Automated load handling system

Abstract

The automated load handling system (50) includes: A) a first automated storage and retrieval system (52) and a second automated storage and retrieval system (54), each of the first and second automated storage and retrieval systems (52, 54) including: i) a grid frame structure (1) including: a) a track system comprising a plurality of grid cells, each grid cell defining a grid opening (15); b) a plurality of storage columns, each storage column being configured to store a corresponding stack of storage containers for storing one or more items, wherein the stack of storage containers is located below the track system, such that each stack of storage containers occupies a single grid space or grid cell; ii) a plurality of robotic load handling devices (31) operating on the track system to lift and move one or more storage containers from the stack; B) at least one interface column (58) from the first and second automated storage and retrieval systems. Each of the track systems in the system has a grid opening that extends downwards, and a corresponding robot load handling device running on the track system can place and retrieve one or more storage containers through the at least one interface column (58); characterized in that the automated load handling system further includes: C) at least one transfer system (56) configured to transfer one or more storage containers or one or more items from the storage containers from at least one interface column (58) of the first automated storage and retrieval system (52) to at least one interface column of the second automated storage and retrieval system (54), and wherein the grid opening (15) of the track system of the first automated storage and retrieval system (52) is different in size from the grid opening (15) of the track system of the second automated storage and retrieval system (54), which makes the grid frame structure of the first automated storage and retrieval system configured to store storage containers of different sizes than the storage containers stored in the grid frame structure of the second automated storage and retrieval system.

Description

Technical Field

[0001] This invention relates to an automated load handling apparatus, including an automated storage and retrieval system for handling storage containers or boxes. Background Technology

[0002] Some commercial and industrial activities require systems capable of storing and retrieving large quantities of different products. Generally, warehouses for storing and retrieving products or items consist of a series of tracks accessible to conveyor systems, including lifting devices (such as forklifts) and conveyor systems that move within aisles between racks. Products or items are typically stored on pallets or other storage containers and placed on different levels of the racks. Conveyor systems, whether manually driven or automated, move back and forth in the aisles between racks, while lifting devices are used to retrieve pallets containing specific products or items from the racks. However, storing and retrieving products is very labor-intensive and time-consuming.

[0003] International publication number WO2015 / 185628A (Okado Corporation) describes a known automated storage and retrieval system in which stacks of boxes or containers are arranged within a grid frame structure. Containers, referred to as boxes or storage bins or storage containers, are stacked on top of one another to form a stack. The stacks are arranged within a grid frame structure in a storage or distribution center. The boxes or containers are accessed by a robotic load handling device (or "robot") that operates remotely on a track located at the top of the grid frame structure. While the automated storage and retrieval system taught in WO2015 / 185628A (Okado Corporation) provides a very dense system for storing items, this automated storage and retrieval system cannot organize the boxes or containers based on the specific attributes of the contents within the stored boxes or containers.

[0004] For example, sorting boxes or containers are necessary in industrial activities for airport baggage handling systems. Airport terminals around the world generally employ some form of system to inspect passenger baggage, load baggage into the aircraft's cargo hold before takeoff, and return passenger baggage at the end of the flight. The equipment required to provide this service, especially in large international airports, can be quite common. Known baggage handling systems used in airports can include check-in systems for departures and collection systems for arrivals.

[0005] Examples of baggage handling at airport check-in and collection may include the following: Passengers deposit their baggage at the terminal's check-in counter. The baggage is then placed on a conveyor belt that transports it to a ramp that guides it to a build cell located on the lower level of the building. Large international terminals may employ up to 200 or more build cells below the check-in area.

[0006] The stacking area used in this type of conventional baggage system typically includes a conveyor that carries baggage leaving the ramp from the ramp exit.

[0007] One or more manual handling personnel are assigned to each stacking area to retrieve baggage from the conveyor and transfer it to the loading station adjacent to the conveyor. Each stacking area is designated to collect baggage for a specific flight to prevent baggage from being sent to the wrong destination. The trailer and trolley transport system then pulls the baggage up the loading station along the side while the baggage is manually loaded into the unit loading device (ULD) (also known as flight tank or baggage cart).

[0008] ULDs are used to pack or organize large quantities of cargo into a single unit. This saves ground staff time and effort when loading aircraft, as fewer individual units need to be handled. Once the ULD is loaded onto trailers and trolleys, it is transported to the aircraft, and, depending on the specific aircraft, route, and any applicable rules or regulations, baggage is either stored in the ULD on the aircraft or manually unloaded onto the aircraft.

[0009] The baggage handling system described above has several problems. The conveyor belts must be located on the lower level so that baggage can be moved to the loading station and retrieved by trailers and trolleys. With multiple stacking areas, a significant amount of surface space is occupied. Furthermore, flight check-in typically takes about three hours. If baggage parked on the conveyor belts cannot be loaded into the ULD before all passengers have completed check-in, specific conveyor belts will be unusable for storing baggage from any other flights during that time.

[0010] The transfer of luggage from the ramp base to the luggage cart or ULD has been accomplished manually by lifting and positioning. However, the potential for injury from such manual work has become a concern.

[0011] Therefore, an automated load processing system that is not affected by the above problems is needed. Summary of the Invention

[0012] This invention alleviates the aforementioned problems by providing an automated load handling system (also referred to as a load handling system or automated handling system) with high storage capacity based on the storage and retrieval system described in PCT application (International Publication No. WO2015 / 185628A, Orcador Technologies). The three-dimensional mesh frame structure described in PCT application (International Publication No. WO2015 / 185628A, Orcador Technologies) is capable of storing high-density items or storage containers within a given coverage area of ​​the mesh frame structure, compared to other storage and retrieval systems known in the art. To overcome the limitation of the storage and retrieval system described in PCT application (International Publication No. WO2015 / 185628A, Orcador Technologies) in its ability to organize and / or classify one or more items in storage, this invention provides an automated load handling system comprising:

[0013] A) First and second automated storage and retrieval systems, each of the first and second automated storage and retrieval systems comprising:

[0014] i) Grid frame structure, including:

[0015] a) A track system comprising a first set of parallel tracks and tracks transversely intersecting the first set of parallel tracks in a generally horizontal plane.

[0016] A second set of parallel tracks from a first set of parallel tracks, the track system being configured as a grid comprising a plurality of grid cells.

[0017] The graphic, where each grid cell defines a grid opening, the grid opening being through a pair of phases of the first set of parallel tracks.

[0018] The adjacent track and the second set of parallel tracks define a pair of adjacent tracks;

[0019] b) Multiple storage columns, each configured to store a corresponding column for storing one or more items.

[0020] A stack of storage containers, wherein the stack of storage containers is located below the track system, which makes each storage container...

[0021] The stacking of containers occupies a single grid space or grid cell;

[0022] ii) A plurality of robot load handling devices operating on the track system.

[0023] To lift and move one or more storage containers from a stack;

[0024] B) At least one interface column, the at least one interface column extending downward from the grid opening of the track system of each of the first and second automated storage and retrieval systems, wherein a corresponding robot load handling device running on the track system is able to place and retrieve one or more storage containers through the at least one interface column.

[0025] The automated load processing system is characterized in that it further comprises:

[0026] C) At least one transfer system configured to transfer one or more storage containers or one or more items from said storage containers from at least one interface column of the first automated storage and retrieval system to at least one interface column of the second automated storage and retrieval system, and

[0027] The grid opening size of the track system of the first automated storage and retrieval system is different from that of the grid opening size of the track system of the second automated storage and retrieval system. This allows the grid frame structure of the first automated storage and retrieval system to be configured to store storage containers with different sizes than the storage containers stored in the grid frame structure of the second automated storage and retrieval system.

[0028] By providing first and second automated storage and retrieval systems, each of which includes a grid frame structure and a plurality of robotic load handling devices running on a track system for lifting and moving one or more storage containers from a stack, the load handling device according to the invention can utilize the high storage density and automation of the respective grid frame structures for storing and retrieving storage containers. To enable the automated load handling system of the invention to sort and / or organize one or more storage containers or one or more items from storage containers, the automated load handling system further includes at least one transfer system configured to transfer one or more storage containers or one or more items from storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system. The relationship between the grid frame structures of the first and second automated storage and retrieval systems provided by the at least one transfer system allows storage containers or items from storage containers to be retrieved from the first storage and retrieval system for sorting, merging, or classifying into one or more storage containers before being stored in the second storage and retrieval system. To organize one or more storage containers or items from storage containers for storage in a second storage and retrieval system, the grid openings of the track system of the first automated storage and retrieval system are of different sizes than those of the grid openings of the track system of the second automated storage and retrieval system. This causes the grid frame structure of the first automated storage and retrieval system to be configured to store storage containers of different sizes than those stored in the grid frame structure of the second automated storage and retrieval system. This results in a mismatch of grid frame structures, each mismatched grid frame structure allowing storage containers of different sizes to be stored in their respective mismatched grid frame structures and requiring at least one transfer system to transfer one or more storage containers or one or more items from storage containers between the mismatched grid frame structures. In the present invention, the size of the grid opening represents the diagonal length of the largest grid opening of the track system when the robotic load handling device moves across the track system. Preferably, the grid opening of the track system of the first automated storage and retrieval system is smaller than that of the track system of the second automated storage and retrieval system, causing the grid frame structure of the first automated storage and retrieval system to be configured to store storage containers smaller than those stored in the grid frame structure of the second automated storage and retrieval system.

[0029] Each corresponding grid frame structure of the first and second automated storage and retrieval systems includes a track system comprising a first set of parallel tracks and a second set of parallel tracks traversing the first set. The first and second sets of parallel tracks are arranged in a horizontal plane as a grid pattern comprising a plurality of grid spaces or grid cells with grid openings. Thus, the first set of parallel tracks guides the robot load handling device in the X direction, while the second set of parallel tracks guides the robot load handling device in the Y direction.

[0030] Storage containers are stored in stacks within one or more storage columns of the respective grid frame structures of the first and second storage and retrieval systems, wherein each storage container stack is configured to occupy a single grid space or grid cell. In this way, the openings of the grid cells or grid spaces correspond to the storage columns above which a load processing device running on the track system can move laterally to retrieve the storage containers from the stacks.

[0031] Each of the plurality of robotic payload handling devices includes a carrier body and a wheel assembly configured to travel in the X and Y directions on a track system of a grid frame structure above the stack. The wheel assembly includes two sets of wheels traveling on the track system. Each of the two sets of wheels is driven to move the carrier along the tracks in the X and Y directions, respectively. The first set of wheels consists of a pair of wheels at the front of the carrier and a pair of wheels at the back of the carrier, configured to engage two adjacent tracks of the first set of tracks. Similarly, the second set of wheels consists of a pair of wheels on each side of the carrier, configured to engage two adjacent tracks of the second set of tracks. When the first set of wheels engages with the first set of tracks and the second set of wheels is lifted off the tracks, the wheels can be driven by a drive mechanism encased in the carrier body to move the robotic payload handling device in the X direction. To move the payload handling device in the Y direction, the first set of wheels is lifted off the tracks, and the second set of wheels is lowered to engage with the second set of tracks. The drive mechanism can then be used to drive the second set of wheels to achieve movement in the Y direction. One or two sets of wheels can be moved vertically to lift each set of wheels off the corresponding track, thereby enabling the vehicle to move in the desired direction on the track system.

[0032] Additionally, each of the plurality of robotic load handling devices includes a container receiving space for receiving and loading storage containers during transport across the top of the grid. The container receiving space may include cavities or recesses within the carrier body, such as those described in WO2015 / 019055 (Otosto Innovations Ltd.). Alternatively, the carrier body of the load handling device may include the cantilever taught in WO2019 / 238702 (Otosto Technologies Ltd.), in which case the container receiving space is located below the cantilever of the robotic load handling device.

[0033] Each of the respective grid frame structures of the first and second storage and retrieval systems has at least one grid column, which is not used as a storage column for storing storage containers in a stack. This at least one grid column is used by a robotic load handling device to place and / or retrieve storage containers so that they can be transferred to at least one transfer system, where the contents of the storage containers can be accessed from outside the grid frame structure of the first storage and retrieval system via the at least one transfer system. In the context of this invention, the grid opening of the at least one grid column is referred to as an "interface," and the at least one grid column containing the interface is referred to as "at least one interface column." The at least one interface column extends downward from the grid opening of the track system of each of the first and second automated storage and retrieval systems. Through the respective grid opening, a corresponding robotic load handling device operating on the track system is able to place and retrieve one or more storage containers. Optionally, the at least one interface column comprises two interface columns: a first interface column is specifically used as a placement interface column and defined as a delivery interface column, where the robotic load handling device can place storage containers to at least one transfer system; and a second interface column is specifically used as a pickup interface column and defined as an inbound interface column, where the robotic load handling device can retrieve storage containers delivered from at least one transfer system to the interface column.

[0034] Optionally, at least one transfer system includes a conveyor system comprising at least one conveyor unit extending from an interface column of the mesh frame structure of a first automated storage and retrieval system to an interface column of the mesh frame structure of a second automated storage and retrieval system, thereby transporting one or more storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system. In this embodiment, at least one conveyor unit extends between the interface columns of the first and second storage and retrieval systems, allowing storage containers to be directly transferred from the first storage and retrieval system to the second storage and retrieval system, where they can be organized based on attributes of the contents of the storage containers, such as user details or flight numbers in the case of airport baggage handling systems.

[0035] To enable the transfer of contents of storage containers from a first storage and retrieval system to a second storage and retrieval system, optionally, at least one transfer system includes a pickup station or retrieval station for receiving storage containers placed from an interface column of the grid frame structure of the first automated storage and retrieval system. The pickup station allows the contents of the storage containers to be placed in at least one interface column for retrieval from outside the grid frame structure. At the retrieval station, one or more items can be retrieved from storage containers placed in at least one interface column of the grid frame structure of the first storage and retrieval system. The retrieved items can then be sorted and / or categorized for transfer to storage containers of different sizes, thereby subsequently stored in the grid frame structure of the second storage and retrieval system via their respective at least one interface column. While the pickup station described in the specific embodiments is configured to transfer the contents of storage containers from at least one interface column of a first storage and retrieval system to a storage container from at least one interface of a second storage and retrieval system via at least one transfer system, the present invention is not limited to transferring the contents of storage containers and may include transferring the storage container itself from the pickup station to storage containers of different sizes via at least one transfer system for storage in the grid frame structure of the second storage and retrieval system. Alternatively, one or more items may be placed in a separate delivery storage container, which may be placed inside the storage container for storage in the grid frame structure of the second storage and retrieval system. The delivery storage container allows one or more items in the storage container to be conveniently placed together and allows the contents of the storage container to be easily transferred to storage containers of different sizes for storage in the grid frame structure of the second storage and retrieval system.

[0036] Optionally, at least one interface column of the grid structure of the second automated storage and retrieval system includes an inbound interface column for receiving one or more storage containers transferred from at least one transfer system and an outbound interface column for delivering one or more storage containers to at least one transfer system. To transfer the contents of storage containers from a pickup station to storage containers for subsequent storage in the grid structure of the second storage and retrieval system, at least one transfer system includes a buffer for temporarily storing one or more storage containers from the outbound interface column of the first and / or second automated storage and retrieval system. Storage containers of different sizes are temporarily stored in the buffer, thereby allowing one or more items from one or more storage containers at the pickup station to be transferred to storage containers of different sizes in the buffer for subsequent transfer to the grid frame structure of the second storage and retrieval system. Alternatively, one or more storage containers can be transferred from at least one interface column of the first automated storage and retrieval system to storage containers temporarily stored in the buffer of the second automated storage and retrieval system. Optionally, the buffer includes an unloading station configured to receive one or more items retrieved from the pickup station.

