orientation measurements indicating the orientation of the container transport vehicle in a three-dimensional Cartesian reference frame; transmitting data related to the orientation measurements to the central control unit; and using the central control unit to process the orientation measurements to identify deviations of the guide rail system from predetermined values.

[0032] In addition, the orientation parameters are measured using an orientation sensor in the form of a tilt sensor, which measures the tilt of the container handling robot relative to Earth's gravity in each of the X and Y directions.

[0033] Measure the pitch angle of the container handling vehicle in each column of the grid. ) and roll angle (Θ).

[0034] An inertial measurement unit (IMU) fixed to the container transport vehicle is used to measure the pitch angle of the container transport vehicle in each column of the grid. ) and roll angle (Θ).

[0035] The method includes the following steps: calculating the height difference between the average heights of each side of a single grid cell, i.e. and .

[0036] The following formula is used to calculate the skewness value of a single grid cell based on the azimuth measurement.

[0037]

[0038] The following formula is used to calculate the skewness value of a single grid cell based on the azimuth measurement.

[0039]

[0040] The graph is generated using the skewness values ​​of each grid cell.

[0041] Plot the deviation level for each grid cell in the graph and output the graph.

[0042] Different colors are used to indicate the severity of horizontal deviations in the grid cells.

[0043] Measurements are taken using a container transport vehicle at predetermined intervals, where the predetermined interval is each grid cell in a series of grid cells of the guide rail system.

[0044] Multiple container handling vehicles operate on a guide rail system, each equipped with at least one orientation sensor. When the container handling vehicles are handling containers of the automated storage and retrieval system, each of the multiple container handling vehicles transmits its orientation measurement value to the central control unit to allow simultaneous determination of the horizontal deviation of the grid cells in different areas of the guide rail system.

[0045] When the container handling vehicle is in normal operation, it is used to measure the deviation in the guide rail system.

[0046] Maintaining a horizontal guide system in an automatic storage and retrieval system includes a method for measuring horizontal deviations in the automatic storage and retrieval system, the method comprising using the measured values ​​to adjust the upright members of the column.

[0047] In a second aspect, the present invention relates to a system for measuring horizontal deviations in an automated storage and retrieval system, wherein the system comprises: a guide rail system including a first set of parallel guide rails and a second set of parallel guide rails, the first set of parallel guide rails being arranged to guide a container transport vehicle to move along a first direction (X) across the top of a frame structure, the second set of parallel guide rails being arranged perpendicular to the first set of guide rails to guide the container transport vehicle to move in a second direction (Y) perpendicular to the first direction (X), the first set of parallel guide rails and the second set of parallel guide rails dividing the guide rail system into a plurality of grid cells; at least one container transport vehicle configured to run on the guide rail system, wherein the at least one container transport vehicle is provided with at least one An orientation sensor is configured to measure at least one orientation parameter of the sensor in a three-dimensional Cartesian reference frame; a central control unit is configured to receive, transmit, and process data signals from a container transport vehicle and to receive and process data signals from the sensor, wherein the container transport vehicle is arranged at a predetermined position on a grid; the central control unit is used to transmit data signals to the container transport vehicle to command the container transport vehicle to move along the grid; the orientation sensor is used to measure at least one orientation parameter at predetermined intervals and transmit data related to the orientation measurement values ​​to the central control unit; and the central control unit is used to process the orientation measurement values ​​to identify deviations of the guide rail system from predetermined values.

[0048] In a third aspect, the present invention relates to a graph displaying the deviation level of each grid cell in an automatic storage and retrieval system. Attached Figure Description

[0049] The following figures are attached to aid in understanding the invention. The figures illustrate embodiments of the invention, which will now be described by way of example only, in which:

[0050] Figure 1 is a perspective view of the framework structure of an existing automated storage and retrieval system.

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

[0052] Figure 3 is a perspective view of a prior art container handling vehicle having a cantilever for supporting storage containers below.

[0053] Figure 4 is a top view of the grid cells of the guide rail system, showing a single-track guide rail system along the X and Y directions.

