Loading and unloading processing system and use method

Abstract

Methods, systems, assemblies, etc., are provided. In some embodiments, an adjustable handling system (ALHS) includes one or more handling arms, where the one or more handling arms are configured to operatively engage one or more transport bins; a cam assembly including: a cam; and a guide plate comprising one or more guide slots, where the one or more loading arms are disposed within the one or more guide slots, and where the one or more loading arms are operatively engaged with the cam such that rotation of the cam causes the one or more loading arms to slide relative to the cam along the one or more guide slots; and a motor operatively engaged with the cam assembly, where the motor is configured to drive rotation of the cam.

Description

Technical Field

[0001] The present disclosure generally relates to a load handling system for a shuttle. In particular, the present disclosure relates to adapting a load handling system in a shuttle for automatically retrieving and storing one or more totes. Background Art

[0002] Load handling systems may be used in warehouses, distribution centers, and other industrial environments to place and / or carry one or more totes, pallets, cartons, etc., distributed throughout the environment. The various totes may vary in size and dimensions; furthermore, some of the totes may be located in locations that are more difficult to access than others. The mechanisms of the load handling system may be complex, inefficient, and / or unable to handle such totes.

[0003] Through effort, ingenuity and innovation, applicants have solved the problems associated with load handling systems by developing the solutions embodied in the present disclosure, which are described in detail below. Summary of the invention

[0004] Generally speaking, embodiments of the present disclosure provide load handling systems, automated storage and retrieval systems, methods, and the like.

[0005] According to various embodiments of the present disclosure, an adjustable loading and unloading system (ALHS) is provided, the ALHS comprising one or more loading arms, wherein the one or more loading arms are configured to operatively engage one or more totes; a cam assembly, the cam assembly comprising: a cam; and a guide plate comprising one or more guide slots,

[0006] wherein the one or more loading arms are disposed within the one or more guide slots, and wherein the one or more loading arms are operatively engaged with a cam such that rotation of the cam causes the one or more loading arms to slide relative to the cam along the one or more guide slots; and a motor operatively engaged with the cam assembly, wherein the motor is configured to drive rotation of the cam.

[0007] In some embodiments, the ALHS further comprises an actuator; and a carriage, wherein the cam assembly is disposed on the carriage, and wherein the actuator is configured to translate the carriage relative to the one or more totes.

[0008] In some embodiments, the ALHS further comprises a mounting plate; and a block, wherein the cam assembly is disposed on the block, wherein the block is disposed on the mounting plate, wherein the motor is disposed on the mounting plate, and wherein the mounting plate is disposed on the carriage.

[0009] In some embodiments, one or more loading arms include one or more guide pins, a cam defines one or more wheel tracks, and the one or more guide pins are disposed within the one or more wheel tracks such that rotation of the cam causes the one or more pins to slide relative to the guide plate along the one or more wheel tracks.

[0010] In some embodiments, the motor is a servo motor or a stepper motor.

[0011] In some embodiments, rotation of the cam in a first direction causes the one or more loading arms to move closer to the guide plate, and rotation of the cam in a second direction causes the one or more loading arms to move away from the guide plate.

[0012] In some embodiments, the cam includes a wheel alignment hole, the guide plate includes a plate alignment hole, and at least a portion of the motor is disposed through the wheel alignment hole and the plate alignment hole.

[0013] In some embodiments, rotation of the cam in a first direction causes the one or more loading arms to operatively engage the one or more totes, and rotation of the cam in a second direction causes the one or more loading arms to avoid operative engagement with the one or more totes.

[0014] In some embodiments, the first direction is clockwise and the second direction is counterclockwise.

[0015] In some embodiments, the one or more loading arms include a first loading arm and a second loading arm, and

[0016] In some embodiments, a first loading arm is disposed on a first side of the cam assembly and a second loading arm is disposed on a second side of the cam assembly.

