Robotic integration station and storage system

Abstract

The present invention provides an integration station for use in a storage system, the storage system comprising a frame structure capable of storing a plurality of storage containers; the integration station comprises: a first transfer route for transferring the storage containers; and a second transfer route for transferring the storage containers, where each of the first transfer route and the second transfer route includes a first end and a second end, where each first end is configured to be operatively connected to the frame structure and each second end is configured to be operatively connected to the frame structure; the first end portion of the first conveying route and the first end portion of the second conveying route are the same first end portion, and / or the second end portion of the first conveying route and the second end portion of the second conveying route are the same second end portion. The invention also provides a storage system comprising the integration station and a method of integrating items stored in the storage system.

Description

[0001] This application is a divisional application of the Chinese patent invention application "Robotic Consolidation Station and Storage System" with an application date of January 28, 2021 and an application number of 202180038960.5. Technical Field

[0002] The present invention relates to a robotic consolidation station (mechanical consolidation station) for an automated storage and retrieval system and an automated storage and retrieval system having a robotic consolidation station. Background Art

[0003] Figure 1 A common prior art automated storage and retrieval system 1 having a frame structure 100 is disclosed, 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 includes upright members 102, horizontal members 103, and a storage volume including storage rows 105 arranged in rows between the upright members 102 and the horizontal members 103. In these storage rows 105, storage containers 106 (also referred to as bins) are stacked one on top of another to form stacks 107. The members 102, 103 can generally be made of metal (such as extruded aluminum profiles).

[0005] The frame structure 100 of the automated storage and retrieval system 1 includes a guide rail system 108 arranged to span the top of the frame structure 100, on which a plurality of container handling vehicles 201, 301 travel to lift storage containers 106 from the storage rows 105 and lower the storage containers 106 into the storage rows, and also to transport the storage containers 106 above the storage rows 105. The guide rail system 108 includes: a first set of parallel guide rails 110 and a second set of parallel guide rails 111, wherein the first set of parallel guide rails is arranged to guide the container handling vehicles 201, 301 to travel across the top of the frame structure 100 in a first direction X, and the second set of parallel guide rails is arranged perpendicular to the first set of guide rails 110 to guide the container handling vehicles 201, 301 in a second direction Y perpendicular to the first direction X. The containers 106 stored in the rows 105 are accessed by the container handling vehicles through access openings 112 in the guide rail system 108. The container handling vehicles 201, 301 can move laterally above the storage rows 105, i.e., in a plane parallel to the horizontal X - Y plane.

[0006] The upright member 102 of the frame structure 100 can be used to guide the storage container during the process of lifting the container from the column 105 and lowering the container into the column. The stack 107 of containers 106 is generally self-supporting.

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

[0008] Each prior art container handling vehicle 201, 301 also includes a lifting device (not shown), which is used for the vertical transportation of the storage container 106, for example, lifting the storage container 106 from the storage column 105 and lowering the storage container 106 into the storage column. The lifting device includes one or more clamping / engaging devices adapted to engage with the storage container 106, and these clamping / engaging devices can be lowered from the vehicles 201, 301 so that the position of the clamping / engaging device relative to the vehicles 201, 301 can be adjusted in a third direction Z orthogonal to the first direction X and the second direction Y. Some parts of the clamping device of the container handling vehicle 301 are shown in Figure 3 and are denoted by the reference numeral 304. The clamping device of the container handling device 201 is located within the vehicle body 301a in Figure 2 .

[0009] Conventionally and for the purposes of the present application, Z = 1 represents the uppermost layer of the storage container, i.e., the layer immediately below the track system 108, Z = 2 represents the second layer below the track system 108, and Z = 3 represents the third layer. In the exemplary prior art disclosed in Figure 1 , Z = 8 represents the bottommost layer of the storage container. Similarly, X = l...n and Y = l...n represent the positions of each storage column 105 on the horizontal plane. Thus, as an example and using the Cartesian coordinate system X, Y, Z shown in Figure 1 , it can be said that in Figure 1The storage container identified as 106’ occupies the storage position of X = 10, Y = 2, Z = 3. It can be said that the container handling vehicles 201, 301 travel in the Z = 0 layer, and each storage column 105 can be identified by its X and Y coordinates.

[0010] The storage volume part of the frame structure 100 is generally referred to as the grid 104, where the possible storage positions within the grid are called storage units. Each storage column can be identified by positions in the X - direction and Y - direction, while each storage unit can be identified by the container number in the X - direction, Y - direction, and Z - direction.

[0011] Each prior - art container handling vehicle 201, 301 includes a storage compartment or space for receiving and loading the storage container 106 when transporting it across the guide rail system 108. The storage space can include a cavity (as Figure 2 shown) centrally arranged within the vehicle body 201a and, for example, as described in WO2015 / 193278A1, the content of which is incorporated herein by reference.

[0012] Figure 3 An alternative configuration of the container handling vehicle 301 with a cantilever structure is shown. Such a vehicle is described in detail, for example, in NO317366, the content of which is incorporated herein by reference.

[0013] Figure 2 The occupied area of the central - cavity container handling vehicle 201 shown in can cover an area that is approximately equal in size in the X - direction and Y - direction to the lateral extent of the storage column 105, for example, as described in WO2015 / 193278A1, the content of which is incorporated herein by reference. The term "lateral" used herein can mean "horizontal".

[0014] Alternatively, the occupied area of the central - cavity container handling vehicle 201 can be larger than the lateral area defined by the storage column 105, for example, as disclosed in WO2014 / 090684A1.

[0015] The guide rail system 108 generally includes guide rails with grooves in which the wheels of the vehicle travel. Alternatively, the guide rails can include upward - protruding elements, where the wheels of the vehicle include flanges to prevent derailment. These grooves and upward - protruding elements are collectively referred to as tracks. Each guide rail can include one track, or each guide rail can include two parallel tracks.