[0037] Optionally, at least one transfer system includes at least one conveyor system, the at least one conveyor unit extending from the outgoing interface column of the grid frame structure of the first or second automated storage and retrieval system to the incoming interface column of the grid frame structure of the first or second automated storage and retrieval system, thereby transporting one or more storage containers in and out of their respective grid frame structures.

[0038] Optionally, at least one transfer system includes a conveyor system comprising at least one conveyor unit extending from at least one interface column of the grid frame structure of the first automated storage and retrieval system to at least one interface column of the grid frame structure of the second automated storage and retrieval system, thereby transporting one or more storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system.

[0039] Optionally, at least one transfer system includes at least one conveyor system, said at least one conveyor system comprising a first conveyor system and a second conveyor system. The first conveyor system is configured to transport one or more storage containers into and out of the grid frame structure of a first automated storage and retrieval system, and the second conveyor system is configured to transport one or more storage containers into and out of the grid frame structure of a second automated storage and retrieval system. The first conveyor system is configured to transport one or more storage containers from a shipping interface column to an receiving interface column via transfer conveyor units of the grid frame structure of the first automated storage and retrieval system. Similarly, the second conveyor system is configured to transport one or more storage containers from a shipping interface column to an receiving interface column via transfer conveyor units of the grid frame structure of the second automated storage and retrieval system.

[0040] For transporting one or more storage containers into or out of the grid frame structure of a first automated storage and retrieval system or a second automated storage and retrieval system, optionally, at least one conveyor system includes an infeed conveyor unit, an outfeed conveyor unit, and a transfer conveyor unit, wherein the outfeed conveyor unit is configured to transport storage containers from an outgoing interface column to the transfer conveyor unit in a first direction, and the infeed conveyor unit is configured to transport storage containers from the transfer conveyor unit to an incoming interface column in a second direction.

[0041] At least one conveyor system of at least one transfer system transports storage containers from a shipping interface to an inbound interface via a buffer, wherein the storage containers are temporarily stored in the buffer to receive storage containers or one or more items from storage containers delivered from the first storage and retrieval system. Optionally, the transfer conveyor unit is configured to transport storage containers from a delivery conveyor unit to an inbound conveyor unit. Optionally, the delivery conveyor unit and the inbound conveyor unit are configured such that a first direction of the delivery conveyor unit is opposite to and parallel to a second direction of the inbound conveyor unit, wherein a third direction of the transfer conveyor unit is substantially orthogonal to both the first direction of the delivery conveyor unit and the second direction of the inbound conveyor unit. In this way, storage containers leaving the grid frame structure of the second storage and retrieval system through the shipping interface travel along a substantially U-shaped path to the inbound interface of the grid structure.

[0042] The transfer of one or more items from the pickup station to the storage container in the buffer zone of the second automated storage and retrieval system can be accomplished manually or automatically. Optionally, the pickup station includes a robotic arm for transferring one or more items from one or more storage containers of the first automated storage and retrieval system delivered to the pickup station to one or more storage containers in the buffer zone of the preferred second automated storage and retrieval system's transfer conveyor unit. To assist in retrieving one or more items from the pickup station, preferably, the pickup station includes a tilting mechanism for tilting the storage container and a chute adjacent to the tilting mechanism for capturing one or more items leaving the tilting mechanism.

[0043] Optionally, the storage container of the first automated storage and retrieval system includes a shallow tray mounted on a spacer tool for perpendicularly spaced from another shallow tray in a stack of the grid frame structure of the first automated storage and retrieval system. Each shallow tray includes a bottom wall and an upwardly extending edge including one or more cuts through which one or more items within the shallow tray can be accessed when the shallow trays are stacked in the grid frame structure of the first automated storage and retrieval system.

[0044] Preferably, each of the plurality of load handling units in the first and second automated storage and retrieval systems includes a lifting mechanism comprising a gripper configured to releasably engage a storage container and a winch mechanism configured to lift the storage container above a track system. The lifting mechanism may be housed within a vehicle body and includes a lifting frame, also referred to as the gripper, adapted to releasably engage the storage container and the winch mechanism, the winch mechanism including a lifting tether wound on at least one spool and a winch motor configured to lift the storage container from the stack above the track system. The gripper may be lowered from the vehicle body to allow its position to be mounted on the top or edge of the storage container. The gripper includes a clamping element configured to clamp the edge of the storage container, thereby lifting the storage container into the container receiving space of the robotic load handling unit when the winch motor is powered.

[0045] To achieve an automated and stable process for receiving items by the automated load handling system of the present invention, the automated load handling system further includes a control system, the control system including one or more processors and memory storing instructions, the instructions being configured, when executed by the one or more processors, to:

[0046] a) Receive storage requests for items that are related to a user or at least a part of a product;

[0047] b) Generate a unique identifier that includes data related to at least a portion of the user or the product;

[0048] c) Assign the unique identifier to a storage container in the first automated storage and retrieval system;

[0049] d) Store the data associated with the unique identifier in a database.

[0050] User-related data includes, but is not limited to, the user's name and / or place of residence and / or other user-related attributes, such as workplace. Alternatively, the unique identifier may include data related to at least a portion of a product. Optionally, the automated load handling system according to the invention may form part of an assembly line in which one or more items retrieved from one or more storage containers of a first automated storage and retrieval system may be assembled together to form at least a portion or a complete product before being transferred for storage in a grid frame structure of a second automated storage and retrieval system. Optionally, at least one transfer system includes at least one assembly station for assembling one or more items from one or more storage containers of the first automated storage and retrieval system.

[0051] Preferably, a unique identifier is assigned to a storage container in the first automated storage and retrieval system by associating the storage container's grid position within the grid frame structure of the first automated storage and retrieval system with a unique identifier. One approach to assigning a user-related unique identifier to a storage container in the first automated storage and retrieval system is to associate the storage container's position within the grid frame structure of the first automated storage and retrieval system with a unique identifier. In the present invention, a track system guides a robotic load handling device to move in the X and Y directions in a horizontal plane, while a lifting mechanism is configured to move a gripper device in a third Z direction to access storage containers in a stack. In the present application, Z=1 defines the uppermost layer of the grid frame structure, i.e., the layer below the track system, Z=2 is the second layer below the track system, Z=3 is the third layer below the track system, and so on. The position of each storage container temporarily stored in the grid frame structure of the first and second storage and retrieval systems can be represented by a Cartesian coordinate system X, Y, Z. For example, a storage container may be referred to as being located at a grid position determined by a Cartesian coordinate system X, Y, Z.

[0052] In addition to assigning unique identifiers associated with their respective users to the storage containers within the grid framework of the first storage and retrieval system, the control system is further configured as follows:

[0053] a) Generate a unique identifier that includes data associated with each storage container in the second automated storage and retrieval system;

[0054] b) Assign a unique identifier to the storage container and its location within the grid framework of the second automated storage and retrieval system.

[0055] In addition to generating a unique identifier associated with the user and assigning that unique identifier to a grid location (X, Y, Z) in the first automated storage and retrieval system, the control system further generates a unique identifier including data associated with each storage container in the grid framework structure of the second automated storage and retrieval system and assigns the unique identifier of the storage container to its grid location in the grid framework structure of the second automated storage and retrieval system. In this way, the control system can correctly identify items or storage containers from the grid framework structure of the first storage and retrieval system for transfer to the correct storage container in the grid framework structure of the second storage and retrieval system. Preferably, the control system is configured to merge or organize multiple items from one or more storage containers in the first storage and retrieval system based on their respective unique identifiers to transfer them to storage containers in the grid framework structure of the second automated storage and retrieval system. One or more items, or even one or more storage containers, can be organized or merged together to transfer to storage containers in the grid framework structure of the second automated storage and retrieval system based on their respective unique identifiers. Preferably, the control system is configured to merge or organize a plurality of items from one or more storage containers in the first storage and retrieval system by merging corresponding unique identifiers associated with one or more users or at least a portion of a product. For example, if one or more items are luggage associated with one or more users, where each piece of luggage has been assigned a unique identifier including user-related data, then the control system is configured to merge or organize the luggage stored in the first storage and retrieval system based on an initial identification of their respective unique identifiers and, once identified, merging their respective unique identifiers. In the case of an assembly line, one or more items may be merged or organized together to be assembled at an assembly station into at least a portion of a product before being transferred to storage containers in the grid framework structure of a second automated storage and retrieval system.

[0056] Preferably, the control system is configured to assign a merged unique identifier associated with one or more users or at least a portion of a product to a unique identifier of a storage container in the second automated storage and retrieval system. Thus, the storage containers in the grid structure of the second automated storage and retrieval system are ready to accommodate merged items from one or more storage containers in the first automated storage and retrieval system. The unique identifier of the storage container in the second automated storage and retrieval system may correspond to the merged unique identifier of the storage container from the first automated storage and retrieval system based on user-related data, another attribute, or an attribute associated with at least a portion of a product. For example, if the automated load handling system is an automated baggage handling system, then the attribute may be data related to common travel details for one or more users, such as a flight number. Thus, the unique identifier of the storage container from both the first and second automated storage and retrieval systems may correspond to data related to flight details. Similarly, if one or more items in a storage container form at least a portion of a product, the unique identifier of one or more storage containers in the second automated storage and retrieval system may correspond to the merged unique identifier of the storage container from the first automated storage and retrieval system based on data associated with at least a portion of said product.

[0057] Preferably, the control system is further configured to, based on the corresponding unique identifier of the storage container of the second automated storage and retrieval system located in at least one transfer system, instruct one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve one or more storage containers to their respective interface columns through the following steps:

[0058] i) Associate a unique identifier associated with one or more users with a corresponding unique identifier of a storage container of a second automated storage and retrieval system located at at least one transfer system;

[0059] ii) Identify one or more storage containers in the grid frame structure of the first automated storage and retrieval system based on associating the unique identifier with the grid position of the storage container in its corresponding grid frame structure in the first automated storage and retrieval system;

[0060] iii) instructs a load processing device running on the track system of the first automated storage and retrieval system to retrieve one or more storage containers from their grid locations and move the one or more storage containers to at least one interface column of the first automated storage and retrieval system.

[0061] Dependent on the unique identifier of a storage container in a second automated storage and retrieval system located in at least one transfer system (i.e., a buffer zone), the control system is configured to associate a unique identifier from a first automated storage and retrieval system, associated with one or more users, with a corresponding unique identifier of a storage container located in at least one transfer system. Storage containers in at least one transfer system have different sizes to accommodate one or more items from the storage container or the storage container itself from the first automated storage and retrieval system. For example, a storage container from the second automated storage and retrieval system may be a unit loading device (ULD) typically used for loading baggage or cargo onto an aircraft bound for an airport. Associating the unique identifier of one or more storage containers from the first automated storage and retrieval system with the unique identifier of a storage container in the second automated storage and retrieval system located in at least one transfer system may be based, for example, on flight data. In the case of a baggage handling system, the unique identifiers of the first and second automated storage and retrieval systems may additionally include data related to the user-specified destination and booking data indicating the user's booked flight.

[0062] Once the control system has associated storage containers with unique identifiers from the first and second automated storage and retrieval systems, it identifies one or more storage containers from the first automated storage and retrieval system to package them into storage containers located in at least one transfer system from the second automated storage and retrieval system. The control system locates one or more storage containers in the grid frame structure of the first automated storage and retrieval system based on the grid position of the storage container within the corresponding grid frame structure of the first automated storage and retrieval system, with the unique identifier associated with it. The control system then instructs one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve one or more storage containers from their locations and move them to at least one interface column of the first automated storage and retrieval system. In at least one interface column, at least one transfer system is configured to transfer one or more storage containers, or one or more items from storage containers, from at least one interface column of the first automated storage and retrieval system to one or more storage containers from at least one interface column of the second automated storage and retrieval system.

[0063] The automated processing system according to the invention can be used as an airport baggage handling system, in which case the automated processing system is an automated baggage handling system, making each of the items stored in one or more storage containers in a first automated storage and retrieval system a baggage item. The unique identifier associated with the user is baggage tag data, which includes data related to the user's specified destination and booking data indicating travel details. In this case, each of the storage containers in a second automated storage and retrieval system is a unit loading device (ULD). The automated processing system is not limited to baggage handling systems and can be used in any automated processing system. For example, the automated processing system can be used for the sorting and storage of items associated with one or more users during relocation. Similarly, "user" can be broadly interpreted to encompass legal entities such as companies or cooperative organizations.

[0064] Where at least a portion of a product comprises components of a plurality of items that have been combined or organized, preferably, the control system is further configured to instruct one or more load handling devices operating on the track system of the first automated storage and retrieval system to retrieve one or more storage containers based on a unique identifier associated with at least a portion of the product, through the following steps:

[0065] i) Identify one or more storage containers comprising one or more articles, each of the one or more articles forming at least a part of the product;

[0066] ii) Locate one or more storage containers in the grid frame structure of the first automated storage and retrieval system based on the grid position of the storage container in the corresponding grid frame structure of the first automated storage and retrieval system by associating the unique identifier with the storage container;

[0067] iii) instructing one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve one or more storage containers from their grid locations and move one or more storage containers to at least one interface column of the first automated storage and retrieval system, each of the one or more storage containers comprising one or more articles for assembling at least a portion of the product.

[0068] When assembling at least a portion or the entirety of a product, the control system identifies the items or components required to assemble at least a portion of the product. Once identified, the control system positions the storage container at a corresponding grid location within a first automated storage and retrieval system and instructs one or more load handling devices operating on a track system to retrieve one or more storage containers and move them to at least one interface column of the first automated storage and retrieval system. One or more items may then be assembled together at the assembly station before being transferred to storage containers in a second automated storage and retrieval system via at least one transfer system.

[0069] The present invention further provides a method for processing one or more articles in an automated load processing system in response to one or more storage containers located in at least one transfer system from a second automated storage and retrieval system, the method comprising the steps of:

[0070] i) Identifying one or more storage containers containing one or more items by associating a unique identifier from a first automated storage and retrieval system, associated with one or more users, with one or more storage containers from a second automated storage and retrieval system, located in at least one transfer system;

[0071] ii) instructing one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve the identified one or more storage containers and move the one or more storage containers to at least one interface of the grid frame structure of the first storage and retrieval system;

[0072] iii) Transferring one or more items from the identified one or more storage containers to one or more storage containers from the second automated storage and retrieval system, located in at least one transfer system;

[0073] iv) instruct one or more load processing devices operating on the track system of the second automated storage and retrieval system to move the one or more storage containers from the at least one transfer system to the storage column of the grid frame structure of the second automated storage and retrieval system.

[0074] In the preparation for transferring one or more items or storage containers from a first automated storage and retrieval system to one or more storage containers in a second automated storage and retrieval system, the method further includes the step of instructing one or more load processing devices operating on the track system of the second automated storage and retrieval system to retrieve one or more storage containers from the grid frame structure of the second automated storage and retrieval system to the at least one transfer system, based on a unique identifier from one or more merged storage containers from the first automated storage and retrieval system.

[0075] The present invention further provides a method for assembling one or more articles from an automated load handling system according to the present invention to form at least a portion of a product, the method comprising the following steps:

[0076] i) Identify one or more storage containers comprising one or more articles and having a unique identifier associated with at least a portion of the product from the first automated storage and retrieval system;

[0077] ii) instructing one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers from their grid locations and move the one or more storage containers to at least one interface column of the first automated storage and retrieval system, each of the one or more storage containers comprising one or more articles for assembling at least a portion of the product.

