Storage system for storage containers comprising a frame structure, a stacking frame, storage containers, a

Abstract

The invention provides a storage system (1) for storage containers, the storage system comprising a frame structure (100), a stacking frame (6), storage containers (106a-d), a stacking frame lifting device (8) and a container lifting device (501); the frame structure defines a plurality of storage columns (105), and each storage column accommodates a plurality of stacking frames (6) arranged one on top of another in the form of a vertical stack; a plurality of stacking frames (6), each of which has an open top end and is configured to accommodate a plurality of storage containers (106a-d); the stacking frame lifting device (8) and the container lifting device (501) are configured to move in two directions perpendicular to each other above the storage column; the container lifting device is configured to remove the storage containers (106a-d) via an open top end (9) of an upper stack frame (6 ') in a stack of stack frames contained in the storage column, and the stack frame lifting device (8) is configured to remove the upper stack frame (6').

Description

Technical Field

[0001] The present invention relates to a storage system for storage containers.

[0002] Background Art and Prior Art

[0003] Figure 1 There is disclosed a prior art automated storage and retrieval system 1 (i.e., storage system) having a frame structure 100, and Figure 2 、 Figure 3 and Figure 4 there are disclosed three different prior art container handling vehicles 201, 301, 401 adapted to operate on the system 1.

[0004] The frame structure 100 includes upright members 102 and a storage volume including storage rows 105 arranged in rows between the upright members 102. In these storage rows 105, storage containers 106 (also referred to as bins) are stacked one on top of the other to form stacks 107. The members 102 can typically be made of metal (e.g., extruded aluminum profiles).

[0005] The frame structure 100 of the automated storage and retrieval system 1 includes a track system 108 (i.e., track grid) arranged across the top of the frame structure 100, on which a plurality of container handling vehicles 201, 301, 401 can operate 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 track system 108 includes a first set of parallel tracks 110 and a second set of parallel tracks 111, wherein the first set of parallel tracks is arranged to guide the container handling vehicles 201, 301, 401 to move across the top of the frame structure 100 in a first direction X, and the second set of parallel tracks is arranged perpendicular to the first set of tracks 110 to guide the container handling vehicles 201, 301, 401 to move 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 201, 301, 401 through access openings 112 in the track system 108. The container handling vehicles 201, 301, 401 can move laterally above the storage rows 105, i.e., move laterally in a plane parallel to the horizontal X - Y plane.

[0006] The upright members 102 of the frame structure 100 can be used to guide the storage containers during lifting the storage containers from the rows 105 and lowering the storage containers into the rows. The stacks 107 of the containers 106 are typically self - supporting.

[0007] Each prior art container handling vehicle 201, 301, 401 includes a vehicle body 201a, 301a, 401a and a wheel assembly including a first set of wheels and a second set of wheels 201b, 201c, 301b, 301c, 401b, 401c, which enable the container handling vehicles 201, 301, 401 to move laterally in the X and Y directions respectively. In Figure 2 , Figure 3 and Figure 4 , two wheels in each set of wheels are fully visible. The first set of wheels 201b, 301b, 401b are arranged to engage two adjacent tracks in the first set of tracks 110, and the second set of wheels 201c, 301c, 401c are arranged to engage two adjacent tracks in the second set of tracks 111. At least one set of the wheels 201b, 301b, 201c, 301c, 401b, 401c can be raised and lowered so that the first set of wheels 201b, 301b, 401b and / or the second set of wheels 201c, 301c, 401c can engage the corresponding set of parallel tracks 110, 111 at any one time.

[0008] Each prior art container handling vehicle 201, 301, 401 also includes a lifting mechanism 404 (i.e., a container lifting mechanism) for vertically transporting the storage container 106, see Figure 4 , for example, raising the storage container 106 from the storage row 105 and lowering the storage container 106 into the storage row. The lifting mechanism 404 includes a lifting frame 2, which includes a container connector 3 and a guide pin 4. The container connector is adapted to engage a connection groove 13 at the upper edge of the side wall 14 of the storage container 106, see Figure 5 . The guide pin 4 is arranged to interact with a guide pin groove 7 at the corner of the storage container and ensure the accurate alignment of the lifting frame 2 and the container connector 3 relative to the storage container. The guide pin 4 also helps to guide the movement of the lifting frame 2 relative to the upright member of the storage row 105. The lifting frame 2 can be lowered from the vehicles 201, 301, 401 so that the position of the lifting frame 2 relative to the vehicles 201, 301, 401 can be adjusted in a third direction Z orthogonal to the first direction X and the second direction Y. In Figure 2 , the lifting mechanism of the container handling vehicle 201 is located within the vehicle body 201a.

[0009] To raise or lower the lifting frame 2 (and optionally the connected storage container 106), the lifting frame 2 is suspended on a belt drive assembly by means of a lifting belt 5. In the belt drive assembly, the lifting belt is typically wound onto / unwound from at least one rotating lifting shaft or drum arranged in the container handling vehicle. Various designs of the belt drive assembly are described, for example, in WO 2015 / 193278 A1, WO 2017 / 129384 A1, and WO2019 / 206438 A1.

[0010] Conventionally and also for the purposes of the present application, Z = 1 identifies the uppermost layer for storing storage containers below the track system 108, i.e., the layer immediately below the track system 108, Z = 2 identifies the second layer below the track system 108, Z = 3 identifies the third layer, and so on. In Figure 1 the exemplary prior art disclosed in, Z = 8 identifies the bottommost 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, by way of example and using Figure 1 the Cartesian coordinate system X, Y, Z shown in, it can be said that the storage container identified as 106' in Figure 1 occupies the storage position of X = 17, Y = 1, Z = 6. It can be said that the container handling vehicles 201, 301, 401 travel in the layer of Z = 0, and each storage column 105 can be identified by its X coordinate and Y coordinate. Thus, Figure 1 the storage containers extending above the track system 108 shown in are also said to be arranged in the layer of Z = 0.