[0017] In some embodiments, the first loading arm and the second loading arm are symmetrical with respect to the guide plate.

[0018] In some embodiments, the first loading arm and the second loading arm are separated by a distance, wherein rotation of the cam in a first direction causes the distance to decrease, and wherein rotation of the cam in a second direction causes the distance to increase.

[0019] According to various embodiments, an automated storage and retrieval system (ASRS) is provided, the ASRS comprising a shuttle assembly having a vehicle frame including one or more wheel mounts and one or more frame slots; one or more loading arms, wherein the one or more loading arms are configured to operatively engage one or more totes; a cam assembly, the cam assembly comprising: a cam; and a guide plate having one or more guide slots, wherein the one or more loading arms are disposed within the one or more guide slots, wherein the one or more loading arms are operatively engaged with the cam such that rotation of the cam causes the one or more loading arms to slide relative to the guide plate along the one or more guide slots, and wherein the cam assembly is disposed within the vehicle frame; and a motor operatively engaged with the cam assembly, wherein the motor is configured to drive rotation of the cam.

[0020] In some embodiments, the ASRS further includes an actuator disposed within the one or more actuator slots; and a carriage, wherein the cam assembly is disposed on the carriage, and wherein the actuator is configured to translate the carriage relative to the vehicle frame.

[0021] In some embodiments, the ASRS further comprises a mounting plate; and a block, wherein the cam assembly is disposed on the block, wherein the block is disposed on the mounting plate, wherein the motor is disposed on the mounting plate, wherein the mounting plate is disposed on the carriage, and wherein the carriage is disposed on the actuator.

[0022] In some embodiments, one or more loading arms include one or more guide pins, a cam defines one or more wheel tracks, and the one or more guide pins are disposed within the one or more wheel tracks such that rotation of the cam causes the one or more pins to slide relative to the guide plate along the one or more wheel tracks.

[0023] In some embodiments, the one or more loading arms include a first loading arm and a second loading arm, and the first loading arm is disposed on a first side of the cam assembly and the second loading arm is disposed on a second side of the cam assembly.

[0024] In some embodiments, the first loading arm and the second loading arm are symmetrical with respect to the guide plate.

[0025] In some embodiments, the first loading arm and the second loading arm are separated by a distance, rotation of the cam in a first direction causes the distance to decrease, and rotation of the cam in a second direction causes the distance to increase.

[0026] According to various embodiments, a method for adjusting a loading and unloading handling system is provided, the method comprising: inserting one or more loading arms into a guide slot of a guide plate of a cam assembly; aligning one or guide pins of the one or more loading arms with one or more tracks of a cam of the cam assembly; rotating the cam by a motor so that the one or more guide pins travel along the one or more tracks relative to the cam and the one or more loading arms slide along the one or more guide slots relative to the guide plate; and translating the cam assembly relative to the vehicle frame of the shuttle by an actuator.

[0027] The above-mentioned summary of the invention is provided only for the purpose of summarizing some exemplary embodiments, so as to provide a basic understanding of some embodiments of the present disclosure. Therefore, it should be understood that the above-mentioned embodiments are merely examples. It should be understood that in addition to those summarized here, the scope of the present disclosure also covers many possible embodiments, some of which will be further described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Having thus generally described the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0029] Figure 1 is an isometric view of an exemplary automated storage and retrieval system (ASRS) according to various embodiments of the present disclosure;

[0030] Figure 2 is a top plan view of an exemplary automated storage and retrieval system (ASRS) according to various embodiments of the present disclosure;

[0031] Figure 3 is an isometric view of an exemplary ALHS according to various embodiments of the present disclosure;

[0032] Figure 4 is an exploded view of an exemplary ALHS according to various embodiments of the present disclosure;

[0033] Figure 5 is an isometric view of an exemplary ALHS according to various embodiments of the present disclosure;

[0034] Figure 6 is a top plan view of an exemplary ALHS according to various embodiments of the present disclosure; and