[0016] WO2018146304 (the content of which is incorporated herein by reference) shows a common configuration of the guide rail system 108, including guide rails and parallel tracks in both the X - direction and Y - direction.

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

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

[0019] The access station can typically be a picking station or a stocking station where product items are removed from or placed into the storage containers 106. In the picking station or stocking station, the storage containers 106 are generally not removed from the automated storage and retrieval system 1 but are returned to the frame structure 100 after access. The ports can also be used to transfer the storage containers to another storage facility (e.g., another frame structure or another automated storage and retrieval system), a transportation vehicle (e.g., a train or a truck), or a production facility.

[0020] A conveyor system including conveyors is typically employed to transport the storage containers between the port columns 119, 120 and the access station.

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

[0022] The transfer system can be arranged to transfer storage containers 106 between different frame structures, as described, for example, in WO2014 / 075937A1, the content of which is incorporated herein by reference.

[0023] WO 2019 / 206971 A1 discloses a prior art access station. The access station is connected to a container outlet and a container inlet. Through the container outlet, a container can be taken out of the frame 100 of the storage system, and through the container inlet, a container can be placed into the frame 100 of the storage system.

[0024] When accessing a storage container 106 stored in one of the columns 105 disclosed in Figure 1 one of the container handling vehicles among the plurality of container handling vehicles 201, 301 is instructed to take out the target storage container from the location where the target storage container 106 is located and transport the target storage container to the unloading port column 119. The operation includes moving the container handling vehicles 201, 301 to a position above the storage column 105 where the target storage container 106 is located, using the lifting devices (not shown) of the container handling vehicles 201, 301 to take out the storage container 106 from the storage column 105, and transporting the storage container 106 to the unloading port column 119. If the target storage container 106 is deep in the stack 107, that is, one or more other storage containers 106 are located above the target storage container 106, the operation further includes temporarily moving the storage containers located above before lifting the target storage container 106 from the storage column 105. This step is sometimes referred to in the art as "digging" and can be performed by the same container handling vehicle subsequently used to transport the target storage container to the unloading port column 119, or by one or more other cooperative container handling vehicles. Alternatively or additionally, the automated storage and retrieval system 1 can have a container handling vehicle dedicated to the task of temporarily removing storage containers from the storage column 105. After the target storage container 106 and the storage containers removed from the storage column 105, the temporarily removed storage containers can be repositioned to the initial storage column 105. However, the removed storage containers can alternatively be repositioned to other storage columns.

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

[0026] To monitor and control an automated storage and retrieval system 1, for example, monitor and control the position of each storage container 106 within the frame structure 100, the contents of each storage container 106; and monitor and control the movement of the container handling vehicles 201, 301 such that the required storage container 106 can be transferred to the required position at the required time without the container handling vehicles 201, 301 colliding with each other, the automated storage and retrieval system 1 includes a control system 500, which is typically computerized and typically includes a database for tracking the storage containers 106.

[0027] Operations performed in some prior art storage systems are to consolidate multiple different items picked from a storage grid, for example, consolidate multiple items belonging to one customer order. These multiple items are consolidated for further processing, such as packaging them in a single parcel for shipment to the customer.

[0028] In prior art systems, the consolidation of multiple items is performed by first transporting the storage containers containing the order items from the storage grid to a manual picking / inventory station (i.e., access station), for example, as disclosed in WO 2019 / 206971 A1. At the picking / inventory station, an operator picks the required order items and places them in a single parcel for further processing, such as shipment to the customer. The different items to be consolidated are typically stored in different storage containers, so the speed of the consolidation process is limited by the speed of the different storage containers available at the picking / inventory station. However, although benefits are obtained through the consolidation process, it has been found that the processing speed of the same order with the same items from the same storage container is not significantly faster than that of different orders because, due to accessing different storage containers sequentially, for each order, the storage container has to cycle between the picking / inventory station and the frame of the storage system. Therefore, there is a need to further improve the prior art consolidation operation.

[0029] An object of the present invention is to provide a storage system that is more efficient than prior art systems in terms of item consolidation. Summary of the Invention

[0030] In a first aspect, the present invention provides a robotic consolidation station for use in a storage system, the storage system including a frame structure in which a plurality of storage containers can be stored; and

[0031] The consolidation station includes: a first transfer route for transferring storage containers containing items to be picked; a second transfer route for transferring storage containers in which items are to be consolidated or have been consolidated; and a robotic picking arm arranged to reach the first transfer route and the second transfer route, wherein

[0032] Each of the first transfer route and the second transfer route includes a first end and a second end, wherein each first end is operatively connected to the container outlet of the frame structure for transferring the storage container out of the frame structure, and each second end is operatively connected to the container inlet of the frame structure for transferring the storage container into the frame structure; and

[0033] The first transfer route includes a picking section, and the second transfer route includes an integration section; and

[0034] The robotic picking arm is arranged such that items can be picked from a first storage container disposed on the picking section by using the robotic picking arm, and the items can be transferred to a second storage container disposed on the integration section by using the robotic picking arm; and

[0035] The first transfer route can be operated independently of the integration section and is arranged such that the first storage container can be transferred from the container outlet to the container inlet via the picking section, while the second storage container is disposed on the integration section.

[0036] In an embodiment of the robotic integration station, a plurality of storage containers can be disposed on the integration section, and the first storage container is transferred from the container outlet to the container inlet via the picking section.

[0037] In an embodiment of the robotic integration station, the picking section can be arranged in parallel with the integration section.

[0038] In an embodiment of the integration station, the integration station can be used for storage containers having a rectangular horizontal perimeter, and the picking section and the integration section can be arranged such that one long side of the first storage container disposed at the picking section faces and is parallel to one long side of the second storage container disposed at the integration section.

