Method for monitoring storage system with flying drone

Abstract

A method of monitoring an automated storage and retrieval system (1) utilizes a flying drone (400) to locate and check for anomalies in operation of the system.

Description

[0001] This application is a divisional application of the Chinese patent invention application "Method for monitoring storage systems using flying drones" with an application date of April 27, 2021 and application number 202180031817.3. Technical Field

[0002] The present invention relates to an automated storage and retrieval system for storing and retrieving containers, and in particular to a method for monitoring such a system for errors, and more particularly to a method for locating and monitoring a disabled or malfunctioning autonomous container handling vehicle operating on such a system. Background Art

[0003] Figure 1 A typical prior art automatic storage and retrieval system 1 having a frame structure 100 is disclosed, and Figure 2 and Figure 3 Two different prior art container handling vehicles 201 , 301 suitable for operating on such a system 1 are disclosed.

[0004] The frame structure 100 comprises upright members 102, horizontal members 103 and a storage volume comprising storage columns 105 arranged in rows between the upright members 102 and the horizontal members 103. In these storage columns 105, storage containers 106 (also called boxes) are stacked one on top of the other to form a stack 107. The members 102, 103 may typically be made of metal, such as extruded aluminum profiles.

[0005] The frame structure 100 of the automated storage and retrieval system 1 includes a rail system 108 arranged across the top of the frame structure 100, on which a plurality of container handling vehicles 201, 301 are operated to raise and lower storage containers 106 from and into storage columns 105, and also to transport storage containers 106 over storage columns 105. The rail system 108 includes: a first set of parallel rails 110 arranged to guide the movement of the container handling vehicles 201, 301 across the top of the frame structure 100 in a first direction X; and a second set of parallel rails 111 arranged perpendicular to the first set of rails 110 to guide the movement of the container handling vehicles 201, 301 in a second direction Y perpendicular to the first direction X. The containers 106 stored in the columns 105 are accessed by the container handling vehicles through access openings / grid units 112 in the rail system 108. The container handling vehicles 201 , 301 are able to move laterally above the storage columns 105 , ie in a plane parallel to the horizontal XY plane.

[0006] The upright members 102 of the frame structure 100 may be used to guide the storage containers during raising and lowering of the containers from and into the columns 105. The stack 107 of containers 106 is typically self-supporting.

[0007] Each of the prior art container handling vehicles 201, 301 includes a vehicle body 201a, 301a and a first set of wheels and a second set of wheels 201b, 301b, 201c, 301c, which respectively enable the container handling vehicle 201, 301 to move laterally in the X direction and the Y direction. Figure 2 and Figure 3 , both wheels in each set are fully visible. The first set of wheels 201b, 301b is arranged to engage with two adjacent tracks in the first set of tracks 110, and the second set of wheels 201c, 301c is arranged to engage with two adjacent tracks in the second set of tracks 111. At least one set of wheels 201b, 301b, 201c, 301c can be raised and lowered so that the first set of wheels 201b, 301b and / or the second set of wheels 201c, 301c can engage with the corresponding set of tracks 110, 111 at any time.

[0008] Each prior art container handling vehicle 201, 301 also includes a lifting device (not shown) for vertically transporting the storage container 106, such as lifting the storage container 106 from the storage column 105 and lowering the storage container 106 into the storage column 105. The lifting device includes one or more clamping / engaging devices suitable for engaging the storage container 106, and the clamping / engaging device can be lowered from the vehicle 201, 301 so that the position of the clamping / engaging device relative to the vehicle 201, 301 can be adjusted in a third direction Z orthogonal to the first direction X and the second direction Y. Part of the clamping device of the container handling vehicle 301 is Figure 3 , indicated by reference numeral 304. The gripping device of the container handling device 201 is located at Figure 2 Inside the vehicle body 301a.

[0009] Conventionally, and also for the purposes of the present application, Z=1 identifies the uppermost level of the storage container, i.e., the level directly below the rail system 108, Z=2 identifies the second level below the rail system 108, Z=3 identifies the third level, etc. Figure 1 In the exemplary prior art disclosed in , Z=8 identifies the lowest bottom layer of the storage container. Similarly, X=1...n and Y=1...n identify the position of each storage column 105 in the horizontal plane. Thus, as an example, and using Figure 1 The Cartesian coordinate system X, Y, Z indicated in, Figure 1The storage container identified as 106' in FIG. 1 can be said to occupy storage location X = 10, Y = 2, Z = 3. The container handling vehicle 201, 301 can be said to be traveling in the Z = 0 level, and each storage column 105 can be identified by its X and Y coordinates.