[0035] Figure 7 is an exemplary flow chart illustrating an exemplary method of using an exemplary ALHS according to various embodiments of the present disclosure. DETAILED DESCRIPTION

[0036] Various embodiments of the present disclosure will now be described more fully below with reference to the accompanying drawings, in which some but not all embodiments of the present disclosure are shown. In fact, the present disclosure can be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; on the contrary, these embodiments are provided so that the present disclosure meets applicable legal requirements. Unless otherwise indicated, the term "or" (also indicated as " / ") is used herein in both alternative and combined senses. The terms "exemplary" and "exemplary" are examples for which there is no indication of a quality level. Throughout the text, similar reference numerals may refer to similar elements. The phrase "in one embodiment", "according to one embodiment", etc. generally means that the specific features, structures or characteristics following the phrase may be included in at least one embodiment of the present disclosure, and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0037] Overview

[0038] According to various embodiments, an adjustable load handling system (ALHS) may include one or more loading arms configured to operatively engage one or more totes; that is, the one or more loading arms may carry, move, and place one or more totes.

[0039] In some embodiments, the ALHS may include a cam assembly that may be configured to adjust the position of one or more loading arms. In some embodiments, the cam assembly may include a cam having one or more wheel tracks that may be configured to receive one or pins disposed on the loading arm. In some embodiments, the cam assembly may include a guide plate having one or more guide slots in which the loading arm may be disposed. In some embodiments, as the pin of the loading arm slides within the wheel track, the loading arm may then slide along the one or more guide slots, causing them to expand (relative to the wheel movement) or approach the cam assembly away from the cam assembly. That is, in some embodiments, the rotation of the cam may cause (depending on the direction of rotation) the loading arm to extend (e.g., position itself around the tote) or compress (e.g., close around the tote and thereby secure the tote for movement). In some embodiments, the cam assembly may be coupled to a motor that may drive such rotation of the cam.

[0040] In some embodiments, the ALHS can be coupled to an actuator that can be configured to drive a cam assembly. In some embodiments, the actuator can be a linear actuator configured to drive the cam assembly laterally in one or more directions. In some embodiments, the actuator can be configured to drive the cam assembly (and by extension one or more loading arms) into proximity with one or more totes such that the one or more arms can be adjusted to close around the one or more totes and thereby carry and place the one or more totes.

[0041] In some embodiments, the loading and unloading handling system can be coupled to the mobile device. For example, the loading and unloading handling system can be integrated into an automatic storage and retrieval system (ASRS). In some embodiments, the automatic storage and retrieval system may include a shuttle car having a frame that is configured to receive a cam assembly and one or more loading and unloading arms. In some embodiments, the car can be configured to run along a track extending through a warehouse or other industrial environment. In some embodiments, a platform can be set on either side of the track; the platform can support one or more totes, and when the cart slides on the track through the platform, it can use the loading and unloading handling system to stop one or more totes and retrieve one or more totes.

[0042] Exemplary ASRS Systems and ALHS Systems

[0043] According to various embodiments, Figure 1 An isometric view of the ASRS 100 is shown, and Figure 2 A top plan view of an exemplary ASRS 100 is shown. In some embodiments, the ASRS 100 includes a shuttle assembly 102. In some embodiments, the shuttle assembly 102 includes a vehicle frame 104. In some embodiments, the vehicle frame 104 can be a generally rectangular metal structure into which one or more components of the shuttle assembly 102 can be stored. In some embodiments, the vehicle frame 104 can include one or more frame slots 105 that can be configured to receive one or more components of any of the shuttle assembly 102 and / or auxiliary systems or components.

[0044] In some embodiments, the shuttle assembly 102 may include one or more wheels 106A to 106D. In some embodiments, one or more wheels 106A to 106D may be configured to run along a track. In some embodiments, the shuttle assembly 102 may travel along a track that has been laid throughout a warehouse, a distribution center, or a similar industrial environment. In some embodiments, the shuttle assembly 102 may be an automatic vehicle configured to run along a set route on a track. In some embodiments, the shuttle assembly 102 may be remotely controlled by an operator on the track.