[0011] The storage volume part of the frame structure 100 is generally referred to as a grid 104, where the possible storage positions within the grid are called storage units. Each storage column can be identified by its position 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.

[0012] Each prior art container handling vehicle 201, 301, 401 includes a storage compartment or storage space for receiving and loading the storage container 106 when transporting the storage container 106 across the track system 108. The storage space may include a cavity arranged inside the vehicle body 201a, as Figure 2 and Figure 4 shown in and described, for example, in WO2015 / 193278A1 and WO2019 / 206487A1, the contents of which are incorporated herein by reference.

[0013] Figure 3Shows an alternative configuration of a container handling vehicle 301 having a cantilever structure. Such vehicles are described in detail, for example, in NO317366, the content of which is also incorporated herein by reference.

[0014] Figure 2 The occupancy area of the chamber container handling vehicle 201 shown in [reference] can cover an area that is approximately equal in size in the X and Y directions to the lateral extent of the storage row 105, as described, for example, in WO2015 / 193278A1, the content of which is incorporated herein by reference. The term "lateral" as used herein may mean "horizontal".

[0015] Alternatively, the occupancy area of the chamber container handling vehicle 401 can be larger than the lateral area defined by the storage row 105, as Figure 1 and Figure 4 shown in [references] and, for example, disclosed in WO2014 / 090684A1 or WO2019 / 206487A1.

[0016] The track system 108 generally includes tracks having grooves in which the wheels of the vehicle travel. Alternatively, the tracks can include upwardly projecting elements, wherein the wheels of the vehicle include flanges to prevent derailment. These grooves and upwardly projecting elements are collectively referred to as guide rails. Each track can include one guide rail, or each track can include two parallel guide rails.

[0017] WO2018 / 146304A1 (the content of which is incorporated herein by reference) shows a typical configuration of the track system 108, which includes tracks and parallel guide rails forming a track grid in both the X and Y directions.

[0018] In the frame structure 100, most of the columns 105 are storage columns 105, i.e., columns 105 in which the storage containers 106 are stored in the form of stacks 107. However, some of the columns 105 can have other purposes. In Figure 1In FIGS. 119 and 120 are such dedicated columns for the container handling vehicles 201, 301, 401 to unload and / or pick up the 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 the outside of the frame structure 100, or the storage containers can be moved in or out of the frame structure 100. In the art, such a location is generally 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 carried out in any direction (i.e., horizontal direction, inclined direction, and / or vertical direction). For example, the storage container 106 can be placed in a random column or a dedicated column 105 within the frame structure 100, and then the storage container can be 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 the transportation of the storage container 106 having a general transportation orientation in a direction between horizontal and vertical.

[0019] In Figure 1 FIGS., the first port column 119 can be, for example, an unloading port column, where the container handling vehicles 201, 301, 401 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 pickup port column, where the container handling vehicles 201, 301, 401 can pick up the storage containers 106 that have been transported from the access station or transfer station.

[0020] The access station can generally be a pickup station or a stocking station, where product items are removed from or positioned into the storage container 106. In the pickup station or stocking station, the storage container 106 is generally not removed from the automated storage and retrieval system 1, but is returned to the frame structure 100 again after access. The port can 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), to a transportation vehicle (e.g., a train or a truck), or to a production facility.

[0021] A conveying system including conveyors is generally adopted to transport the storage containers between the port columns 119, 120 and the access station.

[0022] If the port columns 119, 120 and the access station are at different horizontal heights, the conveying system can include a lifting mechanism having a vertical component for vertically transporting the storage containers 106 between the port columns 119, 120 and the access station.

[0023] The conveying system can be arranged to transfer the storage container 106 between different frame structures, for example, as described in WO2014 / 075937A1, the content of which is incorporated herein by reference.

[0024] When it is desired to access a storage container 106 in one of the plurality of storage columns 105 disclosed in Figure 1 a container handling vehicle 201, 301, 401 of the plurality of container handling vehicles is instructed to pick up the target storage container from the location of the target storage container 106 and transport the target storage container to the unloading port column 119. This operation involves: moving the container handling vehicles 201, 301, 401 to a position above the storage column 105 where the target storage container 106 is located; using the lifting mechanism 404 of the container handling vehicles 201, 301, 401 to pick up 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 within the stack 107, i.e., one or more other storage containers 106 are located above the target storage container 106, this operation also involves: temporarily moving the storage containers located above before lifting the target storage container 106 from the storage column 105. This step (sometimes referred to in the art as "digging") can be performed using the same container handling vehicle that will subsequently be used to transport the target storage container to the unloading port column 119, or using one or more other cooperative container handling vehicles. Alternatively or additionally, the automated storage and retrieval system 1 can have container handling vehicles 201, 301, 401 dedicated to the task of temporarily removing storage containers 106 from the storage column 105. After removing the target storage container 106 from the storage column 105, the temporarily removed storage container 106 can be repositioned back to the original storage column 105. However, the removed storage container 106 can alternatively be repositioned to another storage column 105.

[0025] When a storage container 106 is to be stored in a column 105, a container handling vehicle 201, 301, 401 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 removing any storage containers 106 located at or above the target position within the stack 107, the container handling vehicle 201, 301, 401 positions the storage container 106 at the desired location. The removed storage container 106 can then be lowered back into the storage column 105 or repositioned to another storage column 105.