[0054] Figure 5 is a top view of the grid cells of the guide rail system, showing a guide rail with two tracks along the X direction and a guide rail with two tracks along the Y direction.

[0055] Figure 6 is a top view of a more detailed grid cell.

[0056] Figure 7 This is a schematic diagram of one implementation of a system for recording orientation measurements.

[0057] Figure 8 It is a three-dimensional diagram showing the orientation measurement of the tilt of a container handling vehicle located above a grid cell, the orientation measurement being performed by a container handling vehicle without a pendulum mechanism.

[0058] Figure 9 It is a three-dimensional diagram showing the orientation measurement of the tilt of a container transport vehicle located above a grid cell, the orientation measurement being performed by the container transport vehicle with a pendulum mechanism.

[0059] Figure 10 This is a diagram of a guide rail system, in which the horizontal deviation (e.g., skewness) in different grid cells is shown in the form of a heat map.

[0060] Figure 11 This is a diagram of the guide rail system, in which the height differences in different grid cells are shown in the form of a topographic map. Detailed Implementation

[0061] In the following discussion, embodiments of the invention will be described in more detail with reference to the accompanying drawings. However, it should be understood that the drawings are not intended to limit the invention to the subject matter depicted in the drawings.

[0062] Although the use of wheels is described in this description, it should be understood that other types of drive mechanisms may also be used. Examples of such drive mechanisms are, for example, tracked tracks or any form of continuous track.

[0063] 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 Figures 1 to 3, namely, a plurality of upright members 102 and a plurality of horizontal members 103, the horizontal members being supported by the upright members 102, and the frame structure 100 also includes a first upper guide rail system 108 in the X and Y directions.

[0064] The frame structure 100 also includes storage compartments in the form of storage columns 105, which are arranged between the upright members 102 and the horizontal members 103, wherein storage containers 106 can be stacked into a stack 107 within the storage columns 105.

[0065] The frame structure 100 can be of any size. Specifically, it should be understood that the frame structure can be wider and / or longer and / or deeper than the frame structure disclosed in Figure 1. For example, the frame structure 100 can have a horizontal range of more than 700 × 700 columns and a storage depth of more than twelve containers.

[0066] Now refer to Figures 7 to 10 An embodiment of a method for measuring horizontal deviations in an automated storage and retrieval system according to the present invention will be discussed in more detail.

[0067] In the foregoing description, various aspects of the container handling vehicle and automated storage and retrieval system according to the invention have been described with reference to illustrative embodiments. Specific quantities, systems, and configurations have been set forth for illustrative purposes to provide a comprehensive understanding of the system and its operating principles. However, this description is not intended to be interpreted in a limiting sense. Numerous modifications and variations of the illustrative embodiments, as well as other embodiments of the system, that will be apparent to those skilled in the art to which the disclosed subject matter pertains, are considered to fall within the scope of the invention.

[0068] Figure 7 This is a schematic diagram of a system for recording orientation measurements. The diagram shows one or more sensors 701 and the data flow from the sensors to the recording device. A recorder 702 reads the data, timestamps it, and then records the data in a log 703. Recorder 702 and log 703 may be located on a remote computer 704.

[0069] Recorder 702 performs operations for each stop made by the container transport vehicle during the measurement run. In a preferred embodiment of the invention, the container transport vehicle moves from column to column on a grid and performs measurements. For each column, the sensor performs the necessary measurements. The recorder may be located on the container transport vehicle. Alternatively, the recorder may be located on a central computer system.