[0010] The storage volume of the frame structure 100 is often referred to as a grid 104, wherein the possible storage positions within the grid are referred to as storage units. Each storage column can be identified by a position in the X and Y directions, and each storage unit can be identified by a container number in the X, Y, and Z directions.

[0011] Each prior art container handling vehicle 201, 301 includes a storage compartment or space for receiving and stowing the storage container 106 while transporting the storage container 106 across the track system 108. The storage space may include a cavity centrally disposed within the vehicle body 201a, such as Figure 2 As shown in and described, for example, in WO 2015 / 193278 A1, the content of which is incorporated herein by reference.

[0012] Figure 3 An alternative configuration of a container handling vehicle 301 having a cantilever structure is shown. Such a vehicle is described in detail, for example, in N0317366, the contents of which are also incorporated herein by reference.

[0013] Figure 2 The central cavity container handling vehicle 201 shown may have a footprint covering an area in the X and Y directions, the size of which is generally equal to the lateral extent of the storage column 105, such as described in WO 2015 / 193278 A1, the contents of which are incorporated herein by reference. The term "lateral" as used herein may refer to "horizontally".

[0014] Alternatively, the central cavity container handling vehicle 101 may have a footprint that is larger than the lateral area defined by the storage columns 105, such as disclosed in WO 2014 / 090684 A1.

[0015] The track system 108 typically includes a track with grooves in which the wheels of the vehicle travel. Alternatively, the track may include upwardly protruding elements, wherein the wheels of the vehicle include flanges to prevent derailment. These grooves and upwardly protruding elements are collectively referred to as guide rails. Each track may include one guide rail, or each track may include two parallel guide rails.

[0016] WO2018146304 (the contents of which are incorporated herein by reference) shows a typical configuration of the track system 108, including tracks and parallel guides in the X-direction and the Y-direction.

[0017] In the frame structure 100, most of the columns 105 are storage columns 105, i.e. columns 105 stored in storage containers 106 and stacks 107. However, some columns 105 may have other purposes. Figure 1 In the embodiment of the present invention, columns 119 and 120 are such special columns used by container handling vehicles 201, 301 to unload and / or pick up storage containers 106 so that they can be transported to a storage and access station (not shown), where the storage container 106 can be accessed from the outside of the frame structure 100, or the storage container 106 can be moved out of or into the frame structure 100. In the art, such a position is generally referred to as a "port", and the column where the port is located can be referred to as a "port column" 119, 120. The transportation to the access station can be in any direction, horizontal, inclined and / or vertical. For example, a storage container 106 can be placed in a random or special column 105 within the frame structure 100, then picked up by any container handling vehicle and transported to the port column 119, 120 for further transportation to the access station. Note that the term "inclined" means that the transportation of the storage container 106 has an overall transportation orientation in a direction between horizontal and vertical.

[0018] exist Figure 1 In the embodiment, the first port column 119 can be, for example, a dedicated unloading port column, wherein the container handling vehicle 201, 301 can unload the storage container 106 to be transported to the access station or the transfer station, and the second port column 120 can be a dedicated picking port column, wherein the container handling vehicle 201, 301 can pick up the storage container 106 that has been transported from the access station or the transfer station.

[0019] The access station may typically be a pick-up station or staging station, where product items are removed from or positioned in the storage container 106. In the pick-up station or staging station, the storage container 106 is usually not removed from the automated storage and retrieval system 1, but once accessed, is returned again to the frame structure 100. The port may also be used to transfer the storage container to another storage facility (e.g., to another frame structure or to another automated storage and retrieval system), a transport vehicle (e.g., a train or truck), or a production facility.

[0020] Storage containers are typically transported between the port posts 119, 120 and the access station using a conveyor system including a conveyor.

[0021] If the port columns 119, 120 and the access station are located at different heights, the conveyor system may include a lifting device with a vertical component for vertically transporting the storage container 106 between the port columns 119, 120 and the access station.