[0039] In an embodiment of the robotic integration station, the robotic picking arm can be arranged to minimize the moving distance when the robotic picking arm moves between the picking section and the integration section. The robotic picking arm can be arranged between the picking section and the integration section. The robotic picking arm can have a base, wherein the base is mounted at a substantially equal distance from the picking section and the integration section, for example, at an equal distance from the center of the picking section and the center of the integration section.

[0040] In an embodiment of the robotic integration station, the first transfer route and the second transfer route can have a common first end, that is, the first end of the first transfer route and the first end of the second transfer route are the same end.

[0041] In an embodiment of the robotic integration station, the first transfer route and the second transfer route can have a common second end, that is, the second end of the first transfer route and the second end of the second transfer route are the same end.

[0042] In an embodiment of the robotic integration station, the same first end of the first transfer route and the second transfer route includes an outlet transfer element operatively connected to the container outlet. The outlet transfer element may be a transfer unit for accommodating and transferring a single storage container at a time.

[0043] In an embodiment of the robotic integration station, the same second end of the first transfer route and the second transfer route includes an inlet transfer element operatively connected to the container inlet. The inlet transfer element may be a transfer unit for accommodating and transferring a single storage container at a time.

[0044] In an embodiment of the robotic integration station, the first transfer route and the second transfer route include the same first transfer crossover section, and storage containers leaving the first transfer crossover section can be transferred to the picking section in a first direction or to the integration section in a second direction. The first direction may be perpendicular to the second direction.

[0045] In an embodiment of the robotic integration station, the first transfer route and the second transfer route include the same second transfer crossover section, and storage containers arriving from either the picking section or the integration section can be transferred from the second transfer crossover section to the container inlet.

[0046] In an embodiment of the robotic integration station, the first transfer route includes a first transfer module, and the second transfer route includes a second transfer module. Each transfer module is capable of accommodating a row of three storage containers and includes an intermediate container section, a first end container section, and a second end container section. Each of these container sections is arranged to accommodate a single storage container, and each of these transfer modules includes a moving assembly arranged to move the storage container horizontally between either end container section and the intermediate container section. And each end container section has a roller conveyor arranged to transfer the storage container in a direction perpendicular to the horizontal direction between either end container section and the intermediate container section.

[0047] In an embodiment of the robotic integration station, the picking section is the intermediate container section of the first transfer module.

[0048] In an embodiment of the robotic integration station, the integration section includes the intermediate container section of the second transfer module. The integration section may selectively include either the first end container section or the second end container section of the second transfer module.

[0049] In an embodiment of the robotic integration station, the mobile component may be a lifting component that is arranged to lift a storage container and move it horizontally between any one of the end container sections and the intermediate container section, and a roller conveyor is arranged to transfer the storage container in a direction perpendicular to the horizontal direction along which the lifting component is movable. The lifting component may include a carriage movable in the horizontal direction and two parallel beams connected to the carriage and arranged to raise and lower at least one storage container in the vertical direction. In other words, the two parallel beams may be connected to the carriage such that the beams can raise and lower at least one storage container in the vertical direction and move the storage container horizontally via the carriage.

[0050] In an embodiment of the robotic integration station, the first end container section and the second end container section of the first transfer module and the first end container section and the second end container section of the second transfer module may be connected via transfer elements respectively, which are arranged to transfer containers between the corresponding first end container section and the second end container section.

[0051] In an embodiment of the robotic integration station, each of the first end container section and the second end container section of the first transfer module may be connected to a corresponding transfer element to connect to the container outlet and the container inlet of the frame structure.

[0052] In a second aspect, the present invention provides a storage system comprising a robotic integration station according to any one of the embodiments of the first aspect of the present invention, wherein

[0053] the storage system includes: a frame structure in which a plurality of storage containers can be stored; a container outlet for transferring the storage containers out of the frame structure; and a container inlet for transferring the storage containers into the frame structure;

[0054] wherein the first transfer route and the second transfer route of the robotic integration station are operably connected to the container outlet and the container inlet.

[0055] In an embodiment, the storage system may include at least one container handling vehicle, and the frame structure may include a plurality of storage rows in which the storage containers can be stacked vertically on top of each other, and the container handling vehicle runs on a guide rail system located at the top layer of the frame structure for taking out the storage containers from the storage rows, storing the storage containers in the storage rows, and horizontally transferring the storage containers on the guide rail system.

[0056] In an embodiment of the storage system, the frame structure may include at least one port column through which storage containers may be transferred between a top layer of the frame structure and a transfer location at a lower layer of the frame structure, the transfer location being operably connected to a robotic integration station via a container outlet and a container inlet. The transfer location may be arranged at the same height as the container inlet and the container outlet. Storage containers may be transferred between the top layer of the frame structure and the transfer location by using a container handling vehicle.

[0057] In an embodiment of the storage system, the storage system may include a container transfer assembly for transferring storage containers between the transfer location and the integration station, the container transfer assembly including at least one transfer conveyor module that is capable of accommodating a row of three storage containers and includes a first end container section and a second end container section and an intermediate container section arranged at the transfer location, each container section being arranged to accommodate a single storage container, and the transfer conveyor module including a moving assembly and a roller conveyor, the moving assembly being arranged to move a storage container horizontally between any one of the end container sections and the intermediate container section, and the roller conveyor being arranged to transfer a storage container in a direction perpendicular to the horizontal direction between any one of the end container sections and the intermediate container section. The transfer conveyor module may be substantially similar to the conveyor module of the integration station.

[0058] In an embodiment of the storage system, the moving assembly may be a lifting assembly arranged to lift a storage container and move it horizontally between any one of the end container sections and the intermediate container section, and the roller conveyor is arranged to transfer a storage container in a direction perpendicular to the horizontal direction along which the lifting assembly may move. The lifting assembly may include a trolley movable in the horizontal direction and two parallel beams connected to the trolley and arranged to lift at least one container in the vertical direction.

[0059] In an embodiment, the storage system may include a plurality of port columns, and the container transfer assembly may include a plurality of transfer conveyor modules, wherein each intermediate container section is arranged at a corresponding transfer point.