[0070] The measurement is performed using a sensor that measures the tilt of the grid cell relative to gravity, and thus the tilt of the storage column below relative to gravity. The tilt of the grid cell can be affected by the movement of upright members that define the corner positions of the grid cell. These upright members may shift, they may deform due to thermal and load cycles, the ground may shift, or there may be settlement issues, etc. These are all possible reasons why the top of the grid cell in an automated storage and retrieval system may become uneven over time. At least one sensor located on a container handling vehicle can be used to measure whether and by how much the guide rails on top of the storage column are off-level. This measurement can be performed by the at least one container handling vehicle as it travels along the guide rails above the grid space, moving from one storage column to the next, carrying containers being retrieved and returned for storage in the automated storage and retrieval system. Alternatively, the measurement can be performed by the at least one container handling vehicle performing an inspection operation rather than its usual container handling tasks. This measurement can be performed by first having one or more container handling vehicles scan the entire grid of the guide rail system cell by cell, and then updating the data by having the container handling vehicles repeat their paths while performing their regular tasks. In this way, information about the state of the grid space of the guide rail system can be continuously updated.

[0071] When a problem is identified in a section of the guide rail system, where one or more grid cells are tilted so severely that there is a risk of container handling vehicles traveling on that section of the grid derailing, or problems may occur when raising and lowering storage containers in the storage column, the problem can be resolved by adjusting the height of the upright members in that section of the grid or by making some other modifications so that the plane formed by the guide rails located at the top of the grid is as close to horizontal as possible.

[0072] In a preferred embodiment of the invention, sensor 701 may be an inertial measurement unit (hereinafter referred to as an IMU). An inertial measurement unit (IMU) is an electronic device that uses a combination of accelerometers, gyroscopes, and sometimes magnetometers to measure and report the specific force, angular velocity, and sometimes the orientation of a subject. An advantage of using an IMU is its low cost, which allows IMU units to be included throughout the container handling vehicle. This allows the container handling vehicle to continuously monitor the status of the grid cells and guide rail system.

[0073] In an additional embodiment of the invention, one or more sensors may be precision tilt sensors. These precision tilt sensors measure the tilt of each grid cell by measuring the pitch and roll angles of the container handling vehicle as it passes over or stops on a specific grid cell. Precision tilt sensors are very accurate, but they are also expensive, making it impractical to install them in every container handling vehicle. Therefore, while the container handling vehicle is performing its routine tasks, the sensor may not be suitable for continuous measurement of the grid state, but can be used at periodic intervals.

[0074] As an alternative to sensors permanently mounted on one or more container handling vehicles, there may be at least one sensor and a communication unit that transmits measurements to a grid inspection unit, in which data logging and calculations are performed. The sensor and communication unit are located in a box or unit that can be moved by the gripper unit of the container handling vehicle.

[0075] Figure 8 This is a three-dimensional view of the tilt angle of a container handling vehicle located above a grid space, the measurement being performed by a container handling vehicle without a pendulum mechanism.

[0076] The container handling vehicle has two wheels on each of its four sides. Therefore, there are four wheels for transporting the container handling vehicle along the X direction and four wheels for transporting the container handling vehicle along the Y direction.

[0077] In container handling vehicles without a pendulum mechanism, the set of wheels used for transporting the container in the X direction or the set of wheels used for transporting the container in the Y direction are always fixed relative to each other. That is, all wheels in the same direction are either fixed to the body of the container handling vehicle, or they are all lowered or raised by the same distance.

[0078] With this solution, it is impossible to determine whether all the wheels in one direction are in contact with the guide rail simultaneously. If the height difference between the upright members in the column is large, the container handling vehicle traveling along the storage system may become unstable and may derail, which could lead to a prolonged system downtime.

[0079] When calculating the deviation of the grid cells, and thus the height deviation of the uprights in the column, the lengths of the guide rails along both the X and Y directions (lengths X and Y in Formulas III and IV) are first considered. The lengths of the guide rails in each grid cell direction are known beforehand by the system. Subsequently, the tilt of the container handling vehicle is measured. From these two sets of parameters, the height deviation between different uprights at a specific height for each upright can be calculated.

[0080] This method simulates a robot without a pendulum mechanism (i.e., a container handling vehicle) and calculates the average angle within the cell. For each cell, the height difference between the average heights of each side of the cell is first calculated, i.e. and As shown in Formula I and Formula II

[0081] I:

[0082] II:

[0083] Then, use Formula III and Formula IV to calculate the pitch and roll angles respectively.