[0022] The conveyor system may be arranged to transfer storage containers 106 between different frame structures, for example as described in WO 2014 / 075937 A1, the contents of which are incorporated herein by reference.

[0023] When the access is stored in Figure 1 106, one of the container handling vehicles 201, 301 is instructed to remove the target storage container 106 from its position and transport the storage container to the unloading port column 119. The operation involves moving the container handling vehicle 201, 301 to a position above the storage column 105 in which the target storage container 106 is located, removing the storage container 106 from the storage column 105 using a lifting device (not shown) of the container handling vehicle 201, 301, and transporting the storage container 106 to the unloading port column 119. If the target storage container 106 is located deep within the stack 107, that is, one or more other storage containers 106 are positioned above the target storage container 106, the operation also involves temporarily moving the storage container positioned above before lifting the target storage container 106 from the storage column 105. This step (sometimes referred to as "digging" in the art) can be performed using the same container handling vehicle that is subsequently used to transport the target storage container to the unloading port column 119, or using one or more other cooperating container handling vehicles. Alternatively or in addition, the automated storage and retrieval system 1 may have a container handling vehicle dedicated to the task of temporarily removing a storage container from a storage column 105. Once the target storage container 106 has been removed from the storage column 105, the temporarily removed storage container can be relocated to the original storage column 105. However, the removed storage container may alternatively be relocated to another storage column.

[0024] When a storage container 106 is to be stored in one of the columns 105, one of the container handling vehicles 201, 301 is instructed to pick up the storage container 106 from the pick-up port column 120 and transport the storage container to a position above the storage column 105 where the storage container is to be stored. After all storage containers positioned at or above the target position within the storage column stack 107 have been removed, the container handling vehicle 201, 301 positions the storage container 106 at the desired position. The removed storage container can then be lowered back into the storage column 105, or repositioned to another storage column.

[0025] In order to monitor and control the automatic storage and retrieval system 1, such as monitoring and controlling the positions of the individual storage containers 106 within the frame structure 100, the contents of each storage container 106 and the movement of the container handling vehicles 201, 301, so that the desired storage container 106 can be delivered to the desired location at the desired time without the container handling vehicles 201, 301 colliding with each other, the automatic storage and retrieval system 1 includes a control system 500, which is typically computerized and typically includes a database for keeping track of the storage containers 106.

[0026] Methods of monitoring errors in storage systems in the prior art

[0027] As can be appreciated, prior art storage and retrieval systems such as those described above are highly automated. The complex logistics of the system and the operation of the autonomous container handling vehicles (also referred to as "robots") are managed by a computerized control system. Such systems, as well as the robots themselves, are inevitably prone to errors and failures.

[0028] In such prior art storage systems, the control system typically includes multiple software programs or modules, each responsible for a different aspect of the overall control of the system. One such module is the so-called "Exception Handler" module 501, which is responsible for identifying, monitoring, and repairing errors or failures of the container handling vehicle.

[0029] In many cases, the exception handler module can perform the following actions without user intervention:

[0030] Automatically fix >97% of fixable robot errors without interrupting system operation

[0031] When a robot reports an error, the exception handler module takes over control of the specific robot, while other robots operate as usual

[0032] If a malfunctioning robot is not 100% certain of its own location, the anomaly module can block the cell area around the robot. The system can operate normally outside the boundaries of the blockade area.

[0033] • The anomaly module can use the robot's lifting equipment to search for unique patterns of container depth (in storage columns) within the blocked area to detect the robot's location.

[0034] If desired, another robot can be commanded to create a unique pattern of the container depth to help identify the location of the malfunctioning robot.

[0035] In some cases, it is a challenge to identify the specific cell (or vehicle may be between cells) where a malfunctioning robot is located, or the precise location of other types of anomalies. The latter problem is particularly difficult in the case of very large storage systems with low ceiling heights. In situations with low ceiling heights, all points within a very large surface area appear similar when viewed from above, making visual confirmation of the robot's location (e.g., using a fixed camera) difficult. Therefore, human inspectors are often required to manually inspect the upper surfaces of the storage system frame structure. However, this is a dangerous operation that often requires shutting down the system, which is costly. Therefore, there is a need for additional or alternative equipment to confirm errors, determine the precise location of disabled vehicles, or otherwise perform visual inspections of storage systems.