[0045] According to various embodiments, Figure 3 shows an isometric view of an exemplary ALHS 200, and Figure 4 An exploded view of an exemplary ALHS 200 is shown. In some embodiments, the ALHS 200 may be coupled to the ASRS 100 (operably or fixedly) as desired, or integrated into the ASRS 100. In some embodiments, the ALHS 200 may include one or more loading arms 202A, 202B. In some embodiments, the loading arms 202A, 202B may each include an insert portion 204A, 204B and an attachment portion 206A, 206B. In some embodiments, one or more guide pins 207A to 207B. In some embodiments, the insert portions 204A to 204B and the attachment portions 206A to 206B may be fixedly attached or may be a single integral piece and disposed perpendicular to each other. In some embodiments, the loading arms 202A to 202B may be configured to attach to one or more totes 300 (at least in Figure 5 and Figure 6 In some embodiments, the loading and unloading arms 202A to 202B can be substantially rigid; in some embodiments, the loading and unloading arms 202A to 202B can be flexible or malleable and configured to deform as needed.

[0046] In some embodiments, the ALHS can include a cam assembly 208. In some embodiments, the cam assembly 208 can be configured to convert rotational motion of one or more of its components into linear motion of the loading arms 202A-202B.

[0047] In some embodiments, the cam assembly 208 may include a cam 210. In some embodiments, the cam 210 may include one or more wheel tracks 212A, 212B. In some embodiments, one or more wheel tracks 212A to 212B may be curved wheel tracks and extend parallel to the circumference of the cam 210. In some embodiments, one or more wheel tracks 212A to 212B may be grooved or slotted. In some embodiments, one or more guide pins 207A to 207B may be inserted into one or more wheel tracks 212A to 212B and configured to slide along the wheel tracks 212A to 212B as the cam 210 rotates. In some embodiments, the cam 210 may include a wheel alignment hole 215 disposed at the center of the cam 210.

[0048] In some embodiments, the cam assembly 208 may include a guide plate 214. In some embodiments, the guide plate 214 may include one or more guide slots 216. In some embodiments, the insertion portion 204A-204B of the loading and unloading arms 202A-202B may be at least partially disposed in the one or more guide slots 216. In some embodiments, the insertion portion 204A-204B may be configured to slide in the one or more guide slots 216. In some embodiments, the one or more guide slots 216 may be groove-shaped or slot-shaped as desired. In some embodiments, the guide plate 214 may be a substantially rigid rectangular member. In some embodiments, the plate alignment hole 218 may be disposed at the center of the guide plate 214. In some embodiments, the plate alignment hole 218 may be aligned with the wheel alignment hole 215.

[0049] In some embodiments, the ALHS 200 may include a motor 220. In some embodiments, the motor 220 may be a servo motor or a stepper motor, or any other suitable motor configured to rotate the cam assembly 208. In some embodiments, the motor 220 may be configured to drive one or more components of the ALHS 200. In some embodiments, the motor 220 may be configured to drive one or more components of the cam assembly 208, and the cam assembly 208 may be configured to convert the drive of the motor 220 into a linear motion of one or more loading arms 202A-202B. In some embodiments, the motor 220 may be configured to drive the cam 210 of the cam assembly 208. In some embodiments, the motor 220 may be at least partially disposed through one or more of the wheel alignment aperture 215 and the plate alignment aperture 218.

[0050] In some embodiments, the ALHS 200 can include a block 222. In some embodiments, the block 222 can be disposed between one or more components of the cam assembly 208 and the motor 220. In some embodiments, the block 222 can be a U-shaped block. It should be understood that a variety of different shapes can be used for the block 222 as desired. In some embodiments, the block 222 can include alignment holes (not shown) that are the same as the wheel alignment holes 215 and the plate alignment holes 218 and are aligned in a similar manner, and the motor 220 can be at least partially disposed through the wheel alignment holes, the plate alignment holes, and the block alignment holes.