[0084] III:

[0085] IV:

[0086] Variable overview as follows Figure 8 As shown in the figure, the pitch angle and roll angle are respectively expressed as and Θ.

[0087] Figure 9 This is a three-dimensional view of the tilt angle of a container handling vehicle located above a column, the measurement being performed by the container handling vehicle having a pendulum mechanism.

[0088] A container handling vehicle with a pendulum mechanism is a vehicle in which ball bearings are placed between two parallel wheel sections. This pendulum mechanism ensures that all wheels of the container handling vehicle are in contact with the track in one direction, even if the tracks of the column do not have the same inclination.

[0089] Figure 9 A method for calculating the height difference in each column using a container handling vehicle with a pendulum mechanism is disclosed. The robot with the pendulum mechanism calculates the angles directly on the guide rails. First, the height difference of the upright members along the x and y directions is calculated, as shown in Equations V and VI.

[0090] V:

[0091] VI:

[0092] Subsequently, pitch and roll angles were calculated using Formulas III and IV.

[0093] Variable overview as follows Figure 9 As shown in the figure, the pitch angle and roll angle are respectively expressed as and .

[0094] For container handling vehicles that do not have a pendulum mechanism ( Figure 8 ) and container handling vehicles with pendulum mechanisms ( Figure 9 Both require a way to highlight the skewness level in each grid cell, because the heatmap (i.e., the skewness map) has only one value in each cell, while there are a total of two angles and two delta heights. There are several ways to convert these two values ​​into a single value for the heatmap.

[0095] The absolute value of the height difference in the unit is calculated using formulas VII and VIII.

[0096] VII:

[0097] VIII:

[0098] In a preferred embodiment of the invention, Formula IX is used to calculate the skewness value of a single unit.

[0099] IX:

[0100] In an alternative embodiment of the invention, formula X can be used to calculate the skewness value of a single grid cell.

[0101] X:

[0102] Figure 10 This is a diagram of a grid-based guide rail system, showing the height differences in different columns. Here, the column height differences can be seen displayed in a heatmap. This heatmap shows the location and severity of anomalies detected by the container handling vehicle in the guide rail system. The severity of the anomaly is indicated by color. Alternatively, it can be displayed using gray shading or line intensity. The color, gray shading, or line intensity indicated in the grid cells (or other forms of graphical representation) can indicate whether action is needed to remedy the anomaly. It can also indicate whether immediate action is required or whether the grid can be maintained, for example, by reducing its speed.

[0103] Figure 11 This is a diagram of a guide rail system, where the height differences within different grid cells are shown as a topographic map. This topographic map is a 3D display of the height differences within the grid. The map can show the height difference of each upright member of the grid, and this height difference is relative to the theoretical planar grid.

[0104] This solution also allows for the tracking of anomalies over time. If an area of ​​the grid develops an increasing number of anomalies over time, it may be an indication of subsidence damage. A sudden appearance of an anomaly may indicate a problem with one or more upright members in the column. This could indicate impact damage that has caused one or more upright members to bend, or it could indicate damage due to fatigue or movement due to thermal or load cycling. By studying these graphs and measurement history, indications can be given of the type of damage, what actions need to be taken, and how quickly those actions should be carried out.

[0105] This measurement can be performed periodically by one or more container handling vehicles equipped with sensors, and periodically when the grid is not in operation. Alternatively, one or more container handling vehicles operating normally on the grid can be equipped with sensors and can perform measurements while they are performing their normal tasks on the grid-based rail system.

[0106] The collected data can be used internally by the owner of the automated storage and retrieval system, or it can be shared with a global database where the collected data can be used to indicate the types of problems that may occur and how to better remedy them. If there is a settlement problem in the guide rail system, knowledge on how to avoid this type of damage in the future can be obtained from the database, and information on how to solve the problem can be stored in the database. If there is a problem with fatigue damage or cracking in the equipment, useful information is collected to indicate who is best suited to solve the problem, and if there are design problems in different parts of the storage grid, the equipment manufacturer is instructed.