[0036] Flying drone

[0037] Small flying drones are commercially available. Examples of such commercially available drones include the A fleet of small quadcopters purchased. These drones have become quite sophisticated, with advanced positioning and obstacle avoidance systems making them relatively simple and reliable to operate.

[0038] Drones can be operated both indoors and outdoors. When outdoors, drones use GPS to determine location. Drones hover in a fixed position using GPS information to navigate to a desired location and return home if communications with the pilot are lost. Drones also have various other sensors: front, rear, top, and bottom collision detectors. Air pressure sensors are also used to determine altitude, etc.

[0039] When flying indoors, GPS signals are often unavailable. In this case, drones typically use downward-facing optical sensors to identify patterns on the floor in order to hover in a fixed position. Summary of the invention

[0040] The invention is set forth and characterized in the independent claim, while the dependent claims describe further characteristics of the invention.

[0041] In one aspect, the present invention relates to a method of using a flying drone to perform a visual inspection of a storage system, in particular to locate, identify and inspect malfunctioning container handling vehicles or other errors in an automated storage and retrieval system of the type described above.

[0042] In a second aspect, the present invention relates to a method for locating and resolving errors in an automatic storage and retrieval system, wherein an exception handler module of a control system communicates with a flying drone and controls the flying drone to locate and check suspected errors in the system (e.g., a malfunctioning autonomous container handling vehicle).

[0043] In a third aspect, a human operator pilots a flying drone according to the method to locate and check for possible errors.

[0044] The following are exemplary embodiments of the steps in the method according to the present invention:

[0045] Disable the vehicle from the system or otherwise report an error.

[0046] The control system's exception handler module knows the approximate location of the disabled vehicle. The exception handler module blocks off a large grid section surrounding the assumed location.

[0047] The exception handler module issues commands to the drone flight control module to deploy the flying drone.

[0048] The drone flight control module causes the drone to initiate an automatic takeoff sequence, ascending to a predetermined height that is above the frame structure of the storage system but below the height of the ceiling of the warehouse facility in which the frame is disposed.

[0049] The drone may have a height limiter function defining an upper height and a lower height, enabling the drone to fly safely above a vehicle operating on the upper level of the frame and in the space below the ceiling.

[0050] Based on the assumed location of the disabled vehicle, the drone control module causes the drone to initiate a search pattern.

[0051] In one embodiment, the drone uses an onboard optical sensor to navigate the grid pattern of the framework to the approximate location identified by the exception handler module. The drone can navigate over the grid by multiple means. For example, the drone can simply count the number of cells it passes over in the X and Y directions using an optical sensor to navigate to a given coordinate specified by the exception handler module. Alternatively, a fixed positioning device can help the drone navigate over the grid, such as a beacon, a location identifier, or other device attached to a known location (e.g., on the ceiling or on the frame structure itself). Such a device can have a unique visual identifier, RFD signal, etc. recognized by the drone. Similarly, the drone can identify a robot or multiple robots whose precise location is known to the exception handler module, or can identify a pattern about the vehicle location or container depth.

[0052] Once the approximate location of the disabled vehicle is reached, the drone may execute a preprogrammed search pattern to identify and precisely locate the disabled vehicle or otherwise identify the disabled vehicle (e.g., via a unique identifier on the robot). Alternatively or in addition, a human operator may assume control of the drone, using a camera on the drone to locate the disabled vehicle or other bug and / or perform a visual inspection of the disabled vehicle or other bug.

[0053] In another aspect, the disabled vehicle is instructed to send a short-range distress signal, such as an RFID signal that may be triggered by a signal sent from a drone or other device.

[0054] After the precise location of the disabled vehicle has been identified, the exception handler module can then redefine a smaller locked-off area to allow a larger portion of the storage system to continue normal operation.

[0055] The drone can initiate a return sequence after completing its mission, such as using a grid pattern or other navigational aids to find its way back to its base and the ground.

[0056] It will be appreciated that the method described above may be used for any type of fault requiring visual inspection, including, for example, inspection for suspected fires or other anomalies in the system or even routine visual inspection. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] The following drawings are attached to facilitate understanding of the present invention. The accompanying drawings illustrate embodiments of the present invention, which will now be described by way of example only, in which:

[0058] Figure 1 is a perspective view of a prior art automatic storage and retrieval system for storing and retrieving containers.