[0060] In an embodiment of the storage system, the plurality of transfer conveyor modules are interconnected at their first end container sections and second end container sections by a conveyor element capable of accommodating at least one storage container and transport at least one storage container in the same direction as the roller conveyor of the end container section.

[0061] In a third aspect, the present invention provides a method of integrating items stored in a storage system, the system including a robotic integration station, wherein

[0062] The storage system includes: a frame structure in which a plurality of storage containers can be stored; a container outlet for transferring the storage containers out of the frame structure; and a container inlet for transporting the storage containers into the frame structure; and

[0063] The consolidation station includes: a first transfer route for transferring storage containers containing items to be picked; a second transfer route for transferring storage containers in which items are to be consolidated or have been consolidated; and a robotic picking arm arranged to reach the first and second transfer routes, wherein

[0064] Each of the first and second transfer routes includes a first end and a second end, wherein each first end is operatively connected to the container outlet and each second end is operatively connected to the container inlet; and

[0065] The first transfer route includes a picking section and the second transfer route includes a consolidation section; and

[0066] The method includes the following steps:

[0067] - Transferring a first storage container containing at least one first item from the container outlet to the picking section via the first transfer route;

[0068] - Transferring a second storage container from the container outlet to the consolidation section via the second transfer route; and

[0069] - Picking at least one first item from the first storage container using the robotic picking arm and adding the at least one first item to the second storage container.

[0070] In an embodiment of the method according to the third aspect, the method may include the following steps:

[0071] - Transferring the first storage container to the container inlet via the first transfer route;

[0072] - Transferring a third storage container containing at least one second item from the container outlet to the picking section via the first transfer route; and

[0073] - Picking at least one second item from the third storage container using the robotic picking arm and adding the at least one second item to the second storage container.

[0074] In an embodiment of the method according to the third aspect, the first storage container may contain a plurality of first items, and the method may include the following steps:

[0075] - Transferring a fourth storage container from the container outlet to the consolidation section via the second transfer route; and

[0076] - Picking at least one first item from a first storage container using a robotic picking arm and adding the at least one first item to a fourth storage container.

[0077] The method according to the third aspect can also be referred to as a method of integrating items stored in a storage system into a customer order. The customer order can be used for intermediate storage or transfer to a processing facility.

[0078] In a fourth aspect, the present invention provides a method of integrating items stored in a storage system, the storage system including a robotic integration station, wherein

[0079] The storage system includes: a frame structure in which a plurality of storage containers can be stored; a container outlet for transferring a storage container out of the frame structure; and a container inlet for transferring a storage container into the frame structure; and

[0080] The integration station includes: a first transfer route for transferring a storage container containing an item to be picked; a second transfer route for transferring a storage container in which an item is to be integrated or has been integrated; and a robotic picking arm arranged to reach the first transfer route and the second transfer route, wherein

[0081] Each of the first transfer route and the second transfer route includes a first end and a second end, wherein each first end is operatively connected to the container outlet, each second end is operatively connected to the container inlet; and the first transfer route includes a picking section, and the second transfer route includes an integration section; and

[0082] The method includes the following steps:

[0083] - Transferring a first storage container containing at least one first item from the container outlet to the picking section via the first transfer route;

[0084] - Transferring a second storage container from the container outlet to the integration section via the second transfer route, the second storage container being either empty or having space for at least one first item; and

[0085] - Picking at least one first item from the first storage container using the robotic picking arm and adding the at least one first item to the second storage container; and

[0086] - Repeating the step of picking at least one first item from the first storage container using the robotic picking arm and adding the at least one first item to the second storage container until the first storage container is empty or the second storage container is full.

[0087] In an embodiment of the method according to the fourth aspect, the method may include the following steps:

[0088] - When the first storage container is empty, transfer the first storage container to or towards the container inlet via the first transfer route.

[0089] In an embodiment of the method according to the fourth aspect, the method may include the following steps:

[0090] - Transfer a third storage container containing at least one first item from the container outlet to the picking section via the first transfer route;

[0091] - Pick at least one first item from the third storage container using a robotic picking arm and add the at least one first item to the second storage container; and

[0092] - Repeat the step of picking at least one first item from the third storage container using a robotic picking arm and adding the at least one first item to the second storage container until the third storage container is empty or the second storage container is full.

[0093] In an embodiment of the method according to the fourth aspect, the method may include the following steps:

[0094] - When the second storage container is full and / or the first storage container is empty, transfer the second storage container to or towards the container inlet via the second transfer route.

[0095] In an embodiment of the method according to the fourth aspect, the method may include the following steps:

[0096] - When the fourth storage container is empty or has space for at least one first item, transfer the fourth storage container from the container outlet to the integration section via the second transfer route;

[0097] - Pick at least one first item from the first storage container using a robotic picking arm and add the at least one first item to the fourth storage container; and

[0098] - Repeat the step of picking at least one first item from the first storage container using a robotic picking arm and adding the at least one first item to the fourth storage container until the first storage container is empty or the fourth storage container is full.

[0099] The method according to the fourth aspect may also be referred to as a method for internal integration of items in a storage system.

[0100] The methods according to the third and fourth aspects may be performed by using any embodiment of the present invention according to the first and second aspects.

[0101] In all aspects of the present invention, a robotic picking arm is used to perform all picking and transfer movements of items contained in storage containers.

[0102] The term "robotic picking arm" refers to any robotic picking device suitable for picking and transferring items between two storage containers.

[0103] The term "transfer route" refers to a route on which containers can move provided by any suitable transfer component. The transfer component may include a plurality of transfer units or modules, where each unit or module can accommodate at least one container and move the container in at least one horizontal direction. The transfer component and / or the plurality of transfer units or modules may include any suitable combination of belts, rollers, and horizontally shiftable lifting beams. BRIEF DESCRIPTION OF THE DRAWINGS

[0104] Embodiments of the present invention are described in detail with reference to the following drawings:

[0105] Figure 1 is a perspective view of the framework structure of an automated storage and retrieval system of the prior art.