[0078] iii) Assemble one or more articles from one or more storage containers to form at least a portion of the product;

[0079] iv) Transfer at least a portion of the product to one or more storage containers located in the at least one transfer system from the second automated storage and retrieval system;

[0080] v) Instructs one or more load processing devices operating on the track system of the second automated storage and retrieval system to move the one or more storage containers from the at least one transfer system to the storage column of the grid frame structure of the second automated storage and retrieval system. Attached Figure Description

[0081] The automated processing system will now be described in detail with reference to embodiments, wherein:

[0082] Figure 1 An automated processing system with first and second automated storage and retrieval systems is illustrated schematically.

[0083] Figure 2The diagram illustrates the mesh frame structure and containers;

[0084] Figure 3 schematically shown Figure 1 The track at the top of the grid frame structure shown;

[0085] Figure 4 schematically shown Figure 2 The load handling device at the top of the grid frame structure shown;

[0086] Figure 5 A single load handling unit with a container lifting tool in a lowered configuration is schematically shown.

[0087] Figure 6 A cross-sectional view of a single load handling unit with a container lifting tool in an raising and lowering configuration is schematically shown.

[0088] Figure 7 The first automated storage and retrieval system is schematically shown, which includes a grid frame structure, storage containers, and load processing devices;

[0089] Figure 8 The second automated storage and retrieval system is schematically shown, which includes a grid frame structure, storage containers, and load processing devices;

[0090] Figure 9 An automated processing system with first and second automated storage and retrieval systems is illustrated schematically.

[0091] Figure 10 The diagram schematically illustrates different views of an automated processing system with first and second automated storage and retrieval systems;

[0092] Figure 11(a) schematically illustrates the pickup station;

[0093] Figure 11(b) is Figure 7 A 3D view of the storage container;

[0094] Figure 12 A schematic view of an automated processing system with first and second automated storage and retrieval systems is shown.

[0095] Figure 13 A schematic view of an automated processing system with first and second automated storage and retrieval systems is shown.

[0096] Figure 14 A schematic view of an automated processing system with first and second automated storage and retrieval systems is shown.

[0097] Figure 15This is a block diagram showing the components of an automated processing system according to an exemplary embodiment of the present invention;

[0098] Figure 16 It is a flowchart illustrating the process of assigning a unique identifier to a storage container in a grid-frame structure;

[0099] Figure 17 It is a flowchart illustrating an exemplary specific implementation of classifying storage containers in an automated processing system;

[0100] Figure 18 It is a flowchart illustrating the application of an automated processing system to an assembly system;

[0101] Figure 19 An exemplary specific implementation of the assembly station is shown;

[0102] Figure 20 Demonstrates integration Figure 19 Automated assembly systems at assembly stations;

[0103] Figure 21 The pickup station shown in Figure 11 is adjacent to the second automated storage and retrieval system;

[0104] Figure 22 The pickup station adjacent to the second automated storage and retrieval system was showcased;

[0105] Figure 23 This is a schematic diagram of an automated processing system with first and second automated storage and retrieval systems and a transfer system.

[0106] Figure 24 This is a rear view of an automated processing system showing storage containers being loaded onto a cargo trolley;

[0107] Figure 25 A plan view of an automated processing system. Detailed Implementation

[0108] The automated processing system comprises two or more automated storage and retrieval systems. Each of the two or more automated storage and retrieval systems includes a grid frame structure and one or more load processing devices, which will be described in detail below. The storage containers of the automated storage and retrieval systems are of different sizes, and the storage containers or the items within them are sorted and / or categorized as they are transferred from one automated storage and retrieval system to another.

[0109] The present invention is described below in conjunction with a first automated storage and retrieval system and a second automated storage and retrieval system, wherein the grid opening, storage container and load processing device of the second automated storage and retrieval system are larger than those of the first automated storage and retrieval system.

[0110] The term "large mesh opening" will be used to describe the mesh opening of the second automated storage and retrieval system, while "small mesh opening" will be used to describe the mesh opening of the first automated storage and retrieval system. "Large container" or "large storage container" will be used to describe the storage container of the second automated storage and retrieval system, while "small container" or "small storage container" will be used to describe the storage container of the first automated storage and retrieval system. "Large load processing device" will be used to describe the load processing device of the second automated storage and retrieval system, while "small load processing device" will be used to describe the load processing device of the first automated storage and retrieval system. It should be understood that the automated processing system with two automated storage and retrieval systems described below is one embodiment of the present invention, while the present invention also includes automated processing systems comprising more than two automated storage and retrieval systems and having mesh openings and storage containers of more than two sizes, as well as load processors.

[0111] The size of the large storage container in the second automated storage and retrieval system can be designed such that several smaller storage containers from the first automated storage and retrieval system can be accommodated within the large container. For example, the three dimensions of the large storage container can be chosen as an integer multiple of the three dimensions of the smaller storage containers, plus some spacing allowance. For example, the length, width, and height of the large storage container can be twice the length, width, and height of the smaller storage containers, allowing eight smaller storage containers to be accommodated within one large storage container.

[0112] As an alternative to placing smaller storage containers within larger ones, one or more items can be removed from the smaller containers and placed into the larger ones. In some applications, the storage container can be a tray instead of a deep container to facilitate the removal of items from or placement of items within the container.

[0113] Automated processing systems include one or more transfer systems for transferring storage containers or items within storage containers from one automated storage and retrieval system to another. In the context of this specification, the given embodiment involves transferring a storage container from a first automated storage and retrieval system to a second automated storage and retrieval system.

[0114] Example Application

[0115] Automated processing systems have many possible applications. For example, an automated processing system can be an automated baggage handling system for handling baggage in passenger transport. For example, the storage containers in an automated storage and retrieval system can be freight containers, and the automated processing system can be used to prepare goods for shipment in freight containers. Storage containers can be used to store personal belongings and furniture for customers moving or to place belongings in long-term or short-term storage facilities. Automated processing systems can be used to fulfill vehicle orders for showrooms, retailers, or large customers, and the storage containers can contain vehicles. Automated processing systems can be used to fulfill customer orders (e.g., grocery orders) and organize orders into larger manifests for delivery to the spokes of a hub-and-spoke delivery network. Automated processing systems can be used in prefabricated or modular construction. Automated processing systems can be automated assembly lines where components from a first automated storage and retrieval system are assembled, and the assembled products are transferred to a second automated storage and retrieval system. These applications are merely non-limiting examples, and automated processing systems can be used to process any kind of goods or products or items for retail, distribution, or any other application.

[0116] Figure 1 An automated processing system 50 is schematically shown, which includes a first automated storage and retrieval system 52 and a second automated storage and retrieval system 54. From Figure 1 It is clear that the grid frame structure 1 of the two automated storage and retrieval systems differs in size: in the second automated storage and retrieval system, the spacing between the storage columns 10, storage containers 9, upright members 3, grid openings or holes 15, and load handling devices 31 are all proportionally larger than in the first automated storage and retrieval system. Figure 1 In the specific embodiment shown, the first automated storage and retrieval system 52 is configured to store a small storage container 9, while the second automated storage and retrieval system 54 is configured to store a large storage container 9.

[0117] Figure 1A transfer system 56 is also shown positioned between a first automated storage and retrieval system 52 and a second automated storage and retrieval system 54. This transfer system is used to transfer storage containers or items from storage containers from one automated storage and retrieval system to another. The transfer system may include a conveyor system extending between the first and second automated storage and retrieval systems, the conveyor system comprising one or more conveyor units. One or more interface columns 58 in the second automated storage and retrieval system 54 are used to transport large storage containers 9 into and out of the grid frame structure 1 of the second automated storage and retrieval system 54 to one of the transfer systems 56. The one or more interface columns 58 may be defined as a shipping interface column and an receiving interface column, the shipping interface column being configured to place one or more storage containers into the transfer system, and the receiving interface column being configured to retrieve one or more storage containers from the transfer system. In a similar manner, one or more interface columns 58 (not shown) of the first automated storage and retrieval system 52 are used to transport small storage containers 9 into and out of the grid frame structure 1 of the first automated storage and retrieval system 52 to the same transfer system 56. Items can then be transferred between large and small storage containers, or small storage containers 9 can be placed into or removed from large storage containers 9.

[0118] Automated storage and retrieval system

[0119] The following will combine Figure 2-6 A preferred embodiment of the automated storage and retrieval system is described.

[0120] Figure 2 A grid frame structure 1 is shown, comprising upright members 3 and horizontal members 5 and 7 supported by the upright members 3. Horizontal members 5 extend parallel to another horizontal member 5 and the illustrated x-axis. Horizontal members 7 extend parallel to another horizontal member 7 and the illustrated y-axis, and are transverse to horizontal members 5. Upright members 3 extend parallel to another upright member 3 and the illustrated z-axis, and are transverse to horizontal members 5 and 7. Horizontal members 5 and 7 form a grid pattern defining a plurality of grid spaces or grid cells 14, each grid space or grid cell 14 defining a grid opening 15. In the illustrated embodiment, containers 9 are disposed in a stack 11 below the grid cells 14 defined by the grid pattern, each grid cell 14 having one stack 11 of containers 9. The grid openings 15 provide space for the storage containers 9 to exit the grid frame structure.

[0121] In the illustrated embodiment, the stack 11 of containers 9 occupies storage columns 10, with each storage column 10 located below a grid cell 14. A storage column may be defined as the space between four upright members 3, with one upright member 3 at each corner of the storage column.

[0122] Figure 3 It shows the formation Figure 2 The grid frame structure 1 shown is part of and located in Figure 2 The illustrated grid frame structure 1 is a large-scale plan view of the partitions of the track system 13 on top of the horizontal members 5, 7. The track system 13 may be provided by the horizontal members 5, 7 themselves (e.g., formed in or on the surface of the horizontal members 5, 7) or by one or more additional components mounted on top of the horizontal members 5, 7. For example, the horizontal members 5, 7 may include rails or tracks, or rails or tracks may be mounted on top of the horizontal members. The illustrated track structure 13 includes x-direction rails or tracks 17 and y-direction rails or tracks 19, namely a first set of rails 17 extending in the x-direction and a second set of rails 19 extending in the y-direction, transverse to the first set of rails 17. The rails 17, 19 define a grid opening 15 at the center of the grid cell 14. The size of the grid opening 15 allows the container 9 to be positioned below the grid cell 14 and raised and lowered through the grid opening 15. The x-direction rails 17 are arranged in pairs and spaced apart by passages 21, while the y-direction rails 19 are arranged in pairs and spaced apart by passages 23. Other track layouts are also possible.

[0123] Figure 4 Shown in Figure 2 The storage structure 1 shown comprises a plurality of load handling devices 31 that move at the top. Load handling devices 31, also referred to as automatons 31 or robots 31, are equipped with sets of wheels to engage corresponding x or y direction tracks 17, 19, enabling the robot 31 to traverse the track structure 13 and reach specific grid cells. The illustrated pairs of tracks 17, 19, spaced apart by pathways 21, 23, allow the robot 31 to occupy (allow another to pass through) adjacent grid cells without colliding with each other.

[0124] like Figure 5 As shown in detail, robot 31 includes a body 33, in which one or more components are mounted to enable robot 31 to perform its intended functions. These functions may include moving across the grid frame structure 1 on the track structure 13 and raising or lowering container 9 (e.g., from or to stack 11) so that robot 31 can retrieve or temporarily store container 9 at a specific location defined by the grid pattern.

[0125] The illustrated robot 31 includes first and second sets of wheels 35 and 37, which are mounted on the body 33 of the robot 31 and enable the robot 31 to move along tracks 17 and 19 in the x and y directions, respectively. Specifically, the two wheels 35 are set... Figure 5 The visible short side of robot 31, while the other two wheels 35 are located on the opposite short side of robot 31 (this side and the other two wheels 35 are on...). Figure 5(Not visible in the image). Wheel 35 engages with track 17 and is rotatably mounted on the body 33 of robot 31 to allow robot 31 to move along track 17. Similarly, two wheels 37 are arranged... Figure 5 The visible wheel 31 is on the long side, while the other two wheels 37 are located on the opposite long side of the robot 31 (this side and the other two wheels 37 are on...). Figure 5 (Not visible in the middle). The wheel 37 engages with the track 19 and is rotatably mounted on the body 33 of the robot 31 to allow the robot 31 to move along the track 19.

[0126] Robot 31 also includes a container lifting tool 39 configured to raise and lower container 9. The illustrated container lifting tool 39 includes four belts or reels 41, the lower ends of which are connected to a container engagement assembly 43. The container engagement assembly 43 includes engagement tools (which may be positioned, for example, at a corner of the assembly 43, near the belts 41) configured to engage external features of container 9. For example, container 9 may have one or more holes on its upper side, with the engagement tools engaging these holes. Alternatively or supplementarily, the engagement tools may be configured to hook below the edge or margin of container 9 and / or clamp or grip container 9. The belts 41 can be wound up and down as needed to raise or lower the container engagement assembly. A winch mechanism 40 may be one or more motors or other tools configured to achieve or control the up and down winding of the belts 41.

[0127] like Figure 6 As shown, the main body 33 of the illustrated robot 31 has an upper portion 45 and a lower portion 47. The upper portion 45 is configured to cover one or more operating components (not shown). The lower portion 47 is located below the upper portion 45. The lower portion 47 includes a container receiving space or cavity for accommodating at least a portion of a container 9 that has been raised by the container lifting tool 39. The container receiving space is sized such that the container 9 fits sufficiently within the cavity to allow the robot 31 to move across the track structure 13 on top of the mesh frame structure 1, while the underside of the container 9 does not touch the track structure 13 or another part of the mesh frame structure 1. When the robot 31 has reached its intended destination, the container lifting tool 39 controls the belt 41 to lower the container gripping assembly 43 and the corresponding container 9 out of the cavity of the lower portion 47 and into the intended position. The intended position may be the stack 11 of the containers 9 or the exit point of the mesh frame structure 1 (or, if the robot 31 has moved to collect the containers 9 stored in the mesh frame structure 1, it may be the entry point of the mesh frame structure 1). The interface column provides examples of entry and exit points. Although the upper and lower portions 45, 47 are separated by a physical separator in the illustrated embodiment, in other embodiments, the upper and lower portions 45, 47 may not be separated by a specific component or a part of the body 33 of the robot 31.

[0128] In some embodiments, the container receiving space of robot 31 may not be located within the body 33 of robot 31. For example, in some embodiments, the container receiving space may be adjacent to the body 33 of robot 31, for instance, in a cantilever arrangement where the weight of the body 33 of robot 31 offsets the weight of the container to be lifted. In such embodiments, the frame or arm of container lifting tool 39 may protrude horizontally from the body 33 of robot 31, and the belt / reel 41 may be positioned at corresponding locations on the protruding frame / arm and configured to be raised and lowered from these locations to raise and lower the container into the container receiving space adjacent to the body 33. The mounting height of the frame / arm on the body 33 of robot 31 and the height of its protrusion from the body 33 of robot 31 may be selected to provide the desired effect. For example, it may be preferable that the height at which the frame / arm protrudes from the body 33 of robot 31 allows for the lifting of larger containers (or multiple containers) into the container receiving space below the frame / arm. Alternatively, the frame / arm may be configured to be lower along the main body protrusion (but still high enough to accommodate at least one container between the frame / arm and the track structure 13) to keep the robot 31's center of gravity lower when the robot 31 is loaded with the container.