[0059] Figure 2 and Figure 3 It is a perspective view showing a container transport vehicle of the related art.

[0060] Figure 4 is a perspective view of a frame structure of a prior art automated storage and retrieval system, showing a flying drone taking off from a launch pad and hovering between a ceiling and an upper surface of the frame structure.

[0061] Figure 5 is a perspective view of a frame structure arranged below a ceiling having beams or other obstructions and shows a schematic representation of a human drone operator and a drone operating station.

[0062] Figure 6 is a side view showing the drone using sensors to avoid contact with the ceiling / beams and frame structure.

[0063] Figure 7 is a perspective view showing a drone flying at a relatively low altitude above a grid section where there are no container handling vehicles;

[0064] Figure 8 is a perspective view of a frame structure showing a plurality of container handling vehicles arranged in a recognizable pattern.

[0065] Fig. 9 is a top view showing a drone executing a search pattern and a grid section blocked by an exception handler module.

[0066] Fig.10 is a top view showing a drone locating a container handling vehicle by detecting short-range distress signals. DETAILED DESCRIPTION

[0067] In the following, embodiments of the present invention will be discussed in more detail with reference to the accompanying drawings. It should be understood, however, that the drawings are not intended to limit the present invention to the subject matter depicted in the drawings.

[0068] The present invention comprises an automatic storage and retrieval system 1, comprising a prior art system constructed according to the above described prior art and comprising: Figures 1 to 3 The frame structure 100 (i.e., a plurality of upright members 102 and a plurality of horizontal members 103) shown in the drawing is supported by the upright members 102, and further, the frame structure 100 includes a first upper rail system 108 in the X-direction and the Y-direction, on which the container handling vehicle 201 / 302 operates.

[0069] The frame structure 100 can have any size. In particular, it should be understood that the frame structure can be larger than Figure 1 The frame structures disclosed in the invention are wider and / or longer and / or deeper. For example, the frame structure 100 can have a horizontal extent of more than 700×700 columns and a storage depth of more than 12 containers.

[0070] The operation of the automated storage and retrieval system is directed and monitored by a computerized control system 500, which includes, for example, Figure 1 The exception handler module 501 is conceptually shown in FIG. 5 and is responsible for, among other things, detecting and correcting anomalies or errors in the operation of container handling vehicles, such as, for example, defining a blocked area of ​​a grid surrounding a disabled vehicle.

[0071] Now refer to Figures 4 to 10 One embodiment of an automated storage and retrieval system and a method of monitoring such a system according to the present invention is discussed in more detail.

[0072] The present invention includes the use of a flying drone 400 to monitor the operation of a storage system and to locate and visually inspect various aspects of the system, such as locating and inspecting an out-of-service container handling vehicle 201A / 301A. As used herein, the term "flying drone" refers to an unmanned, remotely operated rotary-wing aircraft (such as a helicopter or quadcopter) that is partially or fully held in the air by a lifting surface (rotor) that rotates about a vertical axis. The drone 400 can be operated by a human pilot 402 (e.g. Figure 5 In another aspect, the flight of the drone may be automated, such as by a flight control module 502 of a control system 500 that communicates with an exception handler module 501, for example.

[0073] The present invention will be described in conjunction with one illustrative example of a monitoring system, namely the location and visual inspection of a malfunctioning container handling vehicle 201A / 301A. However, it should be understood that drones can also be used to locate and inspect many other types of faults and conditions, such as inspecting suspected defects in frame structures, locating suspected fires, or general visual inspection of systems.

[0074] like Figure 4 As shown, drone 400 is launched from launch pad 406. The drone may be controlled by flight control module 502 or may be controlled by a human pilot 402. Drone 400 flies at an altitude in airspace 408 between an upper surface 410 of the frame structure and a ceiling 412 of a building in which the storage system is installed. Figure 5 As shown, airspace 408 may also be the height between upper surface 410 and an obstacle attached to ceiling 412 (eg, beam 414 ).