[0106] Figure 2 is a perspective view of a container handling vehicle of the prior art, which has a centrally arranged cavity for carrying storage containers therein.

[0107] Figure 3 is a perspective view of a container handling vehicle of the prior art, which has a cantilever for carrying a storage container below.

[0108] Figures 4a to 4b is a schematic view of a storage system having an exemplary robotic integration station according to the present invention.

[0109] Figure 5 is a side perspective view of a storage system having an exemplary robotic integration station with a layout similar to that in Figure 4a the schematic view.

[0110] Figure 6 is Figure 5 an enlarged view of the robotic integration station in

[0111] Figure 7 is Figure 6 a top perspective view of the robotic integration station in

[0112] Figure 8 is Figure 6 a front perspective view of the robotic integration station in

[0113] Figure 9 is Figure 6A top-down perspective view of the robot integration station and the container transfer component in it. Detailed implementation

[0114] In the following, embodiments of the present invention will be discussed in more detail with reference to the accompanying drawings. However, the drawings are not intended to limit the present invention to the subject matter described in the drawings.

[0115] The present invention provides an advantageous integration station 2 for a storage system, in which various items are stored in a plurality of containers (i.e., storage containers or bins). The storage system used in conjunction with the integration station can advantageously be similar to the Figure 1 prior art storage system shown. Figure 4a and Figure 4b The schematic diagrams in show the layout of the integration station 2.

[0116] The integration station 2 has a first transfer route 3 for transferring the storage container 106 containing the items to be picked, a second transfer route 4 for transferring the storage container in which the items are to be integrated or have been integrated, and a robotic picking arm 5 arranged to reach the first transfer route 3 and the second transfer route 4. Each of the first transfer route 3 and the second transfer route 4 has a first end 6 and a second end 7, and each first end 6 is operatively connected to the same container outlet 8 of the frame structure 100 for transferring the storage container 106 out of the frame structure 100, and each second end 7 is operatively connected to the same container inlet 9 of the frame structure for transferring the storage container 106 into the frame structure 100. In Figure 4a and Figure 4b , the integration station is arranged at the outer sidewall of the frame structure 100, but in some cases, at least part of the integration structure 2 can be arranged inside the frame structure or arranged in a recess formed in the frame structure.

[0117] The first transfer route 3 includes a picking section 10, and the second transfer route 4 includes an integration section 11.

[0118] The robotic picking arm 5 is arranged such that items can be picked from a first storage container 106' arranged on the picking section 10 by using the robotic picking arm 5 and transferred to a second storage container 106' arranged on the integration section 11 by using the robotic picking arm 5. The picking section 10 and the integration section 11 are arranged in parallel to ensure that the robotic picking arm can move the minimum distance between the picking section and the integration section during the integration operation.

[0119] It is highly advantageous to minimize the floor space occupied by the integration station 2 by connecting it to the same container outlet 8 and the same container inlet 9 through which the first storage container 106' and the second storage container 106" can enter or leave respectively. In addition, setting multiple container outlets and inlets in the frame structure will also reduce the available storage space in the storage system.

[0120] According to the layout of the transfer routes 3, 4, the robotic picking arm 5 can be arranged between the picking section 10 and the integration section 11 (refer to Figure 4a ), or arranged on a gantry (not shown), which is arranged above the picking section 10 and the integration section 11 (refer to Figure 4a ). The robotic picking arm 5 can be provided on a base 12, wherein the base 12 is positioned at a substantially equal distance from the picking section 10 and the integration section 11.

[0121] The first transfer route 3 can operate independently of the integration section 11 of the second transfer route 4, and is arranged such that the first storage container 106' can be transferred from the container outlet 8 to the container inlet 9 via the picking section 10, while the second storage container 106" is arranged on the integration section 11. The first transfer route 3 and the second transfer route 4 have the same first transfer crossover section 13 and the same second transfer crossover section 22. The container 106 leaving the container outlet 8 from the first transfer crossover section can be transferred to the picking section 10 in the first direction or to the integration section 11 in the second direction. Containers arriving from either the picking section 10 or the integration section 11 can be transferred to the container inlet 9 from the second transfer crossover section.

[0122] Figures 5 to 9 An exemplary embodiment of the integration station 2 connected to the frame structure 100 of the storage system is shown. For illustrative purposes, Figure 9 the integration station 2 and the cooperating container transfer assembly 24 are shown without the frame structure 100.

[0123] In the exemplary integration station 2, the first transfer route 3 includes a first transfer module 14, and the second transfer route 4 includes a second transfer module 14'. Each transfer module is capable of accommodating a row of three containers 106 and includes an intermediate container section 15, a first end container section 16, and a second end container section 16'. The container sections 15, 16, 16' are arranged to accommodate a single container 106.

[0124] The transfer modules 14, 14' include a trolley 17 and two parallel beams 19 (i.e., a moving or lifting assembly), the two parallel beams being arranged to move the container 106 horizontally between either of the end container sections 16, 16' and the intermediate container section 15. Each of the end container sections is characterized by having a roller conveyor 18, which is arranged to transfer the container 106 in a direction perpendicular to the horizontal direction between either of the end container sections 16, 16' and the intermediate container section 15. The trolley 17 is movable horizontally between either of the end container sections 16, 16' and the intermediate container section 15, and the two parallel beams 19 are connected to the trolley 17 and arranged to raise and lower at least one container 106 in the vertical direction. In use, the container 106 can be lifted by raising the two parallel beams 19 to move the container out of, for example, the intermediate container section 15, and the container can be moved to the first end container section 16 by moving the trolley 17. When located above the first end container section 16, the two parallel beams can be lowered so that the container is arranged on the conveyor 18 and can be moved by the conveyor.