[0129] To enable the robot 31 to move in the first and second directions using different wheels 35, 37, the robot 31 includes a wheel positioning mechanism for selectively engaging the first set of wheels 35 with the first set of tracks 17 or engaging the second set of wheels 37 with the second set of tracks 19. This wheel positioning mechanism is configured to raise and lower the first set of wheels 35 and / or the second set of wheels 37 relative to the body 33, thereby allowing the load handling device 31 to selectively move the tracks 17, 19 traversing the mesh frame structure 1 in either the first or second direction.

[0130] The wheel positioning mechanism may include one or more linear actuators, rotating components, or other tools for raising and lowering at least one set of wheels 35, 37 relative to the body 33 of robot 31 to disconnect and engage with tracks 17, 19. In some embodiments, only one set of wheels is configured to be raised and lowered, and the action of lowering said set of wheels effectively lifts another set of wheels away from the corresponding track, while the action of raising said set of wheels effectively lowers the other set of wheels to engage with the corresponding track. In other embodiments, both sets of wheels may be raised and lowered, which advantageously means that the body 33 of robot 31 remains substantially at the same height and therefore the weight of the body 33 and the components mounted thereon does not need to be raised and lowered by the wheel positioning mechanism.

[0131] Automated storage and retrieval systems of different sizes

[0132] Figure 7A specific implementation of the first automated storage and retrieval system 52 is illustrated schematically. The first automated storage and retrieval system 52 includes a grid frame structure 1 and a load handling device 31. As described in more detail above, the load handling device 31 operates on top of the grid frame structure 1 and traverses the track system 13 via two sets of wheels 35, 37 engaging with the x-direction track 17 and the y-direction track 19, respectively. The load handling device 31 is configured to retrieve and replace containers 9 from the container stacks 11 in the storage column 10 through grid openings 15.

[0133] Figure 8 A second automated storage and retrieval system 54 is schematically shown. The second automated storage and retrieval system includes a grid frame structure 1 and a load processing device 31, and operates in a similar manner to the first automated storage and retrieval system.

[0134] exist Figure 8 In the automated second storage and retrieval system 54 shown, the storage container 9 is housed within the cage 12 (see Figure 11(a)). As an alternative, the container engagement assembly 43 can be directly engaged with external features of the storage container 9, such as... Figure 5 As shown, the container engaging assembly 43 can engage with external features of the cage 12. For example, the cage 12 may have one or more holes on its upper side, with the engaging tool engaging these holes. Alternatively or supplementarily, the engaging tool may be configured to hook onto the underside of the cage 12 and / or clamp or grip the cage 12.

[0135] Figure 7 The storage container 9 of the first automated storage and retrieval system 52 shown is a tray, rather than a deep container, to facilitate the removal of items from or placement of items into the container. This alternative embodiment of the storage container 9 is advantageous in some applications, such as in the transfer of individual items from the small storage container of the first automated storage and retrieval system 52 to the large storage container of the second automated storage and retrieval system 54.

[0136] Transfer system

[0137] Figure 9 It schematically shows the different ones, such as Figure 7 and Figure 8 Specific embodiments of the first and second storage and retrieval systems 52, 54 and the automated processing system 50 are shown. From... Figure 9It can be seen that the two grid frame structures 1 of the first and second automated storage and retrieval systems 52 and 54 have different sizes and proportions. The storage container 9, load processing device 31, and grid hole 15 of the second automated storage and retrieval system 54 are larger in height and / or length and / or width than the corresponding storage container 9, load processing device 31, and grid hole 15 of the first automated storage and retrieval system 52. The larger storage container 9 of the second automated storage and retrieval system 54 has a larger volumetric capacity than the storage container 52 of the first automated storage and retrieval system.

[0138] Figure 10 Different views of an automated processing system 50 with first and second storage and retrieval systems 52, 54 and a transfer system 56 are schematically shown. Storage containers 9 from the second automated storage and retrieval system 54 are visible at the transfer system 56. Large storage containers 9 are transported in and out of the grid frame structure 1 of the second automated storage and retrieval system 54 via one or more interface columns 58. In the illustrated embodiment, the transfer system 56 transports the large storage containers 9 from the second automated storage and retrieval system 54 to a location adjacent to one or more pickup stations 64 of the first automated storage and retrieval system 52, where one or more items or storage containers retrieved from the first automated storage and retrieval system are transferred to one or more storage containers from the second automated storage and retrieval system. The transfer system 56 includes at least one conveyor system 60. In the illustrated embodiment, at least one conveyor system includes three conveyor units 62 extending into and out of the grid frame structure of the second automated storage and retrieval system.

[0139] The first automated storage and retrieval system 52 is provided with one or more interface rows 58 to transfer small storage containers 9 to locations adjacent to one or more pickup stations 64. At pickup stations 64, items are transferred between the small storage containers 9 of the first automated storage and retrieval system 52 and the large storage containers 9 of the second automated storage and retrieval system 54. Items can be transferred from small storage containers to large storage containers, or vice versa. In the illustrated embodiment, pickup stations 64 are provided with one or more robotic arms 76 configured to extract items from the small storage containers 9 and place them into the large storage containers 9 on the conveyor system 60. The transfer system 56 further includes a unloading station configured to receive items extracted from one or more storage containers at pickup stations 64. Thus, items extracted from storage containers of the first automated storage and retrieval system at the pickup station are transferred to storage containers at the unloading station for storage in the second automated storage and retrieval system.

[0140] Conveyor System

[0141] As mentioned above Figure 10 As described in the specific embodiment of the transfer system 56 shown, at least one conveyor system 60 includes three conveyor units 62. These three conveyor units are referred to as the outgoing conveyor unit 72, the incoming conveyor unit 74, and the transfer conveyor unit 73.

[0142] Conveyor system 60 transports storage bins or containers 9 from the interface column of the second automated storage and retrieval system 54 to the pickup station 64, which is delivered from the first automated storage and retrieval system 52, and then back to the interface column of the second automated storage and retrieval system. In one embodiment, storage bins or containers may be vertically stacked for retrieval and return to their original destination or a new destination on the grid frame structure 1 by a load handling device 31 operating on the grid frame structure 1. In one embodiment of the invention, at least one conveyor system 60 of transfer system 56 includes a plurality of conveyor units 62, namely, an infeed conveyor unit 74, at least one transfer conveyor unit 73, and an outfeed conveyor unit 72 as described above, and is configured to transport storage bins or containers 9 from the interface column of the automated storage and retrieval system to buffer 70. Storage bins or containers 9 are suspended in buffer 70. Pickup station 64 and / or unloading station are located in the buffer, which allows storage containers in the buffer to be accessed from pickup station 64 and / or unloading station. Multiple conveyor units 62 are arranged adjacent to or connected to each other, which allows the storage container 9 to be transported from one conveyor unit to an adjacent conveyor unit as it moves along the conveyor system 60. Figure 10 In one embodiment of the at least one conveyor system shown, buffer 70 is a transfer conveyor unit 73. In other embodiments, buffer 70 may be provided separately from and adjacent to at least one conveyor system 60.

[0143] The infeed conveyor unit 74, transfer conveyor unit 73, and outfeed conveyor unit 72 are on the same level. Each conveyor unit 62 may include any suitable belt, chain, and / or roller arrangement well known in the field of conveyor systems. In one embodiment, the infeed conveyor unit 74, transfer conveyor unit 73, and outfeed conveyor unit 72 include a plurality of roller conveyors for transporting storage boxes or containers along a path on the conveyor system 60. The infeed conveyor unit 74, transfer conveyor unit 73, and outfeed conveyor unit 72 are arranged such that the path of transport direction of the storage boxes or containers (as indicated by the arrow in 10) can follow a U-shaped path or an L-shaped path. The conveyor system 60 may be mounted on a roller frame. The infeed conveyor unit 74 and outfeed conveyor unit 72 are configured to accommodate a single storage container 9 at the top.

[0144] The path or transport direction of the feed into conveyor unit 74 may be parallel to and opposite to the path or transport direction of the output conveyor unit 72, such that the path or transport direction of at least one transfer conveyor unit 73 is perpendicular or orthogonal to the paths or transport directions of the feed into conveyor unit 74 and the output conveyor unit 72. In other words, the storage box or container 9 travels along the conveyor system 60 in a U-shaped path, wherein the storage container 9 leaves the automated storage and retrieval system and returns to the automated storage and retrieval system via at least one transfer conveyor unit 73, i.e., the storage container 9 changes direction twice along the conveyor system 60. Optionally, the path or transport direction of the feed into conveyor unit 74 extends longitudinally in the same transport direction as the transfer conveyor unit 73, i.e., the feed into conveyor unit 74 is an extension of the transfer conveyor unit 73. Here, the path or transport direction of the feed into conveyor unit 74 is perpendicular or orthogonal to the paths or transport directions of both transfer conveyor unit 73 and output conveyor unit 72. This causes the storage box or container 9 to travel along the conveyor system 60 in an L-shaped path, meaning the storage box or container 9 changes direction once as it travels from the interface column to the buffer. In one embodiment, the conveyor system is configured such that the path or transport direction of the storage box can follow both U-shaped and L-shaped paths along the conveyor system. The combination of the U-shaped and L-shaped paths allows the storage box or container 9 to be queued in the buffer 70 before being lifted toward the grid frame structure 1 for subsequent retrieval by the load handling device 31 running on the track system 13 of the grid frame structure 1. This allows multiple storage boxes or containers 9 to be processed by the transfer system 56. The combination of the U-shaped and L-shaped paths allows the transfer system 56 to process multiple storage boxes or containers 9 in the buffer with a relatively small width.

[0145] The transfer conveyor unit 73 extends between the infeed conveyor unit 74 and the outfeed conveyor unit 72 and may include a plurality of conveyor units 62 arranged adjacent to each other in a horizontal plane, allowing the storage bin or container 9 to be transported from one conveyor unit 62 to an adjacent conveyor unit 62. Alternatively, the at least one transfer conveyor unit 73 may be a single conveyor unit extending between the infeed conveyor unit 74 and the outfeed conveyor unit 72. Typically, one or more rollers of at least one conveyor unit 62 include an integrated drive motor, while the remaining rollers are connected to the drive rollers via belts, or they are passive.

[0146] In another embodiment, an additional conveyor unit, referred to as a deflector unit 75, is integrated into the conveyor system 60. This additional conveyor unit or deflector unit (not shown) includes one or more rollers, belts, or chains positioned laterally or interleaved between the rollers of the transfer conveyor unit 73, and is configured to be driven tangentially to the transport direction of the transfer conveyor unit 73. The additional conveyor unit or deflector unit is lowered or raised relative to the rollers of the transfer conveyor unit 73 by a lifting mechanism, such that when the deflector unit is in the raised position, it contacts the storage container 9, causing the deflector unit to drag or pull the storage box from the transfer conveyor unit 73 onto a separate surface of the buffer zone 70. The separate surface of the buffer zone 70 includes an intermediate waiting facility (not shown). While this particular embodiment describes a lifting mechanism that engages the deflector unit 75 with the storage box on the conveyor unit, other deflector units known in the art of conveyor systems are also suitable for this invention, such as conveyor balls and rail-mounted trolleys.

[0147] The control system is used to initiate the movement of the conveyor unit. The control system can send signals to one or more drive motors to start the motors and cause the conveyor unit to move. Alternatively or supplementarily, one or more sensors can be used to detect the presence of one or more storage containers, and the sensors can send signals to the control system, which can then start one or more drive motors to move one or more conveyor units.

[0148] The intermediate waiting facility is part of the buffer zone 70, configured to temporarily store one or more items or storage containers 9 in the transfer system 56. These may be storage containers from the first automated storage and retrieval system 52 and / or from the second automated storage and retrieval system 54, or items from one or more storage containers. For example, the intermediate waiting facility may temporarily store a large storage container from the second automated storage and retrieval system 54 while small storage containers from the first automated storage and retrieval system 52 or items from small storage containers are retrieved and unloaded into the large storage container (see Figure 11(a)).

[0149] Using an intermediate waiting facility improves the efficiency of automated processing systems by eliminating the need for storage containers from the first and second automated storage and retrieval systems to be simultaneously located in the transfer system. For example, items from small storage containers in the first automated storage and retrieval system 52 can be retrieved from the storage container to the intermediate waiting facility, where they can remain until a large storage container from the second automated storage and retrieval system 54 arrives at the buffer 70 of the transfer system. Once an item has been retrieved, the small storage container from the first automated storage and retrieval system 52 can be returned to the grid frame structure of the first automated storage and retrieval system 52 without waiting until the large storage container from the second automated storage and retrieval system 54 is ready to receive the item. This improves efficiency because the storage container no longer needs to wait and prevent the next storage container from being processed through the transfer system.

[0150] Although Figure 10 At least one conveyor system according to a specific embodiment of the present invention shows a conveyor system extending from the outgoing interface column to the incoming interface column of the grid frame structure of the second automated storage and retrieval system. However, at least one conveyor system may include a first conveyor system for transporting storage containers in and out of the grid frame structure of the first automated storage and retrieval system and a second conveyor system for transporting storage containers in and out of the grid frame structure of the second automated storage and retrieval system. Each of the first and second conveyor systems includes an outgoing conveyor unit, an incoming conveyor unit, and a transfer conveyor unit, wherein the transfer conveyor unit extends between the outgoing and incoming conveyor units as described above. Thus, the first conveyor system transports storage boxes or containers 9 from the outgoing interface column of the first automated storage and retrieval system to the retrieval station 64 and then back to the incoming interface column of the first automated storage and retrieval system. Similarly, the second conveyor system transports storage boxes or containers 9 from the outgoing interface column of the second automated storage and retrieval system to the unloading station and then back to the incoming interface column of the second automated storage and retrieval system. The pickup station is located or situated between the first and second conveyor systems, thereby enabling one or more items to be retrieved from storage containers on the first conveyor system and temporarily stored or unloaded into storage containers on the second conveyor system.

[0151] In another exemplary embodiment of the invention, at least one conveyor system includes at least one conveyor unit that extends directly from at least one interface column of the grid frame structure of the first automated storage and retrieval system to at least one interface column of the grid frame structure of the second automated storage and retrieval system. Thus, the first and second automated storage and retrieval systems share the same conveyor system extending between their respective grid frame structures. Therefore, the feed conveyor unit, the output conveyor unit, and the transfer conveyor unit are shared between the first and second automated storage and retrieval systems.

[0152] Weighing unit

[0153] In the case where the conveyor system 60 includes multiple conveyor units 62, one or more conveyor units 62 may include a weighing unit, or the weighing unit may be located anywhere along the conveyor system. The weighing unit is connected to at least one conveyor unit 62 and configured to weigh the storage container 9. Alternatively or supplementally, intermediate waiting facilities and / or pickup stations 64 may be equipped with one or more weighing units. The weighing unit may be a load cell or any other weighing unit well known in the art. The control panel may be configured to display the weight of the storage container 9 as items or other containers are retrieved from or loaded into the storage container. For example, during pickup station operation, the weighing unit determines the weight of the storage container 9 as one or more items are retrieved from the storage container 9. The control system is used to monitor the weight of the storage container as items are retrieved from the storage container. This allows the control system to keep track of the weight of each storage container stored within the grid frame structure.

[0154] The weighing unit prevents storage container 9 from being overloaded, as overloading could hinder the lifting mechanism of the box lifting device and / or load handling device from lifting the storage box or container. The motor of the lifting mechanism of the load handling device and / or the box lifting device is rated to bear a predetermined weight. Once the predetermined weight has been reached, the control panel display will notify the operator, either by providing a notification to the operator via the display panel or by sending a signal to the control system, indicating that the specific storage box or container has reached its weight and no further items can be added to the storage box before it is transported back to the automated storage and retrieval system. As a supplement or alternative, the lifting mechanism of one or more box lifting devices may include a weighing unit that weighs the storage box or container as it is lifted toward the grid frame structure.