[0107] An alternative method for measuring the angle of a unit in this storage system is to use a container handling vehicle with a suspension system on the wheels (such as a pendulum mechanism solution). This solution can measure the height difference between multiple wheels and calculate the angle relative to the horizontal line caused by that difference.

[0108] The pendulum mechanism solution mentioned for container handling vehicles is interchangeable with the suspension system. Any type of suspension system can be used.

[0109] If an anomaly is detected in a region of the grid, that region can be compared to the weight of the containers in that region and the weight of the container transport vehicles located on the grid in that region. If the weight of the containers and the weight of the container transport vehicles in that region are consistent with the uneven grid, the use of that part of the grid can be restricted, for example, by instructing the container transport vehicles to retrieve items similar to those stored in containers in another part of the grid. It is also possible to limit the number of container transport vehicles operating on the affected part of the grid. Moreover, the movement of container transport vehicles in that region can be restricted. Container transport vehicles can be instructed not to change direction in the affected region and to drive, for example, at a reduced speed and with slower acceleration and deceleration.

[0110] Reference tag list

[0111] Prior art (Figures 1 to 6):

[0112] 1. Existing technology for automated storage and retrieval systems

[0113] 100 Frame Structure

[0114] 102 Upright components

[0115] 103 Horizontal components

[0116] 104 Storage Grid

[0117] 105 Storage Columns

[0118] 106 Storage Containers

[0119] 106' Specific location of the storage container

[0120] 107 Stacking

[0121] 108 guide rail system

[0122] 110 First Direction ( X Parallel guide rails on

[0123] 110a First guide rail in the first direction (X)

[0124] 110b Second guide rail in the first direction (X)

[0125] 111 Second Direction ( Y Parallel guide rails on

[0126] 111a First guide rail in the second direction (Y)

[0127] 111b Second guide rail in the second direction (Y)

[0128] 112 Access Opening

[0129] 115 Grid opening

[0130] 119 First Port Column

[0131] 120 Second Port Column

[0132] 122 mesh cells

[0133] 201 Existing Technology Container Handling Vehicles

[0134] 201a Container handling vehicle 201 vehicle body

[0135] 201b Drive mechanism / wheel arrangement, first direction (X)

[0136] 201c drive mechanism / wheel arrangement, second direction (Y)

[0137] 301 Existing Technology: Cantilever Container Handling Vehicle

[0138] 301a Container handling vehicle 301 vehicle body

[0139] 301b Drive device in the first direction (X)

[0140] 301c Drive device in the second direction (Y)

[0141] 304 clamping device

[0142] 500 Control System

[0143] 701 sensor

[0144] 702 recorder

[0145] 703 Log

[0146] 704 Remote Computer

[0147] X First direction

[0148] Y Second direction

[0149] Z Third direction

Claims

1. A method for measuring horizontal deviation in an automatic storage and retrieval system, characterized in that, The system includes: A guide rail system includes: a first set of parallel guide rails arranged to guide a container transport vehicle to move along a first direction (X) across the top of a frame structure; and a second set of parallel guide rails arranged perpendicular to the first set of parallel guide rails to guide the container transport vehicle to move in a second direction (Y) perpendicular to the first direction (X), the first set of parallel guide rails and the second set of parallel guide rails dividing the guide rail system into multiple grid cells. - At least one container handling vehicle configured to operate on the guide rail system, wherein the at least one container handling vehicle is provided with at least one orientation sensor configured to measure at least one orientation parameter of the sensor in a three-dimensional Cartesian reference frame. - A central control unit configured to receive, transmit, and process data signals from the container handling vehicle and configured to receive and process data signals from the sensors. The method includes the following steps: - Position the container transport vehicle at a predetermined location on the grid. - Data signals from the central control unit are transmitted to the container transport vehicle to command the container transport vehicle to move a distance along the grid in one of the first direction (X) and the second direction (Y). - Using the orientation sensor, at least one orientation parameter is measured at predetermined intervals to generate orientation measurements indicating the orientation of the container transport vehicle within the three-dimensional Cartesian reference frame. - The data related to the orientation measurement value is transmitted to the central control unit, and - The central control unit is used to process the orientation measurement values ​​to identify any deviations of the guide rail system from predetermined values.