[0125] The picking section 10 of the exemplary consolidation station 2 is the intermediate container section 15 of the first transfer module 14. The consolidation section 11 includes at least the intermediate container section 15 of the second transfer module 14', but the consolidation section can also include either the first end container section 16 or the second end container section 16'.

[0126] The first transfer module and the second transfer module are parallel and interconnected via the end container sections of the first transfer module and the second transfer module respectively by intermediate transfer elements 25, 25'. The intermediate transfer element can accommodate a single storage container 106 and is advantageous in providing a buffer for the storage container in which the items are to be consolidated or in which the items have been consolidated, or alternatively forms part of the consolidation section 11. In this particular embodiment, the intermediate transfer elements 25, 25' are also required to provide space for the base 12 of the robotic picking arm 5 mounted on the floor.

[0127] It should be noted that for the case of a robotic picking arm mounted on a gantry, the intermediate transfer elements 25, 25' are not required. The advantage of using a robotic picking arm mounted on a gantry is that the picking section 10 can be arranged closer to the consolidation section 11, thus minimizing the movement of the robotic picking arm.

[0128] In the present storage system, the storage container 106 has a rectangular cross-section (i.e., the horizontal perimeter of the storage container is rectangular). To further minimize the required movement of the robotic picking arm 5, when transferring an item from a first storage container 106 on the picking section 10 to a second storage container 106'' on the consolidation section 11, the first transfer module and the second transfer module are arranged such that the longer sides of the first storage container 106' and the second storage container 106'' face each other.

[0129] The consolidation station according to the present invention is highly advantageous because it allows for the performance of multiple beneficial consolidation operations.

[0130] A first exemplary consolidation operation that can be performed by the disclosed consolidation station 2 is consolidating one or more items of a customer order in the storage container 106''. After consolidating the customer order, the storage container 106'' containing the customer order can be temporarily stored in the frame structure 100 or transferred via the frame structure 100 to a processing facility for packaging and shipping of the customer order. The first exemplary consolidation operation may require the following steps:

[0131] - Transfer a first storage container 106' containing at least one first item from the container outlet 8 to the picking section 10 (e.g., the intermediate container section 15 of the first transfer module 14) via the first transfer route 3;

[0132] - Transfer a second storage container 106'' from the container outlet 8 (i.e., from the same container outlet 8 as the first storage container 106') to the consolidation section 11 (e.g., the intermediate container section 15 of the second transfer module 14') via the second transfer route 4; and

[0133] - Pick at least one first item from the first storage container 106' using the robotic picking arm 5 and add the at least one first item to the second storage container 106'.

[0134] When different items are to be consolidated into the second storage container, the consolidation operation may further include the following steps:

[0135] - Transfer the first storage container 106' to or towards the container inlet 9 via the first transfer route 3;

[0136] - Transfer a third storage container 106''' containing at least one second item from the container outlet 8 to the picking section 10 via the first transfer route 3; and

[0137] - Pick at least one second item from the third storage container 106''' using the robotic picking arm 5 and add the at least one second item to the second storage container 106''.

[0138] When integrating a first article into multiple storage containers, the integration operation may further include the following steps:

[0139] - Transfer the fourth storage container 106"" from the container outlet 8 to the integration section 11 via the second transfer route 4; and

[0140] - Pick at least one first article from the first storage container 106' using the robotic picking arm 5 and add the at least one first article to the fourth storage container 106"".

[0141] A second exemplary integration process that can be performed by the integration station 2 of the present invention involves the situation of integrating similar or identical articles within a storage system to optimize storage space utilization. For example, in many cases, multiple storage containers 106 are initially used to store the same type of article. Over time, some of the articles are picked from the storage containers, and the initial number of storage containers is no longer needed to store all the articles. To free up available storage space, these articles can be integrated into fewer storage containers than initially required. Existing integration stations and storage systems do not have any effective solutions to perform such integration. Therefore, the second exemplary integration operation may include the following steps:

[0142] - Transfer the first storage container 106' containing at least one first article from the container outlet 8 to the picking section 10 (e.g., the intermediate container section 15 of the first transfer module 14) via the first transfer route 3;

[0143] - Transfer the second storage container 106"" from the container outlet 8 to the integration section 11 via the second transfer route 4, and the second storage container 106"" can be empty or have space for at least one first article; and

[0144] - Pick at least one first article from the first storage container 106"" using the robotic picking arm 5 and add the at least one first article to the second storage container 106""; and

[0145] - Repeat the step of picking at least one first article from the first storage container 106' using the robotic picking arm 5 and adding the at least one first article to the second storage container 106"" until the first storage container 106' is empty or the second storage container 106"" is full.

[0146] When the first storage container 106' is empty, the second exemplary integration process may include the following steps:

[0147] - Transfer the first storage container 106' to the container inlet 9 or towards the container inlet via the first transfer route 3.

[0148] When the first storage container 106' is empty, the second exemplary integration process may further include the following steps:

[0149] - Transfer a third storage container 106''' containing at least one first item from the container outlet 8 to the picking section 10 via a first transfer route 3; and

[0150] - Pick at least one first item from the third storage container 106''' by using a robotic picking arm 5 and add the at least one first item to the second storage container 106''; and

[0151] - Repeat the step of picking at least one first item from the third storage container 106''' by using a robotic picking arm 5 and adding the at least one first item to the second storage container 106'' until the third storage container 106''' is empty or the second storage container 106'' is full.

[0152] When the second storage container 106'' is full and / or the first storage container 106' is empty, the second exemplary integration process may include the following steps:

[0153] - Transfer the second storage container 106'' to or towards the container inlet 9 via a second transfer route 3.