[0155] Box Lifting Device

[0156] Optionally, to prevent one or more storage boxes or containers from becoming congested in the transfer system 56, the transfer system 56 additionally includes one or more box lifting devices to allow one or more storage boxes to be vertically stacked. The box lifting device includes lifting arms and a lifting mechanism. In a particular embodiment of the invention, the box lifting device includes a pair or two lifting arms. The width of the space between the lifting arms is sufficient to allow the conveyor unit 62 to pass between the lifting arms as the lifting arms descend past the conveyor unit 62. In use, the lifting arms descend to the lowest level below the conveyor unit 62, allowing the lifting arms to engage the bottom wall of the storage boxes on the conveyor unit. The storage boxes or containers are raised from the lowest position on the conveyor unit 62 to the highest position facing the grid structure 1, causing the storage boxes to be vertically spaced from the conveyor unit 62. This allows a second storage box or container to enter the conveyor unit 62 and be vertically stacked below the storage boxes or containers above it.

[0157] The container lifting device can be positioned above the feeder conveyor unit 74 that delivers storage containers into the grid frame structure 1. The feeder conveyor unit 74 and the container lifting device can be located in the interface row 58 of the grid frame structure 1. The storage box at the highest position waits until the load handling device 31 running on the upper grid frame structure 1 can retrieve the storage box or container 9 through the interface row 58. More specifically, the gripper device 43 of the load handling device 31 can grasp the storage box or container 9 at the highest level and lift it into the container receiving space of the load handling device 31. Sensors detect the retrieval of the storage box at the highest level and send a signal to the control system or controller to lower the lifting arm below the second storage box or container docked on the feeder conveyor unit 74, and then lift it to the highest level, so that the third storage box or container can be arranged on the conveyor system for the container lifting device to lift.

[0158] The container lifting device may include multiple pairs of vertically spaced lifting arms to allow multiple storage containers to be vertically stacked at different heights. For example, the first pair of lifting arms may be configured to lift a first storage container to a first height, the second pair of lifting arms may be configured to lift a second storage container to a second height, and so on. This allows multiple storage containers to be vertically stacked at different heights before being transported into the grid frame structure for storage. Furthermore, one or more container lifting devices may be arranged adjacent to each other. To save space and reduce the coverage area of ​​the transfer system 56, the first container lifting device may be located at the end of the conveyor system 60, allowing storage containers or containers to be transported into the first container lifting device along the same path of the conveyor system 60. If the first container lifting device is fully occupied, the conveyor system may be instructed to redirect the storage containers into an adjacent second container lifting device in a direction perpendicular to the conveyor system 60. This can be achieved by controlling the movement of the containers using the deflecting conveyor unit 75 described above to transport the storage containers into the second container lifting device. Here, the control system or a separate controller monitors the occupancy of the first and second container lifting devices and determines whether to transport the storage container into the first or second container lifting device based on the occupancy status. The occupancy status of the container lifting device is determined by detecting the presence of storage boxes or containers using one or more sensors. Examples of sensors include, but are not limited to, proximity sensors, such as light sensors.

[0159] The use of multiple box lifting devices allows for a greater throughput of storage boxes or containers via transfer system 56. The number of box lifting devices is not limited to two, and the feed conveyor unit 74 can be configured to allow multiple box lifting devices to be located at the receiving end of the transfer conveyor unit.

[0160] One or more container lifting devices may include at least two guides for vertically guiding the storage box or container as it is lifted by the lifting arm. In one embodiment, four guides are positioned at the four corners of the container lifting device. The guides are received in interface column 58. Similarly, a bracket may be used to connect the highest part of the container lifting device to the interface column of the grid frame structure 1. The bracket includes guides for guiding the storage box or container into the interface column. This allows the container lifting device to be a separate component of the grid frame structure – and therefore has the ability to be retrofitted into an existing grid frame structure. One or more container lifting devices have sidewalls or plates externally mounted to at least a portion of the guides to surround the container lifting device and prevent components of the container lifting device, such as the lifting arm, from being exposed.

[0161] Pickup station

[0162] Figure 11(a) shows a more detailed embodiment of the pickup station or collection station 64. Conveyor units 62 of the conveyor system 60 transport large storage containers 9 from the second automated storage and retrieval system 52 to a location adjacent to the pickup station 64, thereby allowing items or small storage containers 9 at the pickup station to be transferred to the large storage container 9. The small storage containers 9, located at the pickup station, have been transported there via one or more interface columns 58 of the first automated storage and retrieval system 52 (not shown). In this specific embodiment, the small storage container 9 is a shallow tray 8 (see Figure 11(b)), and the item 6 is stored within the tray 8 (see Figure 11(b)). When used as a definition of the invention, "shallow" tray is interpreted as a shallow container with a raised or upwardly extending outer edge or rim. The upwardly extending rim 8b of the shallow tray 8 ensures that the gripper 39 of the load handling device 31 operating on the track system 13 can grip the storage container 9 including the shallow tray 8 and lift it from the stack 11. In an exemplary embodiment of the invention, the gripper 39 releasably engages the upwardly extending rim 8 of the shallow tray 8. The upwardly extending rim 8b also prevents the item 6 from falling off the shallow tray.

[0163] One problem with storing one or more items 6 within a conventional box-like structure of a storage container 9, including a bottom wall and opposing side and end walls extending upwards, is that when temporarily stored in a stack 11, the contents of the storage container 9 can only be accessed from the opening or open end of the storage container. This requires a load handling device 31 running on the track system 13 to lift the storage container 9 from its grid position to access its contents. However, accessing the interior of the storage container temporarily stored in the stack 11 can become cumbersome if one or more load handling devices 31 are out of service on the track system 13. In the worst-case scenario, one or more storage containers 9 must be lifted from the stack 11 to retrieve and thereby access the contents within the interior space of the target storage container 9 in the stack. To mitigate this problem, the contents of the storage container 9 can be placed on the outer wall of the storage container 9, rather than inside the storage container. This helps to expose the contents of the storage container, allowing access to the contents from the side of the storage container. In the specific embodiment shown in Figure 11(b), using a shallow dish 8 to store one or more items 6 allows for easier access to the contents of the storage container 9 from the side of the storage container, and therefore eliminates the need to elevate the storage container to access its open end.

[0164] To stack a plurality of shallow trays 8 on top of another, in one exemplary embodiment of the invention, the shallow trays 8 are mounted on legs or supports 8c such that the shallow trays 8 are vertically spaced above vertically adjacent shallow trays 8 in the stack 11 of the grid frame structure 1. The stacking of the shallow trays 8 is as follows: Figure 7 As shown above, Figure 7The grid frame structure shown is an embodiment of the grid frame structure of the first automated storage and retrieval system 52. Figure 11(b) shows a perspective view of a storage container 9 according to an exemplary embodiment of the present invention, wherein the storage container 9 is shaped such that a shallow tray 8 is mounted on legs 8c to raise the shallow tray 8 above a vertically adjacent storage container 9 located below in the stack 11. Figure 7 As clearly shown, each shallow tray 8 in the stack 11 is vertically spaced from other trays in the stack by mounting the shallow tray 8 on a leg or support 8c. Each leg 8c extends along the longitudinal length of the shallow tray 8 shown in FIG. 11(b), but other means of vertically spaced the shallow trays in the stack 11 are also applicable to the invention, since mounting the shallow tray 8 on the leg 8c to vertically raise the shallow tray 8 is not necessary. For example, the shallow tray 8 may form an outer wall or external wall of a box-like structure with opposite sidewalls and endwalls. Using legs to vertically raise the shallow tray helps reduce the weight of the storage container. The leg 8c is configured to rest on the surface of the shallow tray 8 of the vertically adjacent storage container below in the stack 11 (see...). Figure 7 ).

[0165] The upward-extending edge 8b of the shallow tray functions as a barrier to prevent one or more items 6 from escaping the storage container 9. In a specific embodiment shown in Figure 11(b), the upward-extending edge 8b includes one or more cuts 8d to allow easier lateral access to the interior of the shallow tray 8. As shown in Figure 11(b), the cuts 8d in the edge of the shallow tray 8 are oriented such that the cuts 8d of vertically adjacent storage containers in the stack 11 all face the same direction (or are aligned), exposing the interior of the vertically adjacent shallow trays to one side of the stack, for example, along the aisles of the grid frame structure. If any load handling device 31 stops operating on the track system 13, the contents of the storage container 9 can still be accessed through the cuts 8d in the edge of the shallow tray 8. Figure 7 In the illustrated embodiment, for example, an operator can retrieve the contents 6 of the storage container 9 by walking along the aisle exposed by the contents of the storage container 9.

[0166] To ensure that one or more items 6 do not fall off the shallow dish 8 when the storage container is moved, a recess or downwardly sloping bottom wall may be formed on the bottom wall 8e of the shallow dish 8, thereby guiding one or more items 6 resting on the bottom wall 8e toward the recess under their own weight. In the specific embodiment shown in FIG11(b), the recess is a pit extending from the edge of the bottom wall 8e. Although the storage container 9 shown in the specific embodiment of FIG11(b) is a separate component, the storage container 9, including the shallow dish 8 and the upwardly extending edge 8b, can be formed as a single unit.

[0167] Returning to Figure 11(a), a tilting mechanism 78 (not shown) tilts the small storage container or tray 9 to an inclined position, allowing items on the small storage tray to slide out of the tray through cuts or openings in the tray edge onto the tilting platform or chute 80. One or more robotic arms 76 are configured to retrieve items from the chute 80 and place them into the large storage container 9 on the conveyor unit 62. The conveyor unit 62 transports the large storage container 9 back to the grid frame structure of the second automated storage and retrieval system 52.

[0168] Figure 21 The pickup station 64 shown in Figure 11 is adjacent to the second automated storage and retrieval system 54. Storage containers 9 are retrieved from the grid frame structure 1 of the second automated storage and retrieval system 54 via load handling device 31 and transferred to pickup station 64 via an interface column. Storage containers 9 are within the reach of robotic arm 76, allowing the robotic arm to extract items from the chute 80 of pickup station 64 and place them directly into one of the large storage containers 9.

[0169] like Figure 22 As shown, multiple pickup stations 64 can be positioned adjacent to the grid frame structure 1 of the second automated storage and retrieval system 54.

[0170] The transfer system 56 is used to bring the large storage container 9 closer to the pickup station 64, thereby bringing the storage container 9 within the reach of the robotic arm 76.

[0171] Figure 23 The position of the transfer system 56 relative to the pickup station 64 is shown. The pickup station 64 is located below the grid frame structure 1 of the first automated storage and retrieval system 52. The gripper of the robotic arm 76 at the pickup station 64 is visible directly below the grid frame structure 1. The transfer system 56 (in this illustration, the transfer system includes the conveyor system 60) transports large storage containers 9 to a position adjacent to the pickup station 64, thus placing the storage containers 9 within the reach of the robotic arm 76. Figure 23 As shown, the interface column 58 is positioned directly above the transfer system 56, allowing the storage container to be lowered onto the transfer system along the interface column. The storage container 9 can then be returned to the grid frame structure by being lifted above the interface column and transported to its position within the grid frame structure via the load handling device 31. Multiple transfer systems can be arranged in a corridor between the grid frame structures of the first and second automated storage and retrieval systems to optimize space utilization and transfer items more efficiently.

[0172] In a specific embodiment of the invention, the pickup station can also serve as a replenishment station. The pickup / replenishment station has a storage and retrieval station that can function as both a pickup station and / or a replenishment station. The pickup station 64 is part of a first automated storage and retrieval system and cooperates with a second automated storage and retrieval system 52 to provide a system for retrieving one or more items from one or more storage containers 9 of the first automated storage and retrieval system and transferring them to the second automated storage and retrieval system. The pickup station includes one or more ramps forming a supply area, a storage and retrieval station, and one or more box lifting devices forming a pickup station buffer. The ramps and box lifting devices are examples of interface column 58. By reference to their names, one or more ramps allow the load handling device 31 operating on the grid frame structure 1 to lower the storage box or container 9 without any lifting assistance from one or more ramps. The storage box or container 9 may descend along the ramp under the weight of the storage box or container 9 and / or under the action of being lowered by the container lifting tool 39 of the load handling device 31, which should be the effect of gravity.

[0173] Depending on whether the storage station is used as a pickup station or a replenishment station, one or more items are retrieved from one or more storage boxes or containers 9 at the storage station. One or more ramps and one or more box lifting devices are configured to cooperate with the upper grid frame structure 1. A plurality of grid cells 14 include a delivery interface (outgoing interface) and a pickup interface (incoming interface) configured to cooperate with one or more ramps and one or more box lifting devices, respectively. More specifically, the storage columns where the delivery interface and the pickup interface are located are configured to cooperate with one or more ramps and one or more box lifting devices of the pickup station 64, respectively.

[0174] The pickup station 64 according to the invention can be configured as a standalone station that can be easily retrofitted into an existing grid frame structure 1 and thus can cooperate with an overhead track system. For example, at least one ramp and at least one container lifting device can be aligned with one or more storage columns 10 so that storage containers or boxes 9 can easily pass through the storage columns 10 into at least one ramp. Similarly, storage boxes or containers 9 can be lifted from at least one container lifting device and pass through the storage columns 10. The pickup station 64 can be a modular building in which the supply area, storage station, and pickup station buffer can be formed as modules assembled together. Therefore, the pickup station 64 no longer depends on being connected to the grid frame structure 1, but can be a separate part of the grid frame structure 1. The versatility of the pickup station 64 in retrofitting into the existing grid frame structure 1 allows the pickup station 64 to be assembled in various locations.

[0175] In one embodiment, the pickup station 64 includes a separate frame dividing the pickup station into a supply area, a pickup buffer zone, and a storage / retrieval station. One or more ramps in the supply area include at least two vertical guides that can be received in the storage column 10 and configured to guide storage boxes or containers 9 through the delivery interface along the storage column 10 into the supply area. By definition, the storage column 10 in the grid where the delivery interface is located is referred to as the delivery column. Similarly, the storage column 10 in the grid where the pickup interface is located is referred to as the retrieval column. In a particular embodiment of the invention, each of one or more ramps includes four guides that can be received in the storage column of the grid frame structure 1. Each guide includes two vertical plates (two container guide plates perpendicular to each other) extending longitudinally along the length of the ramp. One end of each guide is configured to extend into the storage column or delivery column and abut against the four upright members constituting the storage column. Thus, the storage boxes or containers 9 descending along the delivery interface are guided by the guides along the ramps of the supply area through the delivery column (where the delivery interface is located).

[0176] At least two vertical guides are externally mounted to the sidewalls or panels to enclose the vertical ramp. The sidewalls or panels separate the operator from one or more storage bins or containers descending along the ramp in the delivery area. In one embodiment, a first portion of the guide is covered by the sidewall or panel, while a second portion of the guide is received in the delivery column. This allows the sidewalls or panels to enable a seamless transition from the delivery column to the ramp at pickup station 64.

[0177] Transfer small containers directly into large containers

[0178] This invention also covers specific embodiments in which a storage container from one automated storage and retrieval system can be placed directly into a storage container from another automated storage and retrieval system, rather than retrieving items from one storage container to another. Placing a storage container within another storage container can be achieved in several different ways; numerous non-limiting embodiments are given below, but it should be understood that any means of placing a storage container into another storage container falls within the scope of this invention.