[0075] like Figure 6 As shown, drone 400 may include camera 415 (not shown) and obstacle avoidance sensors 416 arranged to maintain the altitude of the drone within airspace 408. The drone may also have a pre-programmed altitude limit, such as controlled by flight control module 502.

[0076] Send a flight mission to the drone to locate the disabled vehicle 201A / 301A. Figure 7 It is understood that the upper surface of the frame structure may have large areas without operating vehicles or other visual cues, wherein the operating vehicles or other visual cues are used for visual confirmation of the precise position of the drone at a given point during the flight mission. Therefore, the method of the present invention includes a navigation device that allows the drone to navigate above the frame structure and determine the precise position.

[0077] Figure 8Conceptually illustrated is one possible method for determining the precise location of a drone at any given point during a flight mission, the method comprising communicating with a control system 500 or an exception handler module 500 that is aware of the precise location of an operating vehicle 201 / 301. The operating vehicle may emit a position signal 418 that may be detected by the drone 400. Alternatively, the drone 400 may be equipped with a camera arranged to detect a plurality of vehicles arranged in a particular pattern 420 at known locations that may be identified by the exception handler module 501.

[0078] Alternatively, the drone 400 may be commanded to fly above the surface of the frame structure, counting cells in the grid structure in the X and Y directions until the drone reaches Fig. 9 4 and 5. The coordinates of the first larger blocked area 422 shown in FIG. 4 are defined by the exception handler module 502 and are based on the estimated location of the disabled vehicle 201A / 301A.

[0079] like Fig. 9 As shown, upon reaching the first blockade area 422, the drone 400 may be commanded to execute a preprogrammed search pattern 424. As the drone executes the search pattern, the exception handler module may periodically redefine a second, smaller blockade area 426. The drone continues to follow the search pattern until it eventually visually locates a disabled vehicle 201A / 301A, whereupon the exception handler module defines a third, most restricted blockade area 428. Fig.10 As shown, drone 400 may alternatively detect a distress signal 430 transmitted by a disabled vehicle.

[0080] Upon reaching its intended location, the drone may perform a visual inspection, for example by recording still images or video with its camera. Alternatively, a human pilot 402 may perform a visual inspection.

[0081] Upon completion of the mission, the drone 400 returns to its launch pad 406 either by a pre-programmed return command, by counting grid cells again, or with assistance from a human pilot.

[0082] In the foregoing description, various aspects of the inspection method using a drone have been described. However, the description is not intended to be interpreted in a limiting sense. Various modifications and variations of the illustrative embodiments and other embodiments of the system that are obvious to those skilled in the art to which the disclosed subject matter belongs are considered to fall within the scope of the present invention.

[0083] Reference Numbers List

[0084] 1. Automatic storage and retrieval system of prior art

[0085] 100 Frame structure

[0086] 102 Vertical members of frame structure

[0087] 103 Horizontal members of frame structures

[0088] 104 Storage Grid

[0089] 105 Storage Column

[0090] 106 Storage Container

[0091] 106' storage container specific location

[0092] 107 Stacking

[0093] 108 Track System

[0094] 110 Parallel tracks in the first direction (X)

[0095] 110a The first track in the first direction (X)

[0096] 110b The second track in the first direction (X)

[0097] 111 Parallel tracks in the second direction (Y)

[0098] 111a The first track in the second direction (Y)

[0099] 111b The second track in the second direction (Y)

[0100] 112 access openings / grid unit

[0101] 119 First port column

[0102] 120 Second port column

[0103] 201 Prior Art Storage Container Vehicles

[0104] 201a The vehicle body of the storage container vehicle 201

[0105] 201b Drive unit / wheel arrangement, first direction (X)

[0106] 201c Drive unit / wheel arrangement, second direction (Y)

[0107] 301 Prior Art Cantilever Storage Container Vehicle

[0108] 301a The vehicle body of the storage container vehicle 301

[0109] 301b Driving device in the first direction (X)

[0110] 301c Driving device in the second direction (Y)