[0154] When the second storage container 106'' is full and / or the first storage container 106' is empty, the second exemplary integration process may further include the following steps:

[0155] - Transfer a fourth storage container 106'''' from the container outlet 8 to the integration section 11 via a second transfer route 4, and the fourth storage container 106'''' may be empty or have space for at least one first item; and

[0156] - Pick at least one first item from the first storage container 106' by using a robotic picking arm 5 and add the at least one first item to the fourth storage container 106''''; and

[0157] - Repeat the step of picking at least one first item from the first storage container 106' by using a robotic picking arm 5 and adding the at least one first item to the fourth storage container 106'''' until the first storage container 106' is empty or the second storage container 106'' is full.

[0158] In the second exemplary integration process, when the first storage container is empty, it is sent back to the frame structure and can thus be used to store new items, while improving the capacity utilization rate of the second storage container.

[0159] In Figures 5 to 8In the exemplary storage system shown, the frame structure 100 includes: a plurality of port columns 119, 120 through which a storage container 106 can be transferred between a top layer of the frame structure 100 and corresponding transfer locations 23 at a lower layer of the frame structure 100. Each of the transfer locations 23 is operatively connected to a robot integration station 2 via a container transfer assembly 24 and a container inlet 8 and a container outlet 9 of the frame structure 100.

[0160] The container transfer assembly 24 is arranged to transfer the storage container 106 between any one of the transfer locations 23 and the integration station 2. The container transfer assembly 24 includes a plurality of transfer conveyor modules 14'' - 14'''''. In an exemplary embodiment, the transfer conveyor modules 14'' - 14'''' are substantially similar to the conveyor modules 14, 14' of the integration station 2. Each of the transfer conveyor modules 14'' - 14'''' can accommodate a row of three storage containers 106 and includes an intermediate container section 15, a first end container section 16, and a second end container section 16' arranged at the transfer location 23, and each of the container sections 15, 16, 16' is arranged to accommodate a single storage container 106. Each of the transfer conveyor modules 14'' - 14'''' includes a carriage 17 and two parallel beams 19 (i.e., a lifting or moving assembly) arranged to lift the container and move it horizontally between any one of the end container sections 16, 16' and the intermediate container section 15. Each of the end container sections 16, 16' is characterized by having a roller conveyor 18 arranged to transfer the storage container in a direction perpendicular to the horizontal direction, wherein the carriage 17 and the beam 19 can move in this horizontal direction.

[0161] The transfer conveyor modules 14'' - 14'''' are interconnected at their respective first end container sections and second end container sections 16, 16' by a conveyor element 26 capable of accommodating at least one storage container 106 and transfer at least one storage container in the same direction as the roller conveyor 18.

[0162] The present invention is illustrated by an exemplary embodiment featuring a very advantageous conveyor module 14. However, the integration station 2 according to the present invention can also be obtained by using other suitable combinations of conveyor elements for the non - manual transfer of storage containers, such as roller conveyors, belt conveyors, and shuttle conveyors.

Claims

1. An integration station (2) for use in a storage system (1), the storage system comprising a frame structure (100) capable of storing a plurality of storage containers (106); The integration station (2) comprises: a first transfer route (3) for transferring the storage containers (106); and a second transfer route (4) for transferring the storage containers (106), wherein each of the first transfer route (3) and the second transfer route (4) comprises a first end (6) and a second end (7), wherein each first end (6) is configured to be operatively connected to the frame structure (100), and each second end (7) is configured to be operatively connected to the frame structure (100); and The first end of the first transfer route (3) and the first end of the second transfer route (4) are the same first end (6), and / or the second end of the first transfer route (3) and the second end of the second transfer route (4) are the same second end (7).

2. An integration station (2) for use in a storage system (1), the storage system comprising a frame structure (100) capable of storing a plurality of storage containers (106); The integration station (2) comprises: a first transfer route (3) for transferring the storage containers (106); and a second transfer route (4) for transferring the storage containers (106), wherein each of the first transfer route (3) and the second transfer route (4) comprises a first end (6) and a second end (7), wherein each first end (6) is configured to be operatively connected to the frame structure (100), and each second end (7) is configured to be operatively connected to the frame structure (100); and The first transfer route (3) comprises a picking section (10), and the second transfer route (4) comprises an integration section (11); and Wherein, the first transfer route (3) and the second transfer route (4) comprise the same first transfer intersection section (13), and the storage container (106) exiting the container outlet (8) from the first transfer intersection section can be transferred to the picking section (10) in a first direction or to the integration section (11) in a second direction, and / or wherein, the first transfer route (3) and the second transfer route (4) comprise the same second transfer intersection section (22), and the storage container (106) arriving from either the picking section (10) or the integration section (11) can be transferred to the container inlet (9) from the second transfer intersection section.

3. The integration station according to claim 1 or 2, wherein A plurality of storage containers (106”) can be arranged on the integration section (11), and the first storage container (106’) is transferred from the container outlet (8) to the container inlet (9) via the picking section (10).

4. The integration station according to any one of claims 1 to 3, wherein, The picking section (10) is arranged parallel to the integration section (11).

5. The integration station according to claim 2, wherein, The first end of the first transfer route (3) and the first end of the second transfer route (4) are the same first end (6).

6. The integration station according to claim 2 or 3, wherein The second end of the first transfer route (3) and the second end of the second transfer route (4) are the same second end (7).

7. The integration station according to claim 1, wherein The first transfer route (3) and the second transfer route (4) include the same first transfer intersection section (13), and the storage container (106) that leaves the container outlet (8) from the first transfer intersection section can be transferred to the picking section (10) in the first direction or to the integration section (11) in the second direction.

8. The integration station according to claim 1, wherein The first transfer route (3) and the second transfer route (4) include the same second transfer intersection section (22), and the storage container (106) that arrives from either the picking section (10) or the integration section (11) can be transferred to the container inlet (9) from the second transfer intersection section.