[0179] Small storage containers from the first automated storage and retrieval system 52 can be retrieved into a large storage container from the second automated storage and retrieval system 54 by one or more robotic arms 76 in a manner similar to that described above for retrieving individual items from small storage containers. The robotic arms may have suitable end effectors with grippers that engage with external features of the small storage containers (such as edges, outer edges, or holes), or the robotic arms may grip the opposite sidewall of the small container.

[0180] Alternatively, a flat surface can be provided on one or more conveyor units of the conveyor system, with one or more holes in the flat surface. These holes are positioned directly above the large storage container on the conveyor, allowing access to the large storage container through the holes in the flat surface. Small storage containers can be lifted, lowered, or slid into the large container through the holes in the flat surface. A robotic arm can be used to lift the small container through the holes into the large container. Alternatively, another conveyor unit located at the same vertical height as the flat surface can be used to transport the small container to the holes, allowing it to fall through the holes into the large container.

[0181] Another option is to have a hole in one of the large container's sidewalls, or to have a removable sidewall, to allow access to the interior of the large container. The smaller container can then slide into the larger container. A conveyor unit at the same vertical height, serving as a base for the large container, can be used to transport the smaller container into the large container. Alternatively, in a similar manner as described above in conjunction with Figure 11(a), a chute or downwardly sloping surface can be used to allow the smaller container to slide down through the hole in the sidewall of the large container into the large container. The advantage of this method is that the smaller container is not restricted by vertical descent and thus avoids the risk of damage to its contents.

[0182] Automated processing system

[0183] Figure 12 Another view schematically illustrates an automated processing system 50 with first and second automated storage and retrieval systems and a transfer system. The first automated storage and retrieval system 52 is adjacent to the second automated storage and retrieval system 54. The first automated storage and retrieval system has an interface column 58 on the side opposite to the second automated storage and retrieval system. The interface column 58 transports containers into the first automated storage and retrieval system 52 and, as described above, is defined herein as a pickup interface column. Figure 12 In a specific embodiment of the automated processing system 50 shown, the grid frame structure 1 of the first automated storage and retrieval system 52 is divided into several sub-partitions, while the interface column 58 is separated from the main grid frame structure. This invention covers specific implementations of any automated storage and retrieval system, including whether the grid frame structure 1 is a single structure or divided into sub-partitions, and specific implementations of whether the interface column 58 is integrated into the grid frame structure or its sub-partitions, or separated from the grid frame structure.

[0184] For example, in an application scenario where the automated processing system 50 is a baggage handling system at an airport or other transportation hub, the items stored in the small containers of the first automated storage and retrieval system 52 can be passenger baggage or carry-on luggage. After passengers register their baggage, the baggage can be transported (e.g., via one or more conveyors not shown) to a receiving area adjacent to the first automated storage and retrieval system 52, and each carry-on or baggage item can be placed in one of the small storage containers 9. The small storage containers 9 are then transferred into the first automated storage and retrieval system 52 via interface columns 58. A load processing device 31 operating on the grid frame structure 1 of the first automated storage and retrieval system 52 retrieves the small storage containers 9 containing the baggage and transports the containers to one or more interface columns 58 on the side of the first automated storage and retrieval system 52 adjacent to the second automated storage and retrieval system 54; here defined as a cargo release interface column as described above. The small containers 9 are transferred from the first automated storage and retrieval system 52 to one or more transfer systems 56 from the interface columns. One or more transfer systems 56 include a pick-up station 64, which retrieves passenger baggage from small containers in the first automated storage and retrieval system 52 and unloads it into large storage containers in the transfer system, i.e., waiting in a buffer zone. A large storage container can hold multiple carry-on bags or baggage items assigned to the same mode of transport (e.g., the same flight) or the same destination. The large storage container 9 is transported via transfer system 56 to the second automated storage and retrieval system 54, and is returned to the grid frame structure 1 of the second automated storage and retrieval system 54 via one or more interface columns on the side adjacent to the transfer system 56. When baggage is needed, the large storage container is retrieved from the second automated storage and retrieval system 54 via a load handling device 31 operating on the grid frame structure of the second automated storage and retrieval system. The large storage container 9 is transported via the load handling device to one or more interface columns 58 on the opposite side of the grid frame structure 1 from the side adjacent to the transfer system. The interface columns on the opposite side of the grid frame structure differ from the loading and unloading interface columns of the round-trip transfer system 56 in that they provide secondary interface columns for one or more storage containers to leave the grid frame structure. Large storage containers 9 are transported out of the second automated storage and retrieval system 54 through their respective interface columns. The large storage containers 9 can then be loaded into the cargo holds of passenger vehicles (such as airplanes, ships, trains, or other means of transport), thereby allowing passenger baggage to be transported to its appropriate destination.

[0185] Figure 13 schematically shown Figure 12The automated processing system 50, platform 57, is located below the top partition of the grid frame structure 1 of the first automated storage and retrieval system 52. Platform 57 provides areas for accommodating the interface columns. Figure 14 schematically shown Figure 13 The automated processing system 50 has a single-layer mesh frame structure 59 located on top of the platform 57. In this specific embodiment, the single-layer mesh frame structure 57 serves two purposes. First, the single-layer mesh frame structure 59 allows the load processing device 31 to move between the interface column and the mesh frame structure 1 of the first automated storage and retrieval system 52 to transport storage containers from the interface to the mesh frame structure. Second, the single-layer mesh frame structure 59 allows the load processing device 31 to move between different sub-partitions of the mesh frame structure 1 of the first automated storage and retrieval system 52 to transport storage containers between sub-partitions.

[0186] Figure 24 yes Figure 12 This is a rear view of the automated processing system. The figure shows a cargo trolley 69 on which large storage containers 9 are loaded. Each cargo trolley 69 is positioned as one of the interface columns 58 of the mesh frame structure 1 near the second automated storage and retrieval system 54. The storage containers 9 are lowered and loaded onto the cargo trolley 69 via the interface columns 58.

[0187] The cargo trolley 69 can be positioned directly below the interface column 58 so that the storage container 9 can be lowered directly onto the cargo trolley 69. Alternatively, the cargo trolley can be positioned as a conveyor unit adjacent to and at the bottom of the interface column 58, which can be used to transfer the storage container from the interface column 58 to the cargo trolley 69.

[0188] In the application scenario of the automated baggage handling system 50, the large storage container 9 is a unit loading device (ULD) that contains baggage items. Once loaded, the cargo trolley transports the ULDs to the passenger vehicle (e.g., an airplane, train, or ship) and loads them into the cargo rack.

[0189] Figure 25 This is a plan view of the automated processing system. The small storage container 9 enters the automated processing system 50 through interface column 58 of the first automated storage and retrieval system 52; in Figure 25In the diagram, rows of storage containers are seen queuing through interface column 58, waiting to enter the grid frame structure 1. Once stored in the grid frame structure 1 of the first automated storage and retrieval system 52, small storage containers 9 are transported to interface column 58 by load handling device 31, from where they fall to pickup station 64. At pickup station 64, robotic arm 76 extracts items from the small storage containers into large storage containers waiting in transfer system 56 (i.e., in a buffer). Once full, the large storage containers are carried through the transfer system to interface column 58 of the second automated storage and retrieval system 54. The large storage containers rise through interface column 58 into the grid frame structure 1 of the second automated storage and retrieval system and are transported by load handling device 31 to their storage location within the grid frame structure. When large storage containers are needed, they are transported from the grid frame structure to interface column 58 on the opposite side, descend through interface column 58, and are loaded onto cargo trolleys 69.

[0190] Automated assembly line

[0191] Another application of the automated processing system 50 is an automated assembly system. In this application, the items stored in the first automated storage and retrieval system 52 are parts to be assembled, while the items stored in the second automated storage and retrieval system 54 are components of the parts or the final product. The transfer system includes one or more assembly stations 65, in which parts are assembled (see...). Figure 19 and 20 The components can be assembled by human operators and / or robotic arms.

[0192] Storage containers are retrieved from the grid frame structure 1 of the first automated storage and retrieval system 52 by load processing device 31 and delivered to assembly station 65 via one or more interface columns. At assembly station 65, components from the small storage containers of the first automated storage and retrieval system 52 are assembled into components or final products. Components and products are then placed into large storage containers in buffer 70. The large storage containers containing the final products or components are then transported via a transfer system to interface column 58 of the second automated storage and retrieval system. The large storage containers are then transported upwards to interface column 58 (retrieval interface column) via one or more load processing devices 31 and transferred to their storage location within the second automated storage and retrieval system.

[0193] Figure 19 An exemplary implementation of the assembly station is illustrated. Interface column 58 transfers storage container 9 from the first automated storage and retrieval system to assembly station 65. The small storage container contains components for assembly. Figure 19 Also on display was bracket 67, which can hold small parts or accessories (such as screws, nuts, bolts) needed for assembly. Figure 19In the specific embodiment shown, assembly is performed by human operators on pallets loaded onto a conveyor system. Each pallet temporarily holds one component, and the pallets are transported along the assembly line from one human operator to the next on the line, allowing different human operators to add different parts to the assembly. Once assembly is complete, the pallets can be placed in a large storage container (not shown), ready for transfer by a transfer system to a second automated storage and retrieval system.

[0194] For example, if an automated assembly system is used to assemble bicycles, small storage containers contain bicycle parts (wheels, frame, gears, chain, brakes, seat, handlebars, etc.), while large storage containers store the assembled bicycles. The first human operator on the assembly line receives a bicycle frame from one small storage container and a bicycle from another. This operator uses bolts from bracket 67 to assemble the bicycle wheels to the frame and places the partially assembled bicycle on a component tray. The component tray is then conveyed along the assembly line, for example, via a conveyor system, to the next operator on the line. The next operator on the line receives the component tray, removes a set of handlebars from another small storage container, and assembles the handlebars to the bicycle frame. The component tray is conveyed to the next operator on the line, who secures the gears to the bicycle frame. The bicycle is thus conveyed along the assembly line until all parts are assembled. The completed bicycle is placed in a large storage container and transported to a second automated storage and retrieval system.

[0195] Figure 20 Showing included Figure 19 An automated assembly system for an assembly station. This automated assembly system includes a first automated storage and retrieval system 52 and a second automated storage and retrieval system 54. The assembly station is located between the two automated storage and retrieval systems, below a track system of a grid frame structure. Small load handling units 31 of the first automated storage and retrieval system retrieve small storage containers from the grid frame structure and deliver them to interface columns 58, after which the storage containers fall along the interface columns to the assembly station. Components are assembled into products or assemblies at the assembly station, and then the finished products or assemblies are placed in large storage containers 9. The large storage containers are then transferred to the second automated storage and retrieval system through one or more interface columns.

[0196] Although not in Figure 20 As shown in the diagram, however, the conveyor can be used to transport large storage containers 9 from assembly station 65 to interface column 58 of the second automated storage and retrieval system, thereby allowing the storage containers to be returned to the grid frame structure of the second automated storage and retrieval system.

[0197] control system

[0198] exist Figure 15In one exemplary embodiment of the invention shown, the control system 82 coordinates the movement of one or more storage containers 9, or one or more items from storage containers, from the grid frame structure 1 of the first automated storage and retrieval system 52 to be stored in the grid frame structure 54 of the second automated storage and retrieval system. For ease of explanation and efficiency, the grid frame structure 52 of the first automated storage and retrieval system is referred to as "Grid A," and the grid frame structure 54 of the second automated storage and retrieval system is referred to as "Grid B." According to the invention described above, Grid A and Grid B are mismatched, storing storage containers or bags of different sizes. The aim is to allow multiple storage containers from Grid A, or the contents of said multiple storage containers, to be combined or organized and stored in a single storage container from Grid B. To combine the contents of multiple storage containers from Grid A into a single storage container in Grid B, the storage containers in Grid A are smaller than the storage containers in Grid B. Therefore, Grid B is configured to accommodate larger storage containers through a grid opening 15 having a larger opening 15 than that of Grid A.

[0199] Figure 15This is a block diagram showing the components of an automated processing system 50 according to an exemplary embodiment of the present invention. The control system 82 includes one or more processors 84, a memory 86 (e.g., read-only memory and random access memory), and a communication bus 88. One or more processors 84 of the control system 82 can execute instructions stored in ROM and / or RAM to at least partially provide the functionality of the automated load processing system described herein. One or more processors 84 of the control system 82 are communicatively coupled to a wireless / wired transceiver (not shown) via the communication bus 88. A cloud (not shown) may be incorporated into the control system, enabling data processing and storage to be performed in the cloud. The control system 82 is instructed to execute instructions operable to receive, transfer, or transport one or more items or goods and generate, in response to such request, unique identifiers 92 (a and b) to be transmitted via a wired / wireless network to a user's personal communication device. Unique identifiers 92 (a and b) include user-related data. The data can be represented as a hierarchical system, where user-related data can represent first-order identification, and, based on the application scenario of the automated load handling apparatus according to the invention, the data may include other user-related attributes, such as flight data as second-order identification in the case of an automated baggage handling system. This hierarchical system allows the control system to identify and merge storage containers in grid A based on specific attributes of a unique identifier. This can be related to first-order data and / or lower-order data, such as flight data, where one or more storage containers for a specific flight are merged together to transfer to a single storage container in grid B. Following a request to merge one or more storage containers in grid A based on a corresponding unique identifier, the control system identifies the relevant storage container in grid A based on specific attributes of the corresponding unique identifier. This may be associated with user details or some lower-order content in the hierarchical system.

[0200] While automated load handling devices are suitable for any application requiring the sorting or consolidation of items, for ease of explanation of the functionality of the control system used to coordinate the movement of one or more storage containers to merge them into a single storage container, automated load handling systems will be described in conjunction with automated baggage handling systems. In the case of automated baggage handling systems, users may include passengers, and unique identifiers include data related to the user-defined destination and / or travel data, such as flight details.

[0201] See Figure 16 The flowchart shown is combined with Figure 15The process 100, which assigns unique identifiers 92 (a and b) to storage containers in a grid-frame structure, begins in step 102 with one or more users requesting that one or more items be temporarily stored for transfer to a user-defined destination. For automated baggage handling systems, one or more items can be one or more pieces of luggage and baggage items. At the check-in counter, the control system generates a tag or baggage identification tag 90a in step 104, including the unique identifier 92, which is associated with the user as a first-order identifier, the user-defined destination as a second-order identifier, and other travel data. The tag 90a, including the unique identifier, can be encoded as a barcode, 1-D barcode, 2-D barcode, QR code, or RFID tag. The tag 90a can be read by a user interface 93a to confirm the identity of the stored luggage. The luggage or suitcase is then temporarily stored in a storage container for subsequent transfer to grid A, where it is stored before being merged into a larger storage container in grid B. A similar process for generating a unique identifier 92b, including data related to specific attributes of the storage container temporarily stored in grid B, is also applicable to this invention. The relationship between the unique identifiers 92 (a and b) of the storage containers temporarily stored in grid A and grid B is further explained below and depends on the specific application of the automated load processing system. For example, in the case that the automated load processing system is an automated baggage handling system, this relationship could be travel data.