[0026] In order to monitor and control the storage system 1, for example, to monitor and control the position of each storage container 106 within the frame structure 100, the content of each storage container 106, and the movement of the container handling vehicles 201, 301, 401, such that the required storage container 106 can be transported to the required position at the required time without the container handling vehicles 201, 301, 401 colliding with each other, the storage system 1 includes a control system 500, which is typically computerized and typically includes a database for keeping track of the storage containers 106.

[0027] Prior art storage systems are limited to using storage containers with the same horizontal perimeter in order to be able to stack them within storage columns. Additionally, the height of the stack of storage containers depends on the actual lifting height of the container handling vehicle and / or the weight that the lower storage containers in the stack of storage containers can support. The object of the present invention is to provide a more efficient and / or more flexible storage system. Summary of the Invention

[0028] The present invention is defined by the appended claims and the following:

[0029] In a first aspect, the present invention provides a storage system for storage containers, the storage system including a frame structure, a plurality of stacking frames, a plurality of storage containers, a stacking frame lifting device, and a container lifting device;

[0030] The frame structure defines a plurality of storage columns, and each storage column accommodates a plurality of stacking frames arranged one on top of the other in a vertical stack;

[0031] Each stacking frame of the plurality of stacking frames has an open top end and is configured to accommodate a plurality of storage containers;

[0032] The stacking frame lifting device and the container lifting device are configured to move in two mutually perpendicular directions (i.e., along two mutually perpendicular horizontal directions) above the storage columns;

[0033] The container lifting device is configured to remove a storage container via the open top end of the upper stacking frame in the stack of stacking frames accommodated in the storage column; and

[0034] The stacking frame lifting device is configured to remove the upper stacking frame.

[0035] In an embodiment of the storage system, at least some of the plurality of storage containers are stacked one on top of the other when accommodated in the stacking frames.

[0036] In an embodiment of the storage system, each stacking frame may include two pairs of opposing sidewalls, and each pair of opposing sidewalls of these two pairs of opposing sidewalls has at least one internal vertical guiding rib. In other words, each stacking frame includes at least one vertical guiding rib disposed at the inner surface of each pair of opposing sidewalls among the two pairs of opposing sidewalls.

[0037] In an embodiment of the storage system, each stacking frame may include a first pair of opposing sidewalls and a second pair of opposing sidewalls, and internal vertical guiding ribs are disposed on each sidewall. The guiding ribs may be disposed at the center of the corresponding sidewall. The internal vertical guiding ribs may be an integral part of the corresponding sidewall.

[0038] The open top end of the stacking frame can be used for the vertical passage of the storage container.

[0039] The stacking frame is configured to support the bottom of the lower storage container of the stack of storage containers accommodated in the stacking frame.

[0040] The stacking frame may include: a bottom portion for supporting the bottom end of the stack of storage containers; a top portion having an open end through which the container can pass in the vertical direction; a side portion extending between the bottom portion and the top portion, the side portion being configured to guide the vertical movement of the lifting frame inside the stacking frame; and connection notches disposed at the upper part of the side portion or at the upper edge of the top portion, these connection notches being adapted to be releasably connected to the stacking frame lifting device.

[0041] The stacking frame may have: an outer perimeter that fits inside the inner perimeter of the storage row; and an inner perimeter inside which the outer perimeter of the storage container fits.

[0042] In an embodiment of the storage system, each storage container may include a sidewall having an external vertical guiding groove, the external vertical guiding groove being configured to cooperate with one guiding rib to prevent the storage container from moving laterally relative to the stacking frame that houses the storage container.

[0043] In an embodiment of the storage system, the container lifting device may include a first type of lifting frame configured to be releasably connected to the upper part of the storage container.

[0044] The outer perimeter of the first type of lifting frame may be smaller than the inner perimeter of the stacking frame. The inner perimeter of the stacking frame may be configured to guide the vertical movement of the first type of lifting frame inside the stacking frame, that is, the inner perimeter of the stacking frame may include vertical surfaces configured to guide the vertical movement of the lifting frame. These vertical surfaces may include some parts of the side portion of the stacking frame that form vertical corner portions for accommodating the corresponding corners of the lifting frame.

[0045] In an embodiment of the storage system, a first type of lifting frame may include a gripper configured to releasably connect to a connection groove disposed in the upper edge of a storage container.

[0046] In an embodiment, the storage system may include at least a first type of storage container and a second type of storage container. The area defined by the outer perimeter of the first type of storage container corresponds to the area defined by the inner perimeter of a stacking frame, and the area defined by the outer perimeter of the second type of storage container is approximately half of the area defined by the inner perimeter of the stacking frame, such that two second type of storage containers can be accommodated in the stacking frame in a side-by-side arrangement.

[0047] In an embodiment of the storage system, a first type of lifting frame may be divided into at least two frame parts. Each of the two frame parts includes a gripper and can be operated independently of the other frame parts, such that a single frame part can take out a second type of storage container, and the two frame parts can cooperate with each other to take out a first type of storage container.

[0048] Each frame part may be connected to a container lifting device by a set of lifting belts, such that the frame part can be raised and / or lowered relative to the body of the container lifting device. The frame parts can be raised and / or lowered independently of each other. Each frame part may be connected to a respective rotatable lifting shaft via four lifting belts. The lifting belts may be connected at four corner portions of the respective frame part. The first type of lifting frame may be divided into any desired number of frame parts that can be operated independently to lift storage containers of any size smaller than the first type of storage container.

[0049] In an embodiment of the storage system, each frame part may include a recess configured to cooperate with a vertical inner guiding rib of the stacking frame during vertical movement of the frame part within the stacking frame. The frame recess allows the frame part to have a maximum-sized perimeter, thereby providing optimal guidance for the frame part when it is lowered / raised within the stacking frame.

[0050] In an embodiment of the storage system, a stacking frame lifting device may include a second type of lifting frame configured to releasably connect to the upper part of the stacking frame. The perimeter of the second type of lifting frame may be smaller than the inner perimeter of the storage column. The second type of lifting frame may be configured to reach a lower position in the storage column compared to the first type of lifting frame.

[0051] In an embodiment of the storage system, each stack frame may have two opposite side portions, with notches disposed at the inner surface of each side portion, and the second type of lifting frame includes latches, each latch configured to enter a corresponding notch from the inside of the stack frame when the second type of lifting frame is releasably connected to the stack frame. The notch may be an orifice extending from the inner surface to the outer surface of the side portion, i.e., the notch may be an orifice or opening in the side portion. In other words, the notch may be disposed in the upper part of the inner surface of the side portion.

[0052] In an embodiment of the storage system, the second type of lifting frame may include a horizontal base frame and at least one latch disposed at each of the opposite sides of the base frame, the connecting portion of each latch configured to move between a release position and a connecting position, the connecting portion being closer to the vertical centerline of the base frame when in the release position than when in the connecting position.

[0053] In an embodiment, the storage system may include a track system, and the container lifting device may move along two mutually perpendicular directions on the track system, the track system being disposed above the storage rows.

[0054] In an embodiment of the storage system, the stack frame lifting device may be configured to move along two mutually perpendicular directions on or above the track system.

[0055] In an embodiment of the storage system, the frame structure may include a plurality of vertical column profiles defining the storage rows. The track system may be disposed on top of the vertical column profiles and supported by the vertical column profiles. The track system may include a first set of parallel tracks and a second set of parallel tracks, wherein the first set of parallel tracks is arranged to guide the container lifting device and / or the stack frame lifting device to move across the top of the frame structure in a first direction, and the second set of parallel tracks is arranged perpendicular to the first set of tracks to guide the container lifting device and / or the stack frame lifting device to move in a second direction perpendicular to the first direction.

[0056] In an embodiment of the storage system, the container lifting device and / or the stack frame lifting device may include a wheel assembly, the wheel assembly including a first set of wheels and a second set of wheels configured to move the container lifting device and / or the stack frame lifter along two mutually perpendicular directions on the track system. The first set of wheels may be arranged to engage with the first set of parallel tracks of the track system, and the second set of wheels may be arranged to engage with the second set of parallel tracks of the track system. At least one of these sets of wheels may be raised and lowered relative to the other sets of wheels such that the first set of wheels and / or the second set of wheels may engage with a corresponding set of tracks at any given time.

[0057] In one embodiment of the storage system, the storage column may include a vertical guiding profile configured to cooperate with a recess at the periphery of a first type of lifting frame (i.e., a recess at the periphery of the first type of lifting frame). The stacking frame may include an external vertical groove configured to cooperate with the guiding profile of the storage column.

[0058] In a second aspect, the present invention provides a stacking frame and storage container assembly for a storage system according to the first aspect and any of its embodiments, which includes a stacking frame for accommodating a plurality of storage containers, wherein the stacking frame includes at least two pairs of opposing side walls, each opposing side wall having an internal vertical guiding rib, and each storage container includes at least one side wall having an external vertical guiding groove configured to cooperate with at least one of the plurality of internal vertical guiding ribs to prevent the storage container from moving laterally relative to the stacking frame.

[0059] In one embodiment of the stacking frame and storage container assembly, the stacking frame may include: a bottom portion for supporting the storage container; a top portion having an open end through which the storage container can pass in the vertical direction; a side portion extending between the bottom portion and the top portion; and a connecting notch disposed at an upper portion of the side portion. In some embodiments, the side portion corresponds to the side wall. The connecting notch of the stacking frame may be disposed at a horizontal height above the stack of storage containers.

[0060] In one embodiment of the stacking frame and storage container assembly, a connecting groove is included at the upper edge of each of the plurality of storage containers.

[0061] In one embodiment, the stacking frame and storage container assembly may include at least a first type of storage container and a second type of storage container, wherein the area defined by the outer periphery of the first type of storage container corresponds to the area defined by the inner periphery of the stacking frame, and the area defined by the outer periphery of the second type of storage container is approximately half of the area defined by the inner periphery of the stacking frame, such that two second type of storage containers can be accommodated in the stacking frame in a side-by-side arrangement.

[0062] In one embodiment of the stacking frame and storage container assembly, the connecting notch of the stacking frame extends from the inner surface of the stacking frame. The connecting notch of the stacking frame may be an orifice extending from the inner surface to the outer surface of the side portion of the stacking frame.

[0063] In one embodiment of the stacking frame and storage container assembly, a connecting groove may be included at the upper edge of each of the plurality of storage containers.

[0064] In one embodiment of the stacking frame and storage container assembly, the bottom portion of the stacking frame may include a recessed portion or a stepped portion, the outer perimeter of which is smaller than the inner perimeter of the top portion, such that two stacking frames can be stacked one on top of the other, and the horizontal movement between the two stacking frames is restricted.

[0065] In a third aspect, the present invention provides a method of removing a target storage container from a storage system according to the first aspect and any of its embodiments, comprising the following steps:

[0066] - Identifying the storage column containing the target stacking frame in which the target storage container is stored;

[0067] - Moving the stacking frame lifting device to a position above the storage column;

[0068] - Removing at least one stacking frame stacked above the target stacking frame from the storage column, and optionally storing the at least one stacking frame in other storage columns until the target stacking frame becomes the upper stacking frame in the storage column;

[0069] - Optionally removing the target stacking frame from the storage column and moving the target stacking frame to another storage column, where the target stacking frame is stacked at the upper horizontal height of the storage column; and

[0070] - Removing the target storage container from the target stacking frame using the container lifting device. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] Embodiments of the present invention are described in detail with reference to the following drawings:

[0072] Figure 1 is a perspective view of the frame structure of an automatic storage and retrieval system of the prior art.

[0073] 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.

[0074] Figure 3 is a perspective view of a container handling vehicle of the prior art, which has a cantilever portion for carrying a storage container therebelow.

[0075] Figure 4 is a perspective view of a container handling vehicle of the prior art, in which a container lifting assembly is shown.

[0076] Figure 5 is in Figure 1 a perspective view of a storage container used in the storage system.

[0077] Figures 6 to 16 Shows a first exemplary storage system according to the present invention.

[0078] Figure 17 Shows a second exemplary storage system in which the storage columns include additional guide profiles for the stacking frames.

[0079] Figure 18 and Figure 19 Shows a side perspective view and a cross-sectional view of a stacking frame and a storage container for use in a storage system in Figure 17 ...

[0080] Figure 20 and Figure 21 is a side view of a lifting frame of a stacking frame lifting device and a corresponding stacking frame.

[0081] Figure 22 and Figure 23 Shows a side perspective view and a cross-sectional view of another embodiment of a stacking frame and a storage container for use in a storage system in Figures 6 to 16 ... Detailed Description

[0082] Hereinafter, embodiments of the present invention will be discussed in more detail with reference to the accompanying drawings. The drawings are not intended to limit the present invention to the subject matter shown.

[0083] As discussed above, as Figure 1 shown, the prior art storage systems are limited in terms of the height of the storage container stack by the actual lifting height of the container handling vehicle and / or the weight that the lower storage containers in the storage container stack can support. Further, it is advantageous to provide a storage system in which the storage containers can have different sizes and the storage containers stored at the lower horizontal levels of the storage columns can be removed by a more efficient "digging" operation.

[0084] The storage system of the present invention is intended to overcome some of the limitations of the prior art systems and / or to provide a storage system in which the "digging" operation can be performed in a more efficient manner.

[0085] A first exemplary storage system is shown in Figures 6 to 11 ... The storage system 1' includes a frame structure 100, a stacking frame 6, storage containers 106a, 106b, a stacking frame lifting device 8, and a container lifting device 501. The frame structure 100 and the container lifting device 501 may be similar to the corresponding features of the prior art systems in Figure 1 ...

[0086] The frame structure 100 includes a vertical column profile 102 that defines a plurality of storage columns 105. Each storage column 105 houses a plurality of stacking frames 6 arranged one on top of the other in a vertical stack.

[0087] See Figure 14 and FIG. 15, each stacking frame 6 has an open top end 9 for the vertical passage of storage containers 106a-c, and each stacking frame is configured to house a plurality of storage containers 106a-c stacked one on top of the other in a vertical stack. The stacking frame 6 is configured to support the bottoms of the storage containers 106a-c in the lower layer of the stack of storage containers 106a-c housed in the stacking frame 6.

[0088] The stacking frame 6 includes: a bottom portion 18 for supporting the bottom ends of the stack of storage containers 106a-c; a top portion 19 including an open end 9 through which the storage containers 106a-c can pass in the vertical direction; side portions 20 extending between the bottom portion 18 and the top portion 19; and connecting notches 12 arranged at the upper parts of two opposite side portions 20. The connecting notches 12 are provided at a height above the horizontal height of the upper layer of the stack of storage containers 106a-c arranged in the stacking frame. The stacking frame 6 includes two pairs of opposite side walls 21a, 21b, and each pair of opposite side walls in these two pairs of opposite side walls has an internal vertical guiding rib 22.

[0089] To improve the stacking stability of the stacking frame, the bottom portion 18 of the stacking frame may have a recessed portion whose outer perimeter is smaller than the inner perimeter of the top portion 19, that is, the outer perimeter of the recessed portion can be fitted inside the inner perimeter of the top portion. In this way, since the horizontal movement between the stacking frames is restricted, the stacking frame 6 can be stacked more stably on top of another stacking frame.

[0090] Figures 6 to 11 The storage containers in the exemplary storage system in include a first type of storage container 106a and a second type of storage container 106b, see Figure 14 and FIG. 15. The area defined by the outer perimeter of the first type of storage container 106a corresponds to the area defined by the inner perimeter of the stacking frame 6. The area defined by the outer perimeter of the second type of storage container 106b is approximately half of the area defined by the inner perimeter of the stacking frame 6, such that two second type of storage containers 106b can be accommodated in the stacking frame 6 in a side-by-side arrangement, see Figure 8 and Figure 16 . An alternative design of the second type of storage container is shown in Figure 14 and is denoted by the reference numeral 106c.

[0091] Each storage container 106a-c includes a sidewall having an external vertical guiding groove 23. The external vertical guiding groove 23 is configured to cooperate with a guiding rib 22 of the stacking frame 6 to prevent lateral movement of the storage container relative to the stacking frame that houses the storage container. When the storage containers 106a-c move vertically within the stacking frame 6, the cooperating guiding rib 22 and guiding groove 23 also provide guidance for the storage container and thus ensure accurate stacking of the storage containers 106a-c.

[0092] The storage system 1’ includes an orbital system 108 disposed above the storage rows 105. The stacking frame lifting device 8 and the container lifting device 501 are configured to move in two mutually perpendicular directions on the orbital system 108. Both the stacking frame lifting device 8 and the container lifting device 501 include a first set of wheels 28, 28’ and a second set of wheels 29, 29’ for moving on the orbital system 108. These wheel sets can be the same as the wheel sets described in Figures 2 to 4 the prior art container handling vehicles.

[0093] The container lifting device 501 can be similar to the prior art container handling vehicle 301 in Figure 3 or similar to any other container handling vehicle shown in Figure 2 and Figure 4 . However, in order to be able to handle storage containers 106a-d of different sizes (e.g., the first type of storage container and the second type of storage container as described above), the container lifting device 501 includes a first type of lifting frame 24 that is divided into at least two frame portions 24a, 24b, see Figure 12 , Figure 13a and Figure 13b . Each of these two frame portions 24a, 24b includes a gripper 3 that is configured to releasably connect to a connection groove 13 disposed in the upper edge 16 of the storage containers 106a-d (e.g., see Figure 14 ). The frame portions 24a, 24b can be operated independently of each other. By operating independently, a single frame portion 24a, for example, can pick up a second type of storage container 106b, or the two frame portions 24a, 24b can cooperate with each other to pick up a first type of storage container 106a. In the illustrated container lifting device 501, each frame portion 24a, 24b is connected to a respective rotatable lifting shaft 26a, 26b via four lifting belts 5 such that the frame portion can be raised and / or lowered relative to the body of the container lifting device. It is also conceivable to include a lifting frame with more than two frame portions in order to be able to pick up storage containers having dimensions different from those of the first type of storage container and the second type of storage container.

[0094] Each frame part 24a, 24b includes a recess 25 configured to cooperate with an internal vertical guide rib 22 of the stacking frame 6 during vertical movement of the frame parts 24a, 24b within the stacking frame 6.

[0095] As Figure 11 shown, the container lifting device 501 is configured to take out the storage container 106b* (e.g., two storage containers 106b of the second type as shown) from the open top end 9 of the upper stacking frame 6* in the stack of the stacking frames. In order to take out the storage containers 106a - c from the stacking frame 6, the lifting frame 24 of the first type has an outer perimeter smaller than the inner perimeter of the stacking frame 6. The inner perimeter of the stacking frame 6 may be configured to guide the vertical movement of the lifting frame 24 of the first type within the stacking frame 6.

[0096] The stacking frame lifting device 8 includes a lifting frame 10 of the second type, see Figure 20 and Figure 21 . The stacking frame lifting device 8 is configured to take out the upper stacking frame 6' accommodated in the storage row 105, see Figure 10 . The lifting frame 10 of the second type includes a horizontal base frame 11 and latches 17 arranged at each of the opposite sides of the base frame 10. The connecting portion 17a of each latch 17 is configured to move between a release position ( Figure 20 ) and a connecting position ( Figure 21 ). The connecting portion 17a is closer to the vertical center line C of the base frame 10 when in the release position than when in the connecting position. When moving from the release position to the connecting position, the connecting portion 17a moves away from the vertical center line C and can extend through the corresponding notch 12 in the side portion 20 of the stacking frame 6, see Figure 21 . The advantage of connecting the latch 17 to the stacking frame at the inner surface of the stacking frame is that the space between the stacks of adjacent stacking frames can be minimized. In addition, the width of the side portion 20 or wall of the stacking frame can also be minimized as long as the stacking frame is made of a suitable material and / or has a suitable configuration, i.e., the material and configuration can provide sufficient support for the stacking frames stacked above. The stacking frame lifting device 8 may be similar to Figure 2 and Figure 4 in the prior art vehicles, in which the size of the cavity is adapted to lift and move the stacking frame 6. In order to increase the lifting height, the lifting frame 10 of the second type can be further modified, for example, by using a guide shuttle as described in WO 2020 / 200631 A1.

[0097] The storage system of the present invention has several advantages in increasing the height of the storage columns and adjusting the dimensions of the storage containers 106a-d accommodated therein. The stacking frames can be configured to support stacks of stacking frames that are higher than the maximum height of the stack of storage containers. The stack of stacking frames is more stable than a stack of storage containers of similar height because, compared to a stack of storage containers, the stack of stacking frames requires fewer individual stacking units to achieve a specific stacking height. The stability of the stack of stacking frames can be further improved by providing a recessed portion (not shown) at the bottom portion 18 of each stacking frame. In addition to the advantages associated with increased height and improved stability, the storage system of the present invention also has the following advantage: the storage containers arranged at the lower horizontal height of the storage column can be removed more efficiently because the number of stacking frames that need to be removed during removal is less than the number of storage containers that need to be removed in a prior art storage system.

[0098] A favorable method for removing the target storage container 106b* from the above storage system is shown in Figures 9 to 11 . The method includes the following steps:

[0099] - Identifying the storage column 105 that houses the target stacking frame 6* in which the target storage container 106b* is stored;

[0100] - Moving the stacking frame lifting device 8 to a position above the storage column 105 ( Figure 9 );

[0101] - Removing at least one stacking frame 6' ( Figure 10 ) stacked above the target stacking frame 6* from the storage column 105 (the at least one stacking frame 6' can optionally be stored in other storage columns) until the target stacking frame 6* becomes the upper stacking frame in the storage column 105;

[0102] - Removing the target storage container 106b* from the target stacking frame 6* using the container lifting device 501 ( Figure 11 ).

[0103] Depending on the configuration of the container lifting device 501 and / or the configuration of the first type of lifting frame 24, the first type of lifting frame 24 may need to be guided during vertical movement inside the storage column 105. If guidance is required, before the container lifting device 501 removes the target storage container 106b*, the method may further include the following steps:

[0104] - Remove the target stacking frame 6* from the storage column 105 and move the target stacking frame 6* to another storage column 105, where the target stacking frame 6* is stacked at the upper horizontal height of the storage column; when stacked at the upper horizontal height of the storage column 105, the open end 9 of the target stacking frame 6* is at the horizontal height directly below the rail system 108. In this way, the first type of lifting frame 2 can be guided by the inner surface of the target stacking frame 6* when moving into the storage column 105.

[0105] A second exemplary storage system according to the present invention is shown in Figures 17 to 19 . The second exemplary storage system is configured such that the first type of lifting frame 24 can be guided during vertical movement inside the storage column 105 (instead of the stacking frame 6). To provide such guidance, the storage column 105 includes a guide profile 30. The guide profile 30 is configured to cooperate with a recess 25 on the first type of lifting frame 24. In the second exemplary embodiment, the stacking frame 6 includes an external vertical groove 31 configured to cooperate with the guide profile 30. In this way, the first type of lifting frame 24 is guided by the guide profile 30 during vertical movement into / vertically out of the stacking frame 6, and the first type of lifting frame is guided by the internal vertical ribs 22 of the stacking frame 22 when moving within the stacking frame. The guide profile 30 ensures that the storage containers 106a-d can be removed from the stacking frame 6 arranged at the lower horizontal height inside the storage column.

[0106] Figure 22 and Figure 23 show an exemplary stacking frame according to the present invention. The stacking frame includes a centrally arranged vertical guide profile 27 extending from the bottom of the stacking frame 6. The centrally arranged vertical guide profile 27 allows the guidance and support of a smaller-sized storage container 106d, the area defined by the outer perimeter of which is approximately one quarter of the area defined by the inner perimeter of the stacking frame 6. Such a smaller-sized storage container 106d requires a first type of lifting frame 24, which includes, for example, four independently operable frame parts (not shown), each of which is configured to lift the smaller-sized storage container 106d.

[0107] List of reference numerals

[0108] 1 Automatic storage and retrieval system of the prior art

[0109] 2 Lifting frame, first type of lifting frame

[0110] 3 Container connector

[0111] 4 Guide pin

[0112] 5 Lifting belt

[0113] 6 Stacking frame

[0114] 7 Guide pin groove

[0115] 8 Stacking frame lifting device

[0116] 9 Open top

[0117] 10 Second type of lifting frame

[0118] 11 Base frame

[0119] 12 Notch (of stacking frame), connecting notch

[0120] 13 Connecting groove (of storage container)

[0121] 14 Side wall of storage container

[0122] 15 Lower bottom surface of lifting frame

[0123] 16 Upper edge of storage container

[0124] 17 Latch

[0125] 18 Bottom part (of stacking frame)

[0126] 19 Top part (of stacking frame)

[0127] 20 Side part (of stacking frame)

[0128] 21a, 21b Inner side walls (of stacking frame)

[0129] 22 Vertical guide rib

[0130] 23 Vertical guide groove

[0131] 24 First type of lifting frame

[0132] 25 Recess (on the first type of lifting frame)

[0133] 26a, 26b Lifting shafts

[0134] 27 Vertical guiding profile (of stacking frame)

[0135] 28, 28’ First set of wheels

[0136] 29, 29’ Second set of wheels

[0137] 30 Guiding profile (of storage row)

[0138] 31 Vertical groove (of stacking frame)

[0139] 100 Frame structure

[0140] Vertical member of the 102 frame structure

[0141] Horizontal member of the 103 frame structure

[0142] 104 Storage grid

[0143] 105 Storage column

[0144] 106a - d Storage containers

[0145] 107 Stack

[0146] 108 Track system

[0147] Parallel tracks in the first direction (X), 110

[0148] First track in the first direction (X), 110a

[0149] Second track in the first direction (X), 110b

[0150] Parallel tracks in the second direction (Y), 111

[0151] First track in the second direction (Y), 111a

[0152] Second track in the second direction (Y), 111b

[0153] Access opening, 112

[0154] First port column, 119

[0155] Second port column, 120

[0156] Container handling vehicle of the prior art, 201

[0157] Vehicle body of the container handling vehicle 201, 201a

[0158] Drive device / wheel device in the first direction (X), 201b

[0159] Drive device / wheel device in the second direction (Y), 201c

[0160] Cantilever - type container handling vehicle of the prior art, 301

[0161] Vehicle body of the container handling vehicle 301, 301a

[0162] Drive device in the first direction (X), 301b

[0163] Drive device in the second direction (Y), 301c

[0164] Container handling vehicle of the prior art, 401

[0165] The vehicle body of the container handling vehicle 401

[0166] 401b The drive device in the first direction (X)

[0167] 401c The drive device in the second direction (Y)

[0168] 501 The container lifting device, the container handling vehicle

[0169] Y The second direction

[0170] Z The third direction

Claims

1. A storage system (1) for storage containers, the storage system comprising a frame structure (100), a stacking frame (6), storage containers (106a-d), a stacking frame lifting device (8), and a container lifting device (501); The frame structure defines a plurality of storage columns (105), and each storage column accommodates a plurality of stacking frames (6) arranged one on top of the other in a vertical stack; Each of the plurality of stacking frames (6) has an open top end and is configured to accommodate a plurality of storage containers (106a-d); The stacking frame lifting device (8) and the container lifting device (501) are configured to move in two mutually perpendicular directions above the storage columns; The container lifting device is configured to take out the storage containers (106a-d) via the open top end (9) of the upper stacking frame (6') in the stack of stacking frames accommodated in the storage column; and The stacking frame lifting device (8) is configured to take out the upper stacking frame (6').

2. The storage system according to claim 1, wherein, Each stacking frame includes two pairs of opposing sidewalls (21a, 21b), and each pair of the two pairs of opposing sidewalls has at least one internal vertical guiding rib (22).

3. The storage system according to claim 1 or 2, wherein Each stacking frame includes a first pair of opposing sidewalls (21a) and a second pair of opposing sidewalls (21b), and internal vertical guiding ribs (22) are arranged on each sidewall.

4. The storage system according to claim 2 or 3, wherein, Each of the plurality of storage containers (106a-d) includes a sidewall having an external vertical guiding groove (23), the external vertical guiding groove being configured to cooperate with one of the guiding ribs (22) to prevent the storage container from moving laterally relative to the stacking frame that houses the storage container.

5. The storage system according to any one of the preceding claims, wherein, The container lifting device includes a first type of lifting frame (24) configured to releasably connect to the upper part of the storage containers (106a-d).

6. The storage system according to claim 5, wherein, The first type of lifting frame includes a gripper (3), the gripper being configured to releasably connect to a connection groove (13) arranged in the upper edge (16) of the storage containers (106a-d).

7. The storage system according to any one of the preceding claims, at least comprising a first type of storage container (106a) and a second type of storage container (106b), an area defined by an outer perimeter of the first type of storage container corresponding to an area defined by an inner perimeter of the stacking frame, and an area defined by an outer perimeter of the second type of storage container being approximately half of the area defined by the inner perimeter of the stacking frame, such that two of the second type of storage containers can be accommodated in the stacking frame in a side-by-side arrangement.

8. The storage system according to claims 5 to 7, wherein, The lifting frame of the first type is divided into at least two frame parts (24a, 24b), each of the two frame parts includes a gripper (3), and can operate independently of other frame parts, so that a single frame part can take out one of the storage containers of the second type, and the two frame parts can cooperate with each other to take out one of the storage containers of the first type.

9. The storage system according to claims 2 and 8, wherein, Each of the at least two frame parts (24a, 24b) includes a recess (25), and the recess is configured to cooperate with one of the internal vertical guide ribs of the stacking frame during the vertical movement of the frame part within the stacking frame.

10. The storage system according to any one of the preceding claims, wherein, The stacking frame lifting device (8) includes a lifting frame (10) of the second type configured to be releasably connected to the upper part of the stacking frame (6).

11. The storage system according to claim 10, wherein, Each stacking frame has two opposite side parts (20), notches (12) are arranged at the inner surface of each side part, and the lifting frame (10) of the second type includes a latch (17), and each latch is configured to enter the corresponding notch (12) from the inside of the stacking frame when the lifting frame of the second type is releasably connected to the stacking frame.

12. The storage system according to claim 7, wherein, The lifting frame of the second type includes a horizontal base frame (11) and at least one latch (17) arranged at each of the opposite sides of the base frame. The connecting part of each latch (17) is configured to move between a release position and a connection position, and the connecting part is closer to the vertical center line of the base frame when in the release position than when in the connection position.

13. The storage system according to any one of the preceding claims, including a track system (108), and the container lifting device (501) can move in two mutually perpendicular directions on the track system, and the track system is arranged above the storage row (105).

14. The storage system according to claim 12, wherein, The stacking frame lifting device (8) is configured to move in two mutually perpendicular directions on or above the track system.

15. A stacking frame and storage container assembly for a storage system according to any of the preceding claims, comprising a stacking frame (6) accommodating a plurality of storage containers (106a-d), wherein, The stacking frame includes at least two pairs of opposite side walls (21a, 21b), each opposite side wall has an internal vertical guide rib (22), and each storage container (106a-d) includes at least one side wall having an external vertical guide groove (23), and the external vertical guide groove is configured to cooperate with at least one of the internal vertical guide ribs (22) to prevent the storage container from moving laterally relative to the stacking frame.

16. The component according to claim 13, wherein, The stacking frame includes: a bottom part (18) for supporting the storage containers (106a-d); a top part (19) having an open end (9) through which the storage container can pass in the vertical direction; a side part (20) extending between the bottom part and the top part; and a connecting notch (12) arranged at the upper part of the side part (20).

17. The component according to claim 13 or 14, wherein, A connecting groove (13) is included at the upper edge (16) of each of the plurality of storage containers (106a-d).

18. A method for removing a target storage container from a storage system according to any one of claims 1 to 14, comprising the following steps: - Identifying a storage column (105) containing a target stack frame (6*), wherein the target storage container (106b*) is stored in the target stack frame; - Moving the stack frame lifting device (8) to a position above the storage column; - Removing at least one stack frame (6) stacked above the target stack frame (6*) from the storage column, and optionally storing the at least one stack frame in another storage column until the target stack frame becomes the upper stack frame in the storage column; - Optionally removing the target stack frame from the storage column and moving the target stack frame to another storage column, where the target stack frame is stacked at the upper horizontal height of the other storage column; and - Removing the target storage container (106b*) from the target stack frame by using the container lifting device.

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