9. The integration station according to any one of the preceding claims, wherein, The first transfer route (3) includes a first transfer module (14), and the second transfer route (4) includes a second transfer module (14’). Each transfer module can accommodate a row of three storage containers (106) and includes an intermediate container section (15), a first end container section (16), and a second end container section (16’). Each of these container sections (15, 16, 16’) is arranged to accommodate a single storage container (106). Each transfer module (14, 14’) includes a moving component (17, 19), and the moving component is arranged to move the storage container horizontally between any one of the end container sections (16, 16’) and the intermediate container section (15). The feature of each end container section is that it has a roller conveyor (18), and the roller conveyor is arranged to transport the storage container (106) between any one of the end container sections (16, 16’) and the intermediate container section (15) in a direction perpendicular to the horizontal direction.

10. The integration station according to claim 9, wherein, The picking section (10) is the intermediate container section (15) of the first transfer module (14), and the integration section (11) includes the intermediate container section (15) of the second transfer module (14’).

11. A storage system including an integration station (2) according to any one of the preceding claims, wherein The storage system includes: A frame structure (100) in which a plurality of storage containers (106) can be stored; A container outlet (8) for transferring the storage container (106) out of the frame structure; and a container inlet (9) for transferring the storage container into the frame structure, wherein the first transfer route (3) and the second transfer route (4) of the integration station (2) are operatively connected to the container outlet (8) and the container inlet (9).

12. The storage system according to claim 11, comprising at least one container handling vehicle (301), and wherein, The frame structure (100) includes a plurality of storage columns (105), in which storage containers (106) can be stacked on top of each other in a vertical stack (107), and the container handling vehicle runs on a guide rail system (108) located at the top layer of the frame structure for taking out storage containers (106) from the storage columns, storing storage containers in the storage columns, and horizontally transporting storage containers across the guide rail system (108), and wherein the frame structure (100) includes at least one port column (119, 120), and storage containers can be transferred between the top layer of the frame structure and a transfer position (23) at the lower layer of the frame structure (100) through the port column, and the transfer position (23) is operatively connected to the integration station (2) via the container outlet (8) and the container inlet (9).

13. The storage system according to claim 12, wherein, The storage system includes a container transfer assembly (24) for transferring storage containers (106) between the transfer position (23) and the integration station (2), the container transfer assembly includes at least one transfer conveyor module (14”), the transfer conveyor module can accommodate a row of three storage containers and includes a first end container section (16) and a second end container section (16’) and an intermediate container section (15) arranged at the transfer position (23), each of these container sections (15, 16, 16’) is arranged to accommodate a single storage container (106), and the transfer conveyor module (14”) includes a moving assembly (17, 19) and a roller conveyor (18), the moving assembly is arranged to move the storage container (106) horizontally between any one of the end container sections (16, 16’) and the intermediate container section (15), and the roller conveyor is arranged to transport the storage container between any one of the end container sections (16, 16’) and the intermediate container section (15) in a direction perpendicular to the horizontal direction.

14. A method for integrating items stored in a storage system, the storage system including an integration station (2) according to any one of claims 1 to 10, wherein The method includes the following steps: - Transfer a first storage container (106’) containing at least one first item from the frame structure to the picking section (10) via the first transfer route (3); - Transfer a second storage container (106”) from the frame structure to the integration section (11) via the second transfer route; And - Pick at least one of the first items from the first storage container and add the at least one first item to the second storage container.

15. The method according to claim 14, including the following steps: - Transfer the first storage container (106’) to the frame structure via the first transfer route (3); - Transfer a third storage container (106''') containing at least one second item from the frame structure to the picking section (10) via the first transfer route (3); and - Pick at least one of the second items from the third storage container (106''') and add the at least one second item to the second storage container (106'').

16. The method according to claim 14 or 15, wherein The first storage container (106') contains a plurality of first items, and the method includes the following steps: - Transfer a fourth storage container (106'''') from the frame structure to the integration section (11) via the second transfer route (4); and - Pick at least one first item from the first storage container and add the at least one first item to the fourth storage container.

17. A method for integrating items stored in a storage system, the storage system including an integration station (2) according to any one of claims 1 to 10, wherein the method includes the following steps: - Transfer a first storage container (106') containing at least one first item from the frame structure to the picking section (10) via the first transfer route (3); - Transfer a second storage container (106'') from the frame structure to the integration section (11) via the second transfer route (4), the second storage container (106'') may be empty or have space for at least one first item; and - Pick at least one of the first items from the first storage container (106') and add the at least one first item to the second storage container (106''); and - Repeat the step of picking at least one of the first items from the first storage container (106') and adding the at least one first item to the second storage container (106'') until the first storage container (106') is empty or the second storage container (106'') is full.

18. The method according to claim 17, including the following steps: - When the first storage container (106') is empty, transfer the first storage container (106') to the frame structure or towards the container inlet via the first transfer route (3).

19. The method according to claim 18, including the following steps: - Transfer a third storage container (106''') containing at least one first item from the frame structure to the picking section (10) via the first transfer route (3); - Pick at least one of the first items from the third storage container (106''') and add the at least one first item to the second storage container (106''); and - Repeat the step of picking at least one of the first items from the third storage container (106''') and adding the at least one first item to the second storage container (106'') until the third storage container (106''') is empty or the second storage container (106'') is full.

20. The method according to any one of claims 17 to 19, comprising the following steps: - When the second storage container (106”) is full and / or the first storage container (106’) is empty, transfer the second storage container (106”) via the second transfer route (3) to the frame structure or towards the container inlet.

21. The method according to claim 20, comprising the following steps: - When the fourth storage container (106””) is empty or has space for at least one first article, transfer the fourth storage container (106””) from the frame structure to the integration section (11) via the second transfer route (4); - Pick at least one first article from the first storage container (106’) and add the at least one first article to the fourth storage container (106””); and - Repeat the step of picking at least one first article from the first storage container (106’) and adding the at least one first article to the fourth storage container (106””) until the first storage container (106’) is empty or the fourth storage container (106”) is full.

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