[0202] To locate a specific user's storage container, in step 106, the control system 82 assigns a generated unique identifier to the storage container temporarily stored in grid A. The process of assigning the generated unique identifier to the container in grid A may include assigning a user-related unique identifier to the storage container's grid position in grid A. This grid position can be represented using a Cartesian coordinate system X, Y, Z. In the present invention, the track system 13 guides the robot load handling device 31 to move in the X and Y directions in a horizontal plane above the track system 13, while the lifting mechanism 39 is configured to move the gripper device 43 in a third Z direction to access the storage container 9 in the stack below 11. In the present invention, Z=1 defines the uppermost layer of the grid frame structure, i.e., the first layer below the track system 13, Z=2 is the second layer below the track system 13, Z=3 is the third layer below the track system 13, and so on. The position of each storage container 9 temporarily stored in the grid frame structure of the first and second storage and retrieval systems (grids A and B) 52, 54 can be represented using a Cartesian coordinate system X, Y, Z. For example, a storage container may be described as being located at a grid position determined by a Cartesian coordinate system X, Y, Z. The unique identifier 92a may include the grid position of the user-related data as a first-order identifier, travel data as a second-order identifier, and the user-related storage container as a third-order identifier.

[0203] The movement of storage containers to and from their respective grid positions in grid A is achieved by one or more robotic payload handling devices 96a operating on the track system 13 of grid A. Typically, one or more payload handling devices 96a operating remotely on the grid frame structure are configured to receive instructions from the main controller to retrieve storage containers 9 from specific storage locations within the grid frame structure. The main controller can form a combination... Figure 15 This is part of the control system 82. Wireless communication and networks can be used to provide a communication infrastructure from the main controller to one or more load handling devices operating on the mesh frame structure via one or more base stations. A controller in the robotic load handling device, responding to received instructions, is configured to control various drive mechanisms to control the movement of the load handling device. For example, the load handling device may be instructed to retrieve a storage container 9 from a storage column 10 at a specific location on the mesh frame structure. The storage column 10 has X and Y coordinates in a specific Cartesian coordinate system, and the depth of the storage column 10 can be represented by the Z coordinate. Instructions may include various movements in the XY directions on the mesh frame structure. Once in the storage column 10, a lifting mechanism 39 operating on the Z-axis is operated to grasp the storage container 9 and lift it into the container receiving space in the body 33 of the load handling device 31, subsequently transporting it to another location on the mesh frame structure, commonly referred to as a loading interface, where the storage container 9 is lowered into an interface column 58. Instructions include moving the storage container 9 to or from its mesh position to at least one interface column 58, where the storage container 9 can be lowered. Once a user has registered their luggage at the check-in counter and the luggage associated with that user has been assigned a unique identifier 92a and placed in storage container 9, storage container 9 is transported by load handling unit 31 running on track system 13 to a grid location in grid A. This can be a designated grid location assigned by control system 82 or a grid location selected by the user at the check-in counter. The grid location of the storage container in grid A is assigned a unique identifier 92a associated with the user, as described above. This process is repeated at the check-in counter for different users.

[0204] Therefore, the dispatching and movement of storage containers to be stored in grid A, and the assignment of unique identifiers to the storage containers' grid locations within grid A, are automated processes occurring remotely to the user or in the logistics department. This contrasts with current practices in the prior art, which require the manual removal of luggage from conveyors to loading stations for subsequent transfer to the ULD. In this invention, the high-density storage of the grid frame structure according to the invention allows multiple luggage items from different users to be transferred to grid A for sorting, and then transferred to storage containers in grid B. A plurality of automated storage and retrieval systems, each comprising a grid frame structure 1 and a plurality of load processing devices 31 operating on the grid frame structure for moving storage containers from their grid locations to interface columns, the operation of which allows storage containers temporarily stored in one grid frame structure to be sorted and / or rearranged for transfer to storage containers in another grid frame structure. Assigning unique identifiers 92 (a and b) to storage containers in step 106 facilitates the sorting and / or merging of one or more items from one grid frame structure for transfer to storage containers in another grid frame structure.

[0205] In step 108, the unique identifier 92a of different users can be stored in database 94a (hereinafter referred to as...). Figure 15 (The "Grid A Database" in the text). This database is communicatively coupled to the control system 82. For example... Figure 15 As shown, the grid A database 94a, which communicates with the control system 82, contains information related to users (passengers). This information includes a unique identifier associated with the user, and / or the amount of available remaining space within a specified storage container, and / or the dimensions / three dimensions / volume / weight of the luggage, and / or the grid location of the storage container within grid A, or other relevant information in the hierarchical system. A unique identifier 92a for each storage container may be included on a label 90a affixed to the storage container, allowing the storage container to be identified by scanning the label using an input device 93a (see [link to documentation]). Figure 15 Input device 93a includes, but is not limited to, RFID readers, linear and / or matrix barcode readers, or infrared readers. The database can store associations between baggage items, such as which baggage items belong to the same user or the same shipment. Storage containers are temporarily stored in grid A until they need to be transferred to be merged into one or more larger storage containers in grid B.

[0206] A similar database 94b communicates with the control system 82 to store information related to storage containers temporarily stored in grid B of the second automated storage and retrieval system 54. The storage containers temporarily stored in grid B are different in size from those in grid A and are intended for storing items or storage containers merged and transferred from grid A to grid B. Similar to the unique identifier 92a associated with one or more users in grid A, the unique information 92b includes data related to the storage containers temporarily stored in grid B and may include information about the storage container's grid location in grid B, the amount of available remaining space within the specified storage container, and / or the dimensions / three dimensions / volume / weight of the luggage, and / or the storage container's grid location within grid A, or other relevant information in the hierarchical system. As with the storage containers temporarily stored in grid A, the unique identifier 92b associated with the storage containers temporarily stored in grid B can be identified by a label or tag 90b affixed to the storage container. An input device 93b at the transfer system 56—for example, at buffer 70—can identify storage containers from grid B from the label or tag 90b.

[0207] In the case of an automated baggage handling system, the storage containers in grid B can be unit loading devices (ULDs) used to load baggage or cargo into vehicles such as airplanes, trains, or ships. Similar to the grid positions of the storage containers in grid A, the grid positions of the storage containers in grid B can be represented using a Cartesian coordinate system X, Y, Z. The difference between grid A and grid B lies in the size of the grid frame structure; the grid openings in grid A are smaller than the grid openings 15 in grid B. Similar to grid A of the first automated storage and retrieval system 52, one or more load handling devices 31 operating on the track system 13 of grid B are instructed to move one or more storage containers 9 back and forth between their respective grid positions to be placed in the interface column 58 of grid B. The instructions include moving the storage containers 9 to their respective grid positions and from their respective grid positions to at least one interface column 58 of grid B. As described above, the load processing device includes a wheel assembly for moving in the X and Y directions on the track system 13 and a gripper device 43 for gripping the storage container 9 from its grid position into the container receiving space of the load processing device 31.

[0208] Although Figure 15 The exemplary implementation shows two databases 94, one 94a for storing data related to the unique identifier 92a of the storage container from grid A, and the other 94b for storing data related to the unique identifier 92b of the storage container from grid B, but the data from the unique identifiers 92 (a and b) can both be stored in a single database 94.

[0209] An exemplary implementation of step 110, which categorizes storage containers from grid A to merge them into specific storage containers with unique identifiers 92 (a and b) in grid B, can be found by referring to... Figure 17 The flowchart will be used to explain this. For ease of explanation, in... Figure 17 In this context, the "Unique Identifier" is abbreviated as "UI," and the load handling device is abbreviated as "Robot." The process begins with steps 112 and 114, in which the control system 82 instructs the load handling device 31, which runs on the track system 13 of grid B, to locate the storage container 9 and retrieve it from its grid position to the delivery interface. The storage container 9 is then lowered through at least one transfer system 56, passes through at least one interface column 58, and is transferred to the buffer 70. The request 112 to retrieve the storage container from grid B may depend on the need to merge items from grid A into the storage container from grid B.

[0210] Moving storage containers from at least one interface column 58 described above via at least one transfer system 56 involves one or more conveyor units 62. A buffer 70 represents a storage container 9 temporarily stored in at least one transfer system 56 from grid B and loaded with one or more items or portions of storage containers from grid A. In buffer 70, the identity of a storage container is determined by using an input device 93b to determine its unique identifier 92b in step 116. The input device 93b can be a scanner, such as a barcode scanner, a QR code reader, or other input device used to determine the unique identifier 92b of the storage container. Inputting the unique identifier 92b into the control system 82 can be done manually, for example, by a handheld scanner, or automatically, such as by an installed scanner. In step 118, once the identity of a storage container is determined by its corresponding unique identifier, the control system identifies and locates the storage container temporarily stored in grid A with the corresponding unique identifier 92a. The correspondence between the unique identifiers of storage containers in grid A and grid B is based on the application of an automated load handling system according to the invention. In the case of an automated baggage handling system, the correspondence between the unique identifiers of the storage containers from grid B and the storage containers from grid A can be travel details, such as flight numbers or user-defined destinations. The tags on the storage containers from grid B may include data related to flight details, destination, etc. The control system 82 can retrieve user-related unique identifiers from a database to identify any corresponding flight details, such as second-order identifiers, that may be temporarily stored or decommissioned in the system along with unique identifiers 92 (a and b).

[0211] Control system 82 identifies one or more storage containers in buffer 70 of grid A that have a corresponding unique identifier 92a to the unique identifier 92b of storage containers from grid B. In step 122, once identified, control system 82 instructs one or more load handling devices 31 operating on the track system 13 of grid A to retrieve the identified storage container 9 and move it along at least one interface column 58 to pick-up station 64. In step 124, at pick-up station 64, one or more items from different storage containers in grid A are transferred to storage containers in buffer 70, where they are merged into storage containers in buffer 70. In an automated baggage handling system, the one or more items can be baggage, and the storage containers in the buffer can be unit loading devices (ULDs). Baggage or suitcases from different storage containers in the pick-up station are transferred to the ULDs in the buffer. Control system 82 ensures that the unique identifier 92a of the storage container containing baggage from grid A corresponds to the unique identifier 92b of the ULD in buffer 70, such as flight details and destination. Automated baggage dispatch from grid A to ULD in grid B eliminates the possibility of misplaced baggage being loaded into the wrong ULD due to human error. Input device 93a at pickup station 64 ensures that the unique identifier 92a of the storage container corresponds to the unique identifier 92b of the storage container in buffer 70, thereby preventing incorrect items from being loaded into the storage container in the buffer and thus implementing a fault protection mechanism.

[0212] The transfer of one or more items from the storage container of pickup station 64 to the storage container of buffer zone 70 can be done manually. However, to improve the automation level of the automated load handling system 50 according to the present invention, items can be automatically retrieved from storage container 9 of pickup station 64 and transferred and merged into storage container 70 by using a robotic arm 76 capable of grabbing items from storage containers and transferring them to storage containers in buffer zone 70. Figure 10As shown. While the exemplary embodiment describes the retrieval of one or more items to be transferred to a storage container in buffer 70, the storage container itself temporarily stored at pickup station 64 may be transferred to be loaded into the storage container in the buffer. Also applicable to the invention is that storage container 9 may include an outer storage container and an inner storage container, also referred to as a delivery container. Delivery containers from one or more storage containers at pickup station 64 may be transferred to a larger storage container in buffer 70. Once one or more items (baggage) from one or more storage containers have been merged into the storage container in the buffer, the storage container in the buffer is moved to at least one interface column 58 of grid B, where it can then be retrieved and transferred by a load handling device 31 operating on the track system 13 of grid B to a grid location in grid B where it can be subsequently stored for future use. In the case of an automated baggage handling system, the ULD temporarily stored in grid B may be subsequently retrieved by the load handling device 31 operating on the track system 13 of grid B when it needs to be loaded onto a vehicle (e.g., placed in the cargo hold of an aircraft). When requested to be loaded into the aircraft cargo hold, the control system 82 may instruct the robotic load handling unit 31, which operates on the track system 13 of grid B, to retrieve the ULD based on its associated unique identifier 92b and temporarily store the ULD in at least one interface column 58, where it may be loaded into a suitable cargo trolley for transport to the aircraft cargo hold.

[0213] However, if no identifiable storage container with a corresponding unique identifier from grid A is found, the control system requests another storage container from grid B. The lack of a storage container with a corresponding unique identifier from grid A may be due to a delay in the allocation of storage containers to their corresponding grid locations within grid A. Alternatively, in this scenario, the storage container from grid B may optionally be retrieved from the grid and temporarily stored in the buffer 70 of the intermediate waiting facility 71 until the storage container from grid A is allocated.

[0214] Although Figure 17 The exemplary implementation in the flowchart is that the control system 82 instructs the load processing device 31 to retrieve the storage container from grid B before identifying the storage container with the corresponding unique identifier 92 in grid A. However, if the control system identifies the storage container with the corresponding unique identifier from grid B as one or more storage containers from grid A in the interface column, then the reverse also applies.

[0215] It is equally reasonable in this invention that at least one transfer system 56 may include at least one conveyor unit 62 to transfer one or more storage containers directly from at least one interface column 58 of grid A to at least one interface column 58 of grid B. Although Figure 17The exemplary embodiments described herein depict an automated load handling system 50 as an automated baggage handling system; however, the automated load handling system 50 according to the invention can be used in other application scenarios requiring the sorting and / or organization of items. At least two automated storage and retrieval systems 52, 54 are used, each of which includes the grid frame structure 1 described above, such that one or more items can be sorted and organized or merged from one storage container into another larger storage container.

[0216] The advantage of using an automated load handling system 50, having first and second automated storage and retrieval systems 52, 54 and at least one transfer system 56 linking them together, to organize or combine one or more items is that the automated load handling system 50 according to the invention can be used on an assembly line in a manufacturing process. For example, items from the first automated storage and retrieval system 52 can be combined and assembled into products that can form part of a machine, such as a pump, a motor, or an entire product, such as a bicycle, a washing machine, etc. Thus, unique identifiers 92 (a and b) can include data related to at least a part or the entirety of a product in the assembly line, rather than including data related to one or more users as described above, which makes the product created when the items are assembled together. In other words, one or more items can be considered as one or more components representing at least a part of a product in the assembly line. Therefore, unique identifiers 92 (a and b) include data related to a product or at least a part of a product. One or more items from one or more storage containers 9 may be combined or organized based on their respective unique identifiers 92 (a and b) associated with at least a portion of a product to be assembled at assembly station 65. Therefore, at least one transfer system 56 may further include an assembly station 65 for assembling one or more items or components retrieved from grid A before the assembled product is transferred to grid B.

[0217] The unique identifier 92a of the storage container in grid A may be associated with at least a portion or a product to be assembled at assembly station 65. Thus, the database 94a for grid A includes data associated with the unique identifiers 92 (a and b) of the product or at least a portion of the product to be assembled at assembly station 65 as first-order identifiers, and their corresponding grid positions as second-order identifiers. The assembled product can then be transferred to the storage container 9 in buffer 70 for subsequent storage in grid B. The storage container 9 in grid B has a unique identifier 92b corresponding to the unique identifier of the product assembled at assembly station 65. As described above, the database 94b for grid B includes data associated with the grid position of the assembled product machine in grid B. The operation of marking items and / or storage containers with information associated with their respective unique identifiers 92 and inputting the unique identifiers 92 into the control system 82 via the input device is as described above.