[0111] 304 Clamping equipment

[0112] 500 Control System

[0113] 501 Exception Handler Module

[0114] X first direction

[0115] Y Second direction

[0116] Z third direction

[0117] 201A / 301A out-of-service vehicles

[0118] 400 Flying Drone

[0119] 402 Pilot

[0120] 404 Flight Control Station

[0121] 406 Launch Pad

[0122] 408 Airspace

[0123] 410 Upper surface of frame

[0124] 412 Ceiling

[0125] 414 Liang

[0126] 415 Camera

[0127] 416 Sensors

[0128] 418 Position signal

[0129] 420 Known patterns of vehicles

[0130] 422 Larger Blocked Area

[0131] 424 Search Pattern

[0132] 426 Smaller blocked area

[0133] 428 Final Blockade Area

[0134] 430 Distress Signal

Claims

1. A method for monitoring an automatic storage and retrieval system (1), the automatic storage and retrieval system include: A storage grid (104) provided by a frame structure (100) arranged below a ceiling (412) in a building, the frame structure (100) comprising a rail system (108) arranged at an upper level of the frame structure, the rail system extending in a first direction (X) and a second direction (Y); a plurality of container handling vehicles (201 / 301) operating on the track system (108) for collecting storage containers (106) and returning the storage containers, and A control system (500) for monitoring and controlling the automatic storage and retrieval system, the control system comprising: an exception handling program module (501) responsible for identifying and attempting to correct anomalies in the operation of the automatic storage and retrieval system; and a flight control module (502) responsible for controlling the flight of the flying drone (400), wherein the flight control module directs the flight of the flying drone in response to instructions received from the exception handling program module (501), The method comprises the following steps: causing the flying drone (400) equipped with a camera (415) to fly at an altitude in an airspace (408) between the ceiling (412) or a rooftop obstacle (414) below the ceiling and an upper surface (410) of the frame structure (100), navigating the flying drone (400) to a suspected location of anomalies in the system or other aspects of the system that require inspection, using the flying drone to locate the anomaly or aspect of the system that requires inspection, A visual inspection of the anomaly or aspect of the system requiring inspection is performed using the camera of the flying drone.

2. The method according to claim 1, in, The flight control module includes instructions for limiting the altitude of the flying drone during horizontal flight to within the airspace between the ceiling (410) and the upper surface (410) of the frame structure.

3. The method according to any one of the preceding claims, in, The flying drone is directed to the suspected location of the anomaly by identifying known patterns in the location of the container handling vehicles.

4. The method according to any one of the preceding claims, in, The track system includes a first set of parallel tracks (110) and a second set of parallel tracks (111), wherein the second set of parallel tracks is arranged orthogonally to the first set of parallel tracks to define grid cells (112), and the flying drone is guided to the suspected location of the anomaly by counting grid cells in the first direction (X) and the second direction (Y) to reach the grid coordinates specified by the anomaly handler module (501).

5. The method according to any one of the preceding claims, in, The exception handler module defines a first larger containment area (422) of the grid surrounding the suspected location of the exception, within which the container handling vehicle is not allowed to operate, and wherein the exception handler module defines a second smaller containment area (426) based on input received from the flying drone.

6. The method according to any one of the preceding claims, in, The flight control module instructs the flying drone to execute a preprogrammed search pattern to locate the anomaly.

7. The method according to any one of the preceding claims, in, The track system includes a first set of parallel tracks (110) and a second set of parallel tracks (111), the second set of parallel tracks being arranged orthogonally to the first set of parallel tracks to define grid cells (112), and the anomaly is a malfunctioning container handling vehicle, the specific cell of the grid at which the container handling vehicle is located being unknown to the anomaly handler module.

8. The method according to any one of the preceding claims, in, A human pilot assumes flight control of the flying drone and performs a visual inspection for the anomaly.

9. The method according to any one of the preceding claims, in, The rail system comprises: a first group of parallel rails (110) arranged in a horizontal plane (P) and extending in the first direction (X); and a second group of parallel rails (111) arranged in the horizontal plane (P) and extending in the second direction (Y) orthogonal to the first direction (X), the first group of parallel rails (110) and the second group of parallel rails (111) forming a grid pattern in the horizontal plane (P), the rail system comprising a plurality of adjacent access openings / grid units (112), and the storage grid defining a plurality of storage columns (105), each of the storage columns being arranged to store a stack (107) of corresponding storage containers (106), wherein the storage columns (105) are located below the rail system (108), and wherein each of the storage columns (105) is vertically located below the corresponding access opening / grid unit (112).

Images