[0051] In some embodiments, the ALHS 200 can include a mounting plate 224. In some embodiments, the mounting plate 224 can be used to mount the motor 220. In some embodiments, the block 222 can also be mounted on the mounting plate 224. In some embodiments, the mounting plate 224 can be a generally rigid rectangular block constructed of metal or a similar "hard" substance.

[0052] In some embodiments, the ALHS 200 can include an actuator 226. In some embodiments, the actuator 226 can be configured to drive one or more components of the ALHS 200. For example, the actuator 226 can be configured to drive one or more components of the cam assembly 208 and thereby move the connected loading arms 202A, 202B.

[0053] In some embodiments, the actuator 226 can be an electric linear actuator 226. In some embodiments, the actuator 226 can include a carriage 228 and an actuator track 230. In some embodiments, the actuator 226 can be configured to move the carriage 228 along the actuator track 230. In some embodiments, the actuator track 230 can be substantially linear and disposed within one or more slot frames of the frame slot 105 of the frame 104. In some embodiments, one or more components of the cam assembly 208 can be disposed on the carriage 228. In some embodiments, the motor 220 mounted on the mounting plate 224 can be disposed on the carriage 228 together with the block 222.

[0054] like Figure 5 and Figure 6 As shown, according to various embodiments, the ALHS 200 can be configured to operably engage one or more totes 300. It should be understood that the ALHS 200 is shown alone in order to draw attention to the various key features of the system 200. It should also be understood that the present disclosure applies in a similar manner regardless of whether the ALHS 200 is installed in the ASRS 100.

[0055] In some embodiments, one or more loading arms 202A, 202B may be spaced apart by a distance "D". In some embodiments, one or more loading arms 202A, 202B are symmetrical about cam assembly 208 such that distance D is evenly divided between the "right hand" side and the "left hand" side of ALHS 200. In some embodiments, motor 220 may drive cam 210 such that guide pins 207A-207B slide along one or more wheel tracks 212A-212B, and insert portions 204A-204B may then slide within guide slots 216 of guide plate 214. Thus, in some embodiments, rotation of cam 210 by motor 220 may cause one or more loading arms 202A, 202B to move such that distance D increases or decreases depending on the direction of rotation of cam 210. In some embodiments, distance D may increase when cam 210 rotates counterclockwise, and distance D may decrease when cam 210 rotates clockwise. In some embodiments, clockwise may cause an increase, while counterclockwise may cause a decrease. It should be appreciated that the expansion and contraction of the distance D between one or more loading arms 202A-202B may also be measured relative to the cam assembly 208 and / or relative to one or more components of the ALHS 200 or the ASRS 100 (assuming the ALHS 200 is installed within the ASRS 100).

[0056] In some embodiments, the actuator 226 can drive one or more components of the ALHS 200 (e.g., the loading arms 202A-202B) to approach one or more totes 300. As an example of operation, according to various embodiments, the actuator 226 can bring the loading arms 202A-202B into proximity with the one or more totes 300. In some embodiments, the cam assembly 208 can then be driven by the motor 220 to increase the distance D between the loading arms 202A-202B (e.g., in the event that the one or more totes 300 are wider than the distance D); the cam assembly 208 can then be driven by the motor 220 to shorten the distance D between the one or more loading arms 202A-202B so that the distance D approaches the width of the tote. In some embodiments, the one or more loading arms 202A-202B are then fixed around the one or more totes 300, and the one or more totes 300 can be moved and / or placed as needed. Once the one or more totes 300 have been moved, the reverse of the process can occur to release the one or more totes.