[0218] Figure 18 Exemplary steps of a process 130 for assembling at least a portion of a product using an automated load handling system 50 according to the invention are shown. In a first step 132, a request is made to assemble a product at assembly station 65. Control system 82 determines the components or items required to assemble the product at assembly station 65. This involves determining, in step 134, a unique identifier 92a of a storage container containing items from grid A. As described above, the unique identifier 92 is associated with the product to be assembled at assembly station 65. This unique identifier 92 includes data related to the grid location of the storage container 9 containing the corresponding assembled item. In step 136, once all items or components have been identified, control system 82 instructs one or more load handling devices 31 operating on the track system 13 of grid A to retrieve the storage container 9 containing the corresponding item. Load handling device 31 transports the storage container 9 to at least one interface column 58 of grid A, and the storage container 9 is subsequently transferred to at least one transfer system 56. A tag including information from the unique identifier of the storage container 9 at at least one transfer system 56 is scanned or entered into control system 82. In step 138, control system 82 determines whether all components or items of assembly station 65 are available for delivery to assemble the product. If not, control system 82 identifies the missing items or components and instructs one or more load handling devices 31 to retrieve them from grid A. If all items are present, they are merged in step 140 for assembly at assembly station 65.

[0219] Similar to the pickup station 64 described above, the assembled items can be handled manually or automatically. For example, automated operation may involve one or more robotic arms 76 performing automated assembly steps (such as welding, securing, placing, etc.). After assembly at assembly station 65, the products are transferred to grid B for storage. In step 122, control system 82 may be instructed to retrieve one or more storage containers 9 bearing a unique identifier corresponding to the product assembled at the assembly station and move said one or more storage containers 9 to buffer zone 70. In step 124, the assembled products are transferred to storage containers 9 in buffer zone 70. This transfer may also involve scanning tags on storage containers 9 in buffer zone 70 and inputting information from the tags into control system 82. The information on the tags includes the unique identifier of the storage container in buffer zone 70, and this information is subsequently stored in database 94b (grid B database). The unique identifier 92b is a record of the assembled product and its corresponding grid location in grid B. A load handling device 31 operating on the track system 13 of grid B transfers storage containers 9 from buffer zone 70 to their grid locations in grid B. The grid location is assigned a unique identifier 92b for the storage container within grid B. The process involves repeatedly assembling one or more items from grid A, assembling them at assembly station 65, and storing the assembled products in grid B. Thus, grid A provides the components of the assembled products, while grid B provides the storage for the assembled products. At least one transfer system 56 connecting grid A and grid B provides the necessary stations to link grid A to grid B.

[0220] The advantage of the automated load handling system 50 according to the invention is that the process of sorting and / or organizing or merging one or more items can be automated. Bottlenecks caused by manual sorting and / or merging of one or more items can be automated, making the sorting and / or merging process much faster. A plurality of transfer systems 56 can work collaboratively to sort and / or organize one or more items with different unique identifiers 92 (e.g., different flight details in an automated baggage handling system scenario) from the first automated storage and retrieval system 52 to the second automated storage and retrieval system 54. Furthermore, the use of a grid frame structure 1 to temporarily store the storage containers 9 allows the storage containers to be temporarily stored at high density within a given coverage area of ​​the storage facility.

[0221] definition

[0222] It has been anticipated that one or more of the aforementioned variations can be implemented in specific implementations of the same automated processing system.

[0223] In this paper, the term "movement in the n-direction" (and related wording), where n is one of x, y, and z, is intended to indicate movement substantially along or parallel to the n-axis in either direction (i.e. towards the positive end of the n-axis or towards the negative end of the n-axis).

[0224] In this document, the term "connection" and its derivatives are intended to include the possibilities of direct and indirect connections. For example, "x connects to y" is intended to include the possibility that x is directly connected to y without any intermediate components, and the possibility that x is indirectly connected to y through one or more intermediate components with one or more intermediate components in between. When intended to indicate a direct connection, the terms "directly connected," "directly connected," or similar terms will be used. Similarly, the term "support" and its derivatives are intended to include the possibilities of direct and indirect contact. For example, "x supports y" is intended to include the possibility that x directly supports and directly contacts y without any intermediate components, and the possibility that x indirectly supports y through one or more intermediate components that contact x and / or y. The term "installation" and its derivatives are intended to include the possibilities of direct and indirect installation. For example, "x is installed on y" is intended to include the possibility that x is directly installed on y without any intermediate components, and the possibility that x is indirectly installed on y through one or more intermediate components.

[0225] In this article, the word "includes" and its derivatives are intended to be inclusive rather than exclusive. For example, "x includes y" is intended to include the possibility that x includes one and only one y, multiple y's, or one or more y's and one or more other elements. When intended to express an exclusive meaning, the phrase "x consists of y" will be used, meaning that x includes only y and excludes nothing else.

[0226] In this document, "controller" is intended to include any hardware suitable for controlling (e.g., providing instructions) one or more other components. For example, a processor equipped with one or more memories and appropriate software for processing data related to the component and sending appropriate instructions to the component so that the component can perform its intended function.

Claims

1. An automated load processing system, including: A) First and second automated storage and retrieval systems, each of the first and second automated storage and retrieval systems comprising: i) Grid frame structure, including: a) A track system comprising a first set of parallel tracks and tracks transversely intersecting the track in a generally horizontal plane. The first set of parallel tracks and the second set of parallel tracks, the track system being configured to include a plurality of grid cells. A grid pattern, wherein each grid cell defines a grid opening, the grid opening being accessible through the first set of parallel tracks. A pair of adjacent tracks and a pair of adjacent tracks in the second set of parallel tracks define the boundary; b) Multiple storage columns, each configured to store a corresponding item for storing one or more items. A stack of storage containers, wherein the stack of storage containers is located below the track system, which makes each The stacking of storage containers occupies a single grid space or grid cell; ii) A plurality of robot load handling devices operating on the track system. To lift and move one or more storage containers from a stack; B) At least one interface column, the at least one interface column extending downward from the grid opening of the track system of each of the first and second automated storage and retrieval systems, wherein a corresponding robot load handling device running on the track system is able to place and retrieve one or more storage containers through the at least one interface column. The automated load processing system is characterized in that it further comprises: C) At least one transfer system configured to transfer one or more storage containers or one or more items from said storage containers from at least one interface column of the first automated storage and retrieval system to at least one interface column of the second automated storage and retrieval system, wherein each of the at least one interface column in the grid frame structure of the first and second automated storage and retrieval systems includes an inlet interface column for receiving one or more storage containers transferred from said at least one transfer system and an outlet interface column for placing one or more storage containers into said at least one transfer system, said at least one transfer system including at least one conveyor unit extending from the outlet interface column of the grid frame structure of the first or second automated storage and retrieval system to the inlet interface column of the grid frame structure of the first or second automated storage and retrieval system, thereby transporting one or more storage containers in and out of their respective grid frame structures, and The grid opening size of the track system of the first automated storage and retrieval system is different from that of the grid opening size of the track system of the second automated storage and retrieval system. This allows the grid frame structure of the first automated storage and retrieval system to be configured to store storage containers with different sizes than the storage containers stored in the grid frame structure of the second automated storage and retrieval system.

2. The automated load processing system according to claim 1, wherein, The grid opening of the track system of the first automated storage and retrieval system is smaller than that of the grid opening of the track system of the second automated storage and retrieval system. This allows the grid frame structure of the first automated storage and retrieval system to be configured to store storage containers that are smaller than the storage containers stored in the grid frame structure of the second automated storage and retrieval system.

3. The automated load processing system according to any of the preceding claims, wherein, The at least one transfer system includes at least one conveyor system, the at least one conveyor unit extending from at least one interface column of the grid frame structure of the first automated storage and retrieval system to at least one interface column of the grid frame structure of the second automated storage and retrieval system, thereby transporting one or more storage containers from the first automated storage and retrieval system to the second automated storage and retrieval system.

4. The automated load processing system according to claim 1, wherein, The at least one conveyor system includes an infeed conveyor unit, an outfeed conveyor unit, and a transfer conveyor unit, wherein the outfeed conveyor unit is configured to transport storage containers from the outgoing interface column to the transfer conveyor unit in a first direction, and the infeed conveyor unit is configured to transport storage containers from the transfer conveyor unit to the incoming interface column in a second direction.

5. The automated load processing system according to claim 4, wherein, The transfer conveyor unit is configured to transport the storage container upwards to a third party.

6. The automated load processing system according to claim 5, wherein, The outgoing conveyor unit and the incoming conveyor unit are configured such that the first direction of the outgoing conveyor unit is opposite to and parallel to the second direction of the incoming conveyor unit, and the third direction of the transfer conveyor unit is substantially orthogonal to both the first direction of the outgoing conveyor unit and the second direction of the incoming conveyor unit.

7. The automated load processing system according to any one of claims 4-6, wherein, The at least one transfer system includes a buffer for temporarily storing one or more storage containers of the transfer conveyor unit of the first and / or second automated storage and retrieval system.

8. The automated load processing system according to claim 7, wherein, The at least one transfer system includes a pickup station for receiving storage containers delivered from at least one interface column of the grid framework structure of the first automated storage and retrieval system.

9. The automated load processing system according to claim 8, wherein, The pickup station includes a robotic arm for transferring one or more items from one or more storage containers of the first automated storage and retrieval system to one or more storage containers at the transfer conveyor unit of the second automated storage and retrieval system.

10. The automated load processing system according to claim 8 or 9, wherein, The pickup station includes a tilting mechanism and a chute. The tilting mechanism is used to tilt the storage container, and the chute is adjacent to the tilting mechanism and is used to capture one or more items leaving the tilting mechanism.

11. The automated load processing system according to any of the preceding claims, wherein, The storage container of the first automated storage and retrieval system includes a shallow tray mounted on a spacing tool for vertically spacing the shallow tray from another shallow tray in a stack of the grid frame structure of the first automated storage and retrieval system.

12. The automated load processing system according to claim 11, wherein, Each of the shallow trays includes a bottom wall and an upwardly extending edge including one or more cuts, through which one or more items within the shallow tray can be accessed when the shallow trays are stacked and stored in the grid frame structure of the first automated storage and retrieval system.

13. The automated load processing system according to any of the preceding claims, wherein, The at least one transfer system includes at least one assembly station for assembling one or more items from one or more storage containers of the first automated storage and retrieval system.

14. The automated load processing system according to any of the preceding claims, wherein, Each of the plurality of load handling devices in the first and second automated storage and retrieval systems includes a lifting mechanism comprising a gripper configured to releasably engage a storage container and a winch mechanism configured to lift the storage container above the track system.

15. The automated load processing system according to any of the preceding claims, further comprising a control system, the control system comprising one or more processors and a memory storing instructions, the instructions being configured, when executed by the one or more processors, to: a) Receive storage requests for items that are related to a user or at least a part of a product; b) Generate a unique identifier that includes data related to at least a portion of the user or the product; c) Assign the unique identifier to a storage container in the first automated storage and retrieval system; d) Store the data associated with the unique identifier in a database.

16. The automated load processing system according to claim 15, wherein, The unique identifier is assigned to the storage container in the first automated storage and retrieval system by associating the grid location of the storage container in the grid framework structure of the first automated storage and retrieval system with the unique identifier.

17. The automated load processing system according to claim 15 or 16, wherein, The control system is further configured as follows: a) Generate a unique identifier that includes data associated with each storage container in the second automated storage and retrieval system; b) Assign the unique identifier of the storage container to the grid location of the storage container in the grid framework structure of the second automated storage and retrieval system.

18. The automated load processing system according to claim 17, wherein, The control system is configured to merge or organize multiple items from one or more storage containers of the first storage and retrieval system based on corresponding unique identifiers to transfer them to storage containers in the grid framework structure of the second automated storage and retrieval system.

19. The automated load processing system according to claim 18, wherein, The control system is configured to merge or organize a plurality of items from one or more storage containers of the first storage and retrieval system by merging corresponding unique identifiers associated with at least a portion of a user or a product.

20. The automated load processing system according to claim 19, wherein, The control system configuration assigns a merged unique identifier associated with one or more users or at least a portion of the product to the unique identifier of the storage container of the second automated storage and retrieval system.

21. The automated load processing system according to claim 20, wherein, The control system is further configured to, based on the corresponding unique identifier of the storage container of the second automated storage and retrieval system located in the at least one transfer system, instruct one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve one or more storage containers through the following steps: i) Associate a unique identifier associated with one or more users with a corresponding unique identifier of the storage container of the second automated storage and retrieval system located at the at least one transfer system; ii) Locate one or more storage containers in the grid frame structure of the first automated storage and retrieval system based on associating the unique identifier with the grid position of the storage container in the grid frame structure of the first automated storage and retrieval system; iii) instruct one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers from their grid locations and move the one or more storage containers to the at least one interface column of the first automated storage and retrieval system.

22. The automated load processing system according to any one of claims 15-21, wherein, The automated processing system is an automated baggage handling system, which makes each of the one or more items stored in the one or more storage containers in the first automated storage and retrieval system a baggage item, and the unique identifier associated with the user is baggage tag data, which includes data related to the user's specified destination and booking data indicating travel details, and each of the one or more storage containers in the second automated storage and retrieval system is a unit loading device (ULD).

23. The automated load processing system according to any one of claims 18-20, wherein, At least a portion of the product comprises components of a plurality of items that have been combined or organized.

24. The automated load processing system according to claim 23, wherein, The control system is further configured to, based on a unique identifier associated with at least a portion of the product, instruct one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve one or more storage containers to their respective interface columns through the following steps: i) Positioning includes one or more storage containers comprising one or more articles, each of the one or more articles forming at least a part of the product; ii) Locate one or more storage containers in the grid framework of the first automated storage and retrieval system based on associating the unique identifier with the grid position of the storage container in the grid framework of the first automated storage and retrieval system; iii) instructing one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers from their grid locations and move the one or more storage containers to at least one interface column of the first automated storage and retrieval system, each of the one or more storage containers comprising one or more articles for assembling at least a portion of a product.

25. A method for processing one or more articles of an automated load processing system according to any one of claims 15-22 in response to processing from a second automated storage and retrieval system, in one or more storage containers located in at least one transfer system, the method comprising the steps of: i) Identifying one or more storage containers containing one or more items by associating a unique identifier associated with one or more users from the first automated storage and retrieval system with one or more storage containers from the second automated storage and retrieval system located in the at least one transfer system; ii) instructing one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve the identified one or more storage containers and move the one or more storage containers to at least one interface of the mesh frame structure of the first storage and retrieval system; iii) Transferring one or more items from the identified one or more storage containers to the one or more storage containers located in the at least one transfer system from the second automated storage and retrieval system; iv) instruct one or more load processing devices operating on the track system of the second automated storage and retrieval system to move the one or more storage containers from the at least one transfer system to the storage column of the grid frame structure of the second automated storage and retrieval system.

26. The method of claim 25, further comprising the step of instructing one or more load processing devices operating on the track system of the second automated storage and retrieval system to retrieve one or more storage containers from the grid frame structure of the second automated storage and retrieval system to the at least one transfer system based on a unique identifier of the one or more storage containers identified from the first automated storage and retrieval system.

27. A method of assembling one or more articles from the automated load handling system of claim 23 or 24 to form at least a portion of a product, the method comprising the steps of: i) Identify one or more storage containers comprising one or more items and having a unique identifier associated with at least a portion of the product from the first automated storage and retrieval system; ii) instructing one or more load processing devices operating on the track system of the first automated storage and retrieval system to retrieve the one or more storage containers from their grid locations and move the one or more storage containers to the at least one interface column of the first automated storage and retrieval system, each of the one or more storage containers comprising one or more articles for assembling at least a portion of the product. iii) Assemble the one or more articles from the one or more storage containers to form at least a portion of the product; iv) Transfer at least a portion of the product to one or more storage containers located in the at least one transfer system from the second automated storage and retrieval system; v) Instruct one or more load processing devices operating on the track system of the second automated storage and retrieval system to move one or more storage containers from the at least one transfer system to the storage column of the grid frame structure of the second automated storage and retrieval system.

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