2. The method according to claim 1, wherein, The orientation parameters are measured using an orientation sensor in the form of a tilt sensor, which measures the tilt of the container handling robot relative to Earth's gravity in each of the first and second directions.

3. The method according to any one of the preceding claims, comprising: Measure the pitch angle of the container handling vehicle in each column of the grid. ) and roll angle (Θ).

4. The method according to claim 1, wherein, An inertial measurement unit (IMU) fixed to the container transport vehicle was used to measure the pitch angle of the container transport vehicle in each column of the grid. ) and roll angle (Θ).

5. The method according to claim 1, comprising the following steps: Calculate the height difference between the average heights of each side of a single grid cell, i.e. and .

6. The method according to claim 5, wherein, The skewness value of a single grid cell is calculated using the following formula based on the azimuth measurement. 。 7. The method according to claim 5, wherein, The skewness value of a single grid cell is calculated using the following formula based on the azimuth measurement. 。 8. The method according to claim 6 or 7, comprising: The graph is generated using the skewness values ​​of each grid cell.

9. The method of claim 8, comprising: Plot the deviation level for each grid cell in the graph and output the graph.

10. The method of claim 9, comprising: Different colors are used to indicate the severity of horizontal deviations in the grid cells.

11. The method of claim 1, further comprising using a container transport vehicle to perform measurements at predetermined intervals, wherein, The predetermined interval is the length of each grid cell in the guide rail system along the first direction (X) or the second direction (Y).

12. The method according to claim 11, wherein, Multiple container handling vehicles operate on the guide rail system, each of which is equipped with at least one orientation sensor. When a container handling vehicle is handling a container of the automated storage and retrieval system, each of the multiple container handling vehicles transmits its orientation measurement value to the central control unit to allow simultaneous determination of the horizontal deviation of grid cells in different areas of the guide rail system.

13. The method according to claim 1, comprising: When the container handling vehicle is in normal operation, the container handling vehicle is used to measure the deviation in the guide rail system.

14. A method for maintaining a horizontal guide rail system in an automatic storage and retrieval system, comprising employing a method for measuring a horizontal deviation in the automatic storage and retrieval system according to any one of the preceding claims, the maintaining method comprising using the measured value to adjust the upright members of the column.

15. A system for measuring horizontal deviations in an automatic storage and retrieval system, characterized in that, The system includes: a guide rail system comprising a first set of parallel guide rails and a second set of parallel guide rails, the first set of parallel guide rails being arranged to guide a container transport vehicle to move along a first direction (X) across the top of a frame structure, and the second set of parallel guide rails being arranged perpendicular to the first set of parallel guide rails to guide the container transport vehicle to move in a second direction (Y) perpendicular to the first direction (X), the first set of parallel guide rails and the second set of parallel guide rails dividing the guide rail system into multiple grid cells; at least one container transport vehicle configured to operate on the guide rail system, wherein the at least one container transport vehicle is provided with at least one orientation sensor, the orientation sensor being configured to measure the position of the container transport vehicle. The system includes: at least one orientation parameter of the sensor in a three-dimensional Cartesian reference frame; a central control unit configured to receive, transmit, and process data signals from the container transport vehicle and configured to receive and process data signals from the sensor, the container transport vehicle being arranged at a predetermined position on the grid; the central control unit for transmitting data signals to the container transport vehicle to command the container transport vehicle to move along the grid; an orientation sensor for measuring at least one orientation parameter at predetermined intervals and transmitting data related to the orientation measurement values ​​to the central control unit; and using the central control unit to process the orientation measurement values ​​to identify deviations of the guide rail system from predetermined values.

16. A graph displaying the deviation level of each grid cell in an automatic storage and retrieval system, characterized in that, The figure is generated by the method according to any one of claims 1 to 14 and the system according to claim 15.

Images