[0057] Example usage

[0058] Figure 7A flow chart illustrating a method 400 of adjusting a load handling system according to various embodiments is shown. In some embodiments, the method can be used with a load handling system and its various components as previously described. It should also be understood that the method 400 can be used with any suitable system and components.

[0059] In some embodiments, method 400 may include step 402: inserting one or more loading arms into guide slots of a guide plate of a cam assembly. In some embodiments, method 400 may include step 404: aligning one or more guide pins of one or more loading arms with one or more tracks of a cam of the cam assembly. In some embodiments, method 400 may include step 406: rotating the cam by a motor so that the one or more guide pins travel along the one or more tracks relative to the cam and the one or more loading arms slide along the one or more guide slots relative to the guide plate. In some embodiments, method 400 may include step 408: translating the cam assembly relative to the car frame of the shuttle by an actuator.

[0060] Many modifications and other embodiments of the disclosure set forth herein will occur to those skilled in the art having the benefit of the foregoing description and the teachings presented in the associated drawings. Therefore, it should be understood that the disclosure is not limited to the specific embodiments disclosed, and modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used only in a general and descriptive sense and not for the purpose of limitation.

Claims

1. An adjustable loading and unloading handling system (ALHS), comprising: One or more loading arms, wherein the one or more loading arms are configured to operatively engage one or more totes; A cam assembly, the cam assembly comprising: Cam; and a guide plate, the guide plate comprising one or more guide slots, wherein the one or more loading arms are disposed in the one or more guide slots, and wherein the one or more loading arms are operatively engaged with the cam such that rotation of the cam causes the one or more loading arms to slide relative to the cam along the one or more guide slots; and a motor operatively engaged with the cam assembly, Wherein the motor is configured to drive the rotation of the cam.

2. The ALHS according to claim 1, further comprising: Actuator; and Slide, wherein the cam assembly is disposed on the slide, and Wherein the actuator is configured to translate the carriage relative to the one or more totes.

3. The ALHS according to claim 2, further comprising: Mounting plate; and piece, wherein the cam assembly is disposed on the block, wherein the block is disposed on the mounting plate, wherein the motor is disposed on the mounting plate, and The mounting plate is arranged on the sliding frame.

4. The ALHS according to claim 1, wherein the one or more loading arms include one or more guide pins, wherein the cam defines one or more wheel tracks, and Wherein the one or more guide pins are disposed within the one or more wheel tracks such that the rotation of the cam causes the one or more pins to slide relative to the guide plate along the one or more wheel tracks.

5. The ALHS according to claim 1, wherein the rotation of the cam in a first direction causes the one or more loading arms to move closer to the guide plate, and Wherein the rotation of the cam in the second direction causes the one or more loading arms to move away from the guide plate.

6. The ALHS according to claim 1, wherein the cam includes a wheel alignment hole, wherein the guide plate includes a plate alignment hole, and Wherein at least a portion of the motor is disposed through the wheel alignment aperture and the plate alignment aperture.

7. The ALHS according to claim 1, wherein said rotation of said cam in a first direction causes said one or more loading arms to operatively engage said one or more totes, and Wherein the rotation of the cam in a second direction causes the one or more loading arms to avoid operative engagement with the one or more totes.

8. The ALHS according to claim 1, wherein the one or more loading arms include a first loading arm and a second loading arm, and The first loading arm is disposed on a first side of the cam assembly, and the second loading arm is disposed on a second side of the cam assembly.

9. The ALHS according to claim 1, wherein the first loading and unloading arm and the second loading and unloading arm are separated by a distance, wherein said rotation of said cam in a first direction causes said distance to decrease, and wherein the rotation of the cam in a second direction causes the distance to increase.

10. The ALHS of claim 1, further comprising: A shuttle assembly, the shuttle assembly comprising: a vehicle frame, the vehicle frame comprising one or more frame slots; One or more loading arms, Wherein the one or more loading arms are configured to operatively engage one or more